Part II

MUMBAI METROPOLITAN REGION
DEVELOPMENT AUTHORITY
WATER SUPPLY RESOURCE MANAGEMENT CELL

Tender No. MMRDAWSRM / 2016
Implementation of Surya Regional Bulk Water Supply Scheme for
Western Sub Region of Mumbai Metropolitan Region (MMR) on Design,
Build, Maintain, Operate and Transfer (DBMOT) basis
Part - II: EMPLOYERS REQUIRMENTS

Section 6A : GENERAL REQUIREMENTS
OCTOBER 2016
SUB-SECTION 6A.1
PROJECT REQUIREMENTS
1 of 2461
SURYA REGIONAL BULK WATER SUPPLY SCHEME
MMRDA
Table of Contents
SUB-SECTION 6A.1: PROJECT REQUIREMENTS ......................................................................... 1
1.1
Project Region and the MMRDA .................................................................................... 1
1.2
Surya Regional Water Supply Scheme........................................................................... 2
1.2.1
Project Background ................................................................................................. 2
1.2.2
Objectives of the Project ......................................................................................... 3
1.2.3
Guidelines ................................................................................................................ 3
1.3
Source and location of Intake ........................................................................................ 4
1.3.1
Surya River ............................................................................................................... 4
1.3.2
Location of Intake .................................................................................................... 5
1.4
Service Areas and locations of MBRs ............................................................................ 5
1.4.1
Vasai-Virar Sub-Region ............................................................................................ 5
1.4.2
Mira-Bhayandar Sub-Region.................................................................................... 7
1.5
Location of Water Treatment Works............................................................................. 8
1.6
Incorporation of Break Pressure Tank (BPT) ................................................................. 9
1.7
Brief Description of Water Supply System .................................................................... 9
1.8
Scope of Contract ......................................................................................................... 11
1.8.1
Activities Included ................................................................................................. 11
1.8.2
Detailed Scope ....................................................................................................... 12
1.8.3
Other Incidental Works ......................................................................................... 15
1.8.4
Completeness of the Works and System............................................................... 16
1.9
Design Life..................................................................................................................... 17
2 of 2461
MMRDA
SUB-SECTION 6A.1: PROJECT REQUIREMENTS
1.1
Project Region and the MMRDA
The project is in Mumbai Metropolitan Region (MMR) which comprises

Greater Mumbai and developed and developing areas on periphery of
Mumbai. Figure 1.1 shows expanse of Mumbai Metropolitan Region.
The peripheral areas are in Thane district and Raigad district. Total
area of Greater Mumbai is 468 km2 and that of rest of MMR is 3887
km2. The region lies between 185338 193339 N and between
724741- 731526 E. The cities and towns in MMR apart from
Mumbai are Navi Mumbai, Thane, Bhiwandi, Mira-Bhayandar, VasaiVirar, Kalyan-Dombivali, Ambernath, Ulhasnagar, Kulgaon-Badlapur,
Karjat, Matheran, Khopoli, Panvel, Uran, Pen and Alibag. The cities
and towns are administered by Municipal Corporations and Municipal
Councils.
Mumbai Metropolitan Region Development Authority (MMRDA) was set
up on the 26th January, 1975 under the Mumbai Metropolitan Region
Development Authority Act, 1974 by the Government of Maharashtra
as an apex body for planning and co-ordination of development
activities in the Mumbai Metropolitan Region.
Mumbai Metropolitan Region Development Authority (MMRDA) is the
planning and implementing agency for all infrastructure development
projects such as road widening, new roads, bridges, flyovers, ROBs,
subways, elevated roads, Metro-Monorail Projects, Water Resource
Development and other related works for the Mumbai Metropolitan
Region (MMR). As part of above activities, MMRDA is planning bulk
water supply to two cities i.e. Mira-Bhayandar and Vasai-Virar and
municipal corporation.
SECTION 6A.1: PROJECT REQUIREMENTS
PAGE 1 of 19
3 of 2461
MMRDA
Figure 1.1: Expanse of Mumbai Metropolitan Region
1.2
Surya Regional Water Supply Scheme
1.2.1
Project Background
The MMRDA has conceived a regional water supply scheme with the
Surya River as the source for 403 MLd bulk water supply for meeting
partially the water requirement of western sub-region of Mumbai
Metropolitan Region (MMR) which includes Vasai-Virar City Municipal
Corporation (VVCMC), Mira Bhayandar Municipal Corporation (MBMC)
and 27 villages in Vasai-Virar sub-region not merged in VVCMC.
Surya river located at about 57 km from service area is the source.
The map showing MMR, Surya river and service area are enclosed in
tender drawings.
Government of Maharashtra has allocated 146.33 Mm3 of water from
Surya dam for drinking water supply to the western subregion. The
raw water is to be abstracted from Kawadas pick up weir. The capacity
PAGE 2 of 19
4 of 2461
MMRDA
of the scheme is accordingly kept 403 ML/day. It is intended to give

bulk water supply to the two urban local bodies and 27 villages.
The tentative allocation of Bulk Water Supply from the proposed
scheme to the beneficiaries in the sub-region shall be as per Table 1.1
below.
Table 1.1: Distribution of Water to Beneficiaries
Beneficiaries
S.
Allocated
Quantity
No.
(ML/day)
1
Vasai -Virar City Municipal Corporation
170
Mira Bhayandar Municipal Corporation
218
27 villages in Vasai - Virar Sub-region not

merged in VVCMC
Total
1.2.2
15
403
Objectives of the Project

The broad objective of the Surya Regional Water Supply Scheme is to
abstract adequate raw water from Surya river at Kawadas pickup weir,
treat to required quality standards and transmit to Master Balancing
Reservoirs (MBRs) for 403 ML/day bulk treated water supply to
VVCMC, MBMC and 27 villages in Vasai Virar Sub-region. Points of
bulk water supply under the project shall be MBRs located at outskirts
of the two ULBs and 7 (seven) number of tappings for supply to
villages.
1.2.3
Guidelines
Guidelines in following manuals and Institutions shall be generally
followed for designing the project components and framing the project.
-
Manual on Water Supply and Treatment by CPHEEO
PAGE 3 of 19
5 of 2461
MMRDA
WHO guidelines for drinking water quality
The system design, selection of process and material of construction

for various components shall achieve the following objectives as per
guidelines in CPHEEO Manual on Water Supply and Treatment.
Supply safe and clear water treated to acceptable standard as per

WHO Standards / IS 10500
Adequate quantity
Economical
pumping
and
transmission
system
aiming
at
conservation of energy
Water conservation, low leakage and reuse wherever feasible
Design life as given in Manual on Water Supply and Treatment

published by CPHEEO and in this section
1.3
Source and location of Intake
1.3.1
Surya River
The Surya river originates from Sahyadri mountain in Mokhada Tehsil
of Palghar District.
The Surya Dam located at Dhamni on Surya river was constructed by
the Water Resources Department of Government of Maharashtra and
is located about 60 km beyond the boundary line of MMR to the North.
Water from the dam is released through the tail race of the
hydroelectric power house located at the foot of the dam. A pick-up
weir at Kawadas about 5.5 km downstream of dam was constructed.
Two intakes for BARC and Reliance are located at Kawadas and
together draw 36 MLd.
PAGE 4 of 19
6 of 2461
1.3.2
MMRDA
Location of Intake
It is proposed to lift water at Kawadas pick up weir by constructing
Intake and convey it to WTP where it will be treated. Thereafter it will
be conveyed by appropriate transmission system to Master Balancing
Reservoirs (MBRs) for bulk supply to above ULBs and 7 tappings for
groups of villages. Further transmission from MBRs and tappings and
distribution shall be responsibility of ULBs and Village Panchayats as
applicable.
This proposed Intake at Kawadas is starting point of the project. The
location is about 57 km from boundary of VVCMC area and 85 km from
boundary of MBMC area.
1.4
Service Areas and locations of MBRs
Service areas include two sub regions i.e. Vasai-Virar subregion and
Mira-Bhayandar subregion. These two sub regions are separated by
Vasai creek.
1.4.1
Vasai-Virar Sub-Region
Vasai-Virar sub-region is located on northern boundary of MiraBhyandar and generally on west of Mumbai-Ahmedabad National
Highway (NH-8). A small area of Vasai-Virar subregion is on east of
NH-8. The sub-region is coastal area with Arabian sea on West. The
area lies between 192842- 192037 N and between 755223 724643 E and covers 380 sq.km.
Topography of the sub-region is moderately flat with ground level

varying from 1 m to 30 m rising from West to East. There are some
hillocks with high elevation.
PAGE 5 of 19
7 of 2461
MMRDA
Figure 1.2: Vasai-Virar Subregion
The Sub-region includes Vasai Virar Municipal Corporation (VVMC)

and other 27 villages not merged in the City Corporation.
Population of VVCMC is 12.21 Lakhs as per census 2011.
As stated in the project objective, 170 ML/day bulk drinking water is to
be supplied to VVCMC in MBR at suitable location. Ideal location is
Kashidkopar hillock on which three MBRs of capacities 10 ML, 5 ML
and 5 ML are constructed and in operation. VVCMC need bulk supply
from this proposed MBR at reservoir level of 70.0 m RL.
PAGE 6 of 19
8 of 2461
MMRDA
Suitable plot for locating MBR is identified near existing MBRs.

This MBR location shall be end point of part of the project for VVCMC.
The location of the MBR is 58 km from Kawadas Intake and 56 km
from Suryanagar WTP.
Population of 27 villages not merged in Vasai-Virar Corporation is
60,560. 7 (Seven) tappings are proposed for bulk water supply to the
villages divided in 7 groups.
1.4.2
Mira-Bhayandar Sub-Region
Mira-Bhayandar city is located on Northern boundary of Mumbai and
on Western side of Mumbai-Ahmedabad National Highway (NH-8).
The sub-region is coastal with Arabian sea on West and Vasai creek
on North.
The area lies between 191903 - 191612 N and
725110 - 725354 E.
Topography of the sub-region is fairly flat with ground levels varying

from 1 m to 15 m rising from West to East. The terrain also includes
some hillocks having elevation upto 70 m.
PAGE 7 of 19
9 of 2461
MMRDA
Figure 1.3: Mira-Bhayandar Sub region
Mira Bhayandar Municipal Corporation (MBMC) is the civic body for the
city and was established in the year 2002 by merging Mira and
Bhayandar towns. Total area within the corporation limit is 79.4 sq.km.
The population as per 2011 census is 8.15 Lakhs.
As stated in the project objective 218 ML/day bulk drinking water is to
be supplied to MBMC in MBR at suitable location. A location on hillock
at Chene village is identified. MBMC need bulk supply from the MBR
at reservoir level of 52.50 m RL. The elevation at the plot meets the
elevation requirement.
This MBR shall be end point of the part of the project. The location of
MBR is 85 km from Kawadas Intake and 83 km from Suryanagar WTP.
1.5
Location of Water Treatment Works
Suitable large land about 20-25 Ha is required for water treatment

works. The plot should also be at an appropriate elevation so as to
optimize energy cost. Very ideal land is available at Suryanagar for the
PAGE 8 of 19
10 of 2461
MMRDA
treatment works. The contours and variation in levels are appropriate

to attain required 5.0 6.0 m drop in levels in process units.
The location is at about 2 km from Kawadas Intake.
1.6
Incorporation of Break Pressure Tank (BPT)
Incorporation of BPT is of paramount importance as due to BPT,

downstream lines function as gravity main and are free from transient
pressures and thus frequency and extent of maintenance and repairs
are significantly reduced.
Suitable location is available at high ground in WTP plot for locating the
BPT. Due to introduction of BPT, almost entire 84 km long clear water
transmission system shall function as gravity main and length of clear
water pumping main is reduced to mere 0.1 km.
1.7
Brief Description of Water Supply System
Location of source and Intake, water treatment plant, breaks pressure

tank and two MBRs are discussed in paragraphs 1.3, 1.4, 1.5 and 1.6
above. Pumping mains and gravity mains are planned by shortest and
feasible transmission routes.
Overall working requirement of the system are as under:
i)
Daily operation period
22 hours /
day
ii)
Bulk supply to Kashidkopar -
170 ML/day
MBR
iii)
Bulk supply to Chene MBR
218 ML/day
iv)
Bulk supply to 27 villages
15 ML/day
403 ML/day
Total bulk supply
Capacities of WTP and Intake are accordingly designed with due

PAGE 9 of 19
11 of 2461
MMRDA
allowance for leakage losses and wash water requirement.

Components from Intake to MBRs are shown in Flow Diagram in
tender drawings and are as follows:
i)
Intake and raw water pumping station
ii)
2.035 km long raw water pumping main including surge tank for
protection of the pumping main from water hammer pressures
iii)
Water treatment plant including sludge treatment and reuse of

waste wash water
iv)
Clear water pumping station at WTP
v)
315 m long clear water pumping main to break pressure tank

(BPT)
vi)
Break pressure tank adjacent to WTP
vii)
86 km long clear water transmission system upto the two MBRs

including three tunnels
About 75 km long route is along NH-8 out of which 8 km is

on east and 67 km on west side of NH-8
One tunnel of 1.7 km length is for crossing NH from east to

west
Second tunnel of 4.3 km length is for underground crossing

of Tungareshwar Wild Life Sanctuary
viii)
Third tunnel of 0.9 km length is for crossing Vasai creek
River and creek crossings comprising crossing below bed level
PAGE 10 of 19
12 of 2461
MMRDA
for Vaitarna river, Vandri river and Tansa river and by

Microtunnel for crossing common creek for Kaman creek
In addition, number of minor crossing for nallahs and small
water courses are encountered. Most of the crossings shall be
by laying pipeline below bed level.
ix)
Additional 3 (three) major crossing are involved
Crossing of Vasai-Diva railway track which will be done by

pushing RCC box under railway track and pipeline within
box. RCC box work will be done by Railway and pipeline
work under this contract
Crossing NH-8 at Ghodbunder which will be constructing

RCC box. RCC box work will be done by National Highway
Authority and pipeline work under this contract
Crossing of Ghodbunder-Thane Road at Ghodbunder

junction by micro-tunneling under this contract
x)
7 (Seven) number of branches for water supply to 27 villages

divided in seven groups
xi)
Two master balancing reservoirs; one 38 ML capacity at

Kashidkopar and second 45 ML capacity at Chene
xii)
Rechlorination system at two MBRs
xiii)
Instrumentation, automation and SCADA
1.8
Scope of Contract
1.8.1
Activities Included
PAGE 11 of 19
13 of 2461
MMRDA
The contract is for Design, Build, Operation and Maintenance for the
works and components included in description of water supply system
and scope of the works.
The scope of contract includes following
activities for entire works.
Raw water analysis and survey and geotechnical investigation
Design
Manufacture, Inspection of material, plant and equipment at

factories and supply
Storage, erection or build and pipeline laying
Trial run and pre-commissioning tests and checks
Commissioning of the work and performance test
Any activity not listed above, but is essential for the completion of
works
1.8.2
Training to employers staff
Operation and maintenance of works for 8 years operation period
Detailed Scope
The scope of the Contractor who will execute the works and guarantee
plant and process performance will include, but will not be limited to the
following:
All preparatory work including clearing and leveling of site, site

grading/ dressing of site as per specified formation or finished
ground level (FGL), provision of access roads etc., excavation,
dewatering as required and disposal of all surplus earth to a
PAGE 12 of 19
14 of 2461
MMRDA
suitable location;
Carrying out required raw water analysis;
Necessary topographic survey and geotechnical investigation and

any other investigation(s) as considered necessary for pipeline
profile, layout of
Intake, WTP, MBR, BPT, road campus
development, deciding foundation level, type of foundation, tunnel

levels and profile, bridge foundations etc. and reconfirming
hydraulic levels at Kawadas weir;
Prepare process and hydraulic design with layout and hydraulic flow
diagram of the complete water treatment plant, with wastewater
reuse to minimize losses, to meet the treated water quality
parameters;
Preparation of wooden/ fabric model 1/5000 scale with live water

lights and music etc.;
Preparation of documents of entire programme of Works from T0 to

T34 months, showing all monthly preparation, key events, visitation
of delegates, dignitaries etc.
Preparation of capital simulation and walk through.
The entire Project shall be green, clean and sustainable (energy

efficient).
The WTP site shall be green landscaped and under CCTV

coverage. Footage of the CCTV recordings must be provided to
MMRDA, central control center (CCC). While the control shall be at
CCC at WTP site, video footage shall be provided to the CCC at
Bandra-Kurla Complex.
Undertake complete detailed engineering design and development
PAGE 13 of 19
15 of 2461
MMRDA
of the water supply system including civil structural works, tunnels,

pipeline work, mechanical, electrical and instrumentation/SCADA
system equipment and allied works with construction drawings, to
ensure performance, and submit for approval of the Employer and
shall include;
Design, drawings, data sheet, samples etc. and specification;
General arrangement drawing and architectural drawings of

structures, buildings etc.
Structural design and drawings including reinforcement details
Detailed working drawings on basis conceptual design and plan

approved
After approval of the designs and drawings by the Employers

representative or the Employer, the Contractor will commence
implementation of civil, mechanical, electrical and instrumentation
and allied works;
Execution will include setting out and complete execution as per

approved civil construction drawings to suit equipment requirement;
Placing of order, manufacture, testing at place of manufacture,

inspection by the Employer or Employers representative, supply
after painting and packing, transport, delivery, storage, erection/
installation, testing and commissioning of the plant;
Providing as built drawings for all components in soft and hard

copy;
After satisfactory testing and commissioning of the complete plant,

to meet the performance requirement, the Contractor shall maintain
and operate the plant for a period of 8 years including defects
PAGE 14 of 19
16 of 2461
MMRDA
liability period stated in condition of contract;
Contractor shall provide the operation and maintenance manuals for

the plant and shall update them regularly;
Contractor shall provide all services including manpower as

designated in the bid documents, tools and spares etc. required to
operate the plant successfully to meet the required product water
quality;
The Contractor shall be responsible for all aspects of design and

execution in order to meet the finished water quality and other
standards laid down in the specification within the defined battery limits.
1.8.3
Other Incidental Works

The contract also includes following incidental works and cost of all
such works shall be borne by the contractor.
i)
Setting up of suitably equipped / manned field offices for

supervision of the works for the Contractors staff and the
Employers Representative and Engineers.
ii)
Development of suitable storage spaces for construction

material and equipment to be received for the works.
iii)
Identification of suitable quarries / sources for construction

material
and
get
them
approved
from
the
Employers
Representative.
iv)
Setting up, and staffing with qualified engineers / technicians, of

suitable laboratories for observing the Quality Standards.
v)
Setting up of suitable labor camps with all water and sanitation

arrangements and other facilities required under the relevant
PAGE 15 of 19
17 of 2461
MMRDA
Labor Laws.
vi)
Disposal of surplus excavated material, muck and water etc. to

identified and approved site.
1.8.4
Completeness of the Works and System

The Contractor shall be fully responsible to ensure that the whole of the
works and system including each individual component, is designed
and constructed in a manner so that the system as a whole operates
as a fully integrated system which is capable of achieving the required
output in an efficient and economical manner, and include all plant,
equipment and accessories required for the safe and satisfactory
operation of the facilities. To achieve this, the Contractor shall ensure
that each individual component performs in a manner which is
complimentary to that of all other components. Any accessories which
are not specifically mentioned in the specifications, but which are usual
or necessary for completion of the works and successful performance
of the system and facilities shall be provided by the Contractor within
the tendered cost.
The Contractor shall to the maximum extent
practical and feasible, endeavor to standardize on the manufacture and

supply of plant and equipment so as to minimize the operation and
maintenance requirements.
The contractor shall ensure that his
designs are maintenance-friendly and that all items of plant and

equipment are designed and installed in a manner which will facilitate
routine and periodic maintenance.
The works, plant and item shall be selected, designed, manufactured,
erected and commissioned to meet following essential requirements.
Suitable for design life specified in subsection 1.9
Energy conservation shall be of vital importance. Particularly high

energy consuming equipment e.g. pumps, motors and transformer,
cables etc. shall be selected such that the equipment operates at
PAGE 16 of 19
18 of 2461
MMRDA
optimum efficiency level and energy consumptions are minimum
Maintenance and repair requirement shall be minimized
Access to all components of plant / equipment / item shall be

feasible
Adequate clear space shall be provided for staff to attend the

component for maintenance of any component of plant and
equipment
1.9
Design Life
Design life means the period for which an item or works is designed
to operate at full design output without major overhaul involving
extensive dismantling, serious erosion and corrosion or necessity for
substantial renewal of any anti corrosion system, reduction of efficiency
in excess of 5%, or replacement of major components essential to the
functioning of the item etc. except for consumables and for any limited
life components explicitly agreed at the time of contract award.
Minimum design lives shall be as follows:
a)
Roads, structure of concrete, brick or block work
60
years
b)
Pipelines and valves
30
years
c)
Pumps, motors, electric actuators
15
years
d)
Lifting equipment, control panels, generating sets, -
20
transformers, switchgear, cabling, air blowers,
years
PAGE 17 of 19
19 of 2461
MMRDA
compressors, process plant, electrical installations,

building services etc.
e)
Chlorination equipment
10
years
f)
Instrumentation, control and automation
10
years
g)
Computer systems
5 years
All items and systems shall be designed to allow replacement or major

overhaul at the end of the design life without requiring major work or
dismantling of other items which interrupt operation of independent
items and systems.
PAGE 18 of 19
20 of 2461
SUB-SECTION 6A.2
CONTRACT ADMINISTRATION
21 of 2461
MMRDA
Table of Contents
SUB-SECTION 6A.2: CONTRACT ADMINISTRATION .................................................. 1
2.1
General ...................................................................................................................... 1
2.2
Contractors Design Office in Project Area ..................................................... 2
2.3
Project Management Team .................................................................................. 2
2.3.1 Contractors Representative ................................................................................ 3
2.3.2 Staff for Design Activities ..................................................................................... 5
2.3.3 Key Staff of Contractor ......................................................................................... 6
2.4
Programme............................................................................................................... 9
2.5
Milestones .............................................................................................................. 10
2.6
Monitoring of Progress, Progress Reports and Meetings ........................ 18
2.7
Photographs / Videography............................................................................... 19
2.8
Details and Data by the Employer ................................................................... 20
2.9
Sub-letting .............................................................................................................. 21
2.10
Minimum Construction Equipment to be brought by Contractor on Site .
................................................................................................................................... 22
2.11
Field Laboratories ................................................................................................ 23
2.12
Settling up Factory for Pipe manufacturing in the Project Area ............. 25
2.13
Materials: General Requirements and Manufacturers Experience ........ 26
2.14
Substances and Products .................................................................................. 27
2.15
Delivery and Storage of Plant ........................................................................... 27
2.15.1
Packing and Protection .................................................................................. 27
2.15.2
Delivery to Site ................................................................................................. 28
2.15.3
Storage.............................................................................................................. 29
2.15.4
Erection, Testing and Commissioning ......................................................... 30
22 of 2461
MMRDA
SUB-SECTION 6A.2: CONTRACT ADMINISTRATION
2.1
General
The Contractor shall be responsible for administration of the Contract

from award of Contract through design, manufacture, manufacturer's
works testing, and delivery of Plant to Site, installation, commissioning,
testing and performance proving to final take over.
The employer lays great importance on all aspects of contract

administration including setting up design and field offices deployment
of Contractors key staff, their qualifications and experience, duties,
responsibilities and authorities defined and delegated to them, and all
aspects of works management including finalization of vendors and
subcontractors, placement of work orders and purchase orders, predelivery inspection and testing, storage, erection and commissioning.
The Contractor shall submit to the Employers representative a diagram
showing the structure of the organization for administration of the
Contract. This structure shall include a project managing organization
as part of the Contractors organization.
The structure diagram shall state the names of the firms to be

employed to carry out the following portions of the works:
Process plant;
Mechanical plant;
Electrical plant;
Instrumentation, control and automation systems;
Civil works
SECTION 6A.2: CONTRACT ADMINISTRATION
PAGE 1 of 30
23 of 2461
MMRDA
Designs, drawings and documents that are required to be submitted to

the Employers representative for approval shall be considered as
bonafide by the him only if they have been submitted by the
Contractors representative.
Prior to submission, the Contractors
representative shall have reviewed the design, drawing or document.

Each item submitted shall be stamped checked by name and
designation, dated and shall be clearly identified as to its final location
and function.
Contractors Design Office in Project Area
2.2
The Employer requires a high level of input for the initial investigation
and design phase and requires the Contractor to be prepared with all
necessary inputs so as to not lose time at the beginning of the Contract
in these activities including approval of various designs and drawings.
It is expected that the Contractor shall mobilize the necessary Design
engineers as stipulated in these documents and equipment and base
them at a location approved by the employer immediately after receipt
of the Letter of Acceptance issued. The Contractor shall make the
office functional within two weeks. The office will have required
furniture, computer hardware required Design software packages with
valid licenses, printers, plotters, projection system with screen and
other office requirements. It shall have design team of qualified
personnel for preparing and submitting the necessary design and
drawings for all activities. The office shall also have a conference room
of not less than 50 sq.m. with seating arrangement for 20 persons, for
discussions and reviews.
2.3
Project Management Team
GENERAL MANAGEMENT (FOR 3 +8 YEARS)

S.
POSITION
NOs. QUALIFICATION REMARKS
NO.
1 Chief Executive Officer
1 BE/ME. MBA
20+ Years
PAGE 2 of 30
24 of 2461
MMRDA
GENERAL MANAGEMENT (FOR 3 +8 YEARS)

S.
POSITION
NOs. QUALIFICATION REMARKS
NO.
2 Chief Finance Officer
1 BE/ME. MBA
20+ Years
3 Chief Technology Officer
1 BE/ME.
20+ Years
4 PROJECT DIRECTOR
1 BE/ ME, MBA
20+ Years
5 General Manager (Execution/
1 BE/ ME Civil,
15-20
Operations)
MBA
6 General Manager (Planning & Co-
1 BE/ME. MBA
ordination)
years
15-20
years
7 General Manager (Civil Engg)
1 BE/ME. civil
15-20
years
8 General Manager (Electro-
1 BE/ME.
Mechanical Engg)
Electrical/
15-20
years
Mechanical Engg
9 Statutory Auditor
1 Chartered
Accountant
10 Internal Auditor
1 Chartered
Accountant
15-20
years
15-20
years
The staff will be deployed after approval of their CVs by the Employer.
Initially the CVs of key personnel to be deployed will be submitted in
the bid. The staff as mentioned above shall be deployed well in
advance when the works on the relevant field are being actively carried
out. The Contractor will be expected to arrange and maintain
experienced workers and foremen and other support staff as required
on sites in sufficient numbers.
2.3.1
Contractors Representative
The Contractors representative shall be minimum a graduate in
engineering with at least 20 years of experience in contract
management in field of water supply.
Specific responsibilities of the Contractors Representative shall be:
PAGE 3 of 30
25 of 2461
(a)
MMRDA
The sole representative on behalf of the Contractor in all

discussion, correspondence and matters relating to the Works.
(b)
He shall be delegated with power of attorney to sign on behalf of

contractor on all issues related to contract and payments.
(c)
The co-ordination and monitoring of Contract progress, which

shall include the preparation of the Contract programme,
monitoring of progress and submission of monthly progress
reports. At the discretion of the Employers representative,
regular meetings shall be called at which the Contractors
Representative shall give a full account of the Contract progress
and programme.
(d)
The Contractors Representative shall be responsible for coordinating the design, technical information and data between
sub-contractors. All calculations, drawings and information
submitted to the Employers representative shall be checked by
the Contractors Representative and certified as having been
checked before submission.
(e)
The Contractors Representative shall attend all meetings

involving the Contractor and the Employers representative
(f)
The co-ordination and programming of inspection and testing at

manufacturer's works and the submission of test certificates.
(g)
The co-ordination and programming of Plant delivery.
(h)
The co-ordination and programming of the installation of Plant

on the Site, all tests and commissioning.
(i)
The Contractors Representative shall be responsible for the
PAGE 4 of 30
26 of 2461
MMRDA
various sub-contractors. At the discretion of the Employers

representative regular site meetings will be held during which
the Contractors Representative shall give full account of site
progress and programme.
(j)
The Contractors Representative shall also be responsible for

producing in advance of the work being undertaken, detailed
method statements of any work, which involves or affects the
performance of existing equipment, processes, or disruption to
existing water supplies.
(k)
The co-ordination and preparation of As-Built Drawings and

operating and maintenance manuals.
(l)
The preparation and co-ordination of training.
(m)
The submission of applications for payment.
The Contractor at his discretion may delegate some duties and

authority to the Project Manager with prior approval of the Employer.
2.3.2
Staff for Design Activities
The employer lays due importance on qualification and experience and

adequate number of key staff deployed in design phase. Minimum
staff as under shall be deployed.
Table 2.1: Key Staff for Design Phase
DESIGN ENGINEERING PHASE (6 MONTHS)
Sr
POSITION
NOs.
1 Senior Design Co-
QUALIFICATION
REMARKS
ME Env. Engg.,
10 + Years
1 ME Struct.Engg.
10 + Years
1 ME Geotech/ Tunneling
10 + Years
Coordinators
2 Senior Design CoCoordinators
3 Senior Design Co-
PAGE 5 of 30
27 of 2461
MMRDA
DESIGN ENGINEERING PHASE (6 MONTHS)

Sr
POSITION
NOs.
QUALIFICATION
REMARKS
Coordinators
4 Senior Design Co-
1 ME Mechanical
10 + Years
1 ME Electrical
10 + Years
1 ME
10 + Years
7 Quantity Surveyor
1 BE
10 + Years
8 Project Planning Engineer
1 BE, MBA
10 + Years
9 Mech / Electrical-
1 BE
10 + Years
10 GIS Experts
1 BE Civil
10 + Years
11 Coordinators for Land
2 Graduate
10 + Years
2 Graduate
10 + Years
Coordinators
5 Senior Design CoCoordinators
6 Information Technology
Hardware expert
Procurement Specialists
Acquisition
12 Coordinators for Forest
Clearance
2.3.3
Key Staff of Contractor
a) Project Manager
Project
Manager
shall
be
person
deployed
by
the
JV/Consortium/Contractor as an overall in-charge for the works and

shall be deployed at project office. He should be a senior level staff
member of the Lead firm of the consortium. He shall be minimum
graduate in engineering with at least 15 years of experience in
execution of works in water supply sector.
He shall be responsible for day to day progress of works at site and

all matters related to site works.
He may perform some of duties and responsibilities of the

PAGE 6 of 30
28 of 2461
MMRDA
Contractors representative with prior approval of the Employer.
b) Senior Managers
There shall be one or more Senior Manager for each of the major
components of the Contract Intake, Water Treatment Plant,
Pipelines, tunnel, MBRs, Mechanical, Electrical and ICA Works.
The Senior Manger shall have minimum following qualifications:
Education: B.E. (relevant discipline)
Experience: Minimum 12 years of general field supervision of

Contracts and minimum 8 years experience in supervision in
construction/erection of similar works.
c) Supervisory Staff
There shall be supervisory staff with the following minimum

qualifications deployed in sufficient numbers to ensure day to day
quality supervision of the work:
Education: B.E. in relevant discipline with minimum 8 years
experience in relevant field or Diploma Holder in relevant discipline
with 15 years field experience in relevant field. Safety Engineer
shall be qualified in Safety Engineering.
CONSTRUCTION & EXECUTION PHASE (THREE (3) YEARS)
Sr
POSITION
1 PROJECT DIRECTOR
NOs
QUALIFICATION
1 BE/ ME, MBA
REMARK
S
25 30
Years
2 Chief Construction
1 ME / BE. Civil Engg.
Engineer
3 Senior Construction
25 +
Years
1 ME Env. Engg., ME
10 15
PAGE 7 of 30
29 of 2461
MMRDA
CONSTRUCTION & EXECUTION PHASE (THREE (3) YEARS)

POSITION
Sr
Engineer Civil
4 Senior Construction
NOs
QUALIFICATION
Struct.Engg.
1 ME Geotech.
Engineer Civil
5 Engineers Civil
REMARK
S
years
10 15
years
12 BE in Civil/Env Engg
10 15
years
6 Chief Engineer Tunneling
1 ME / Ph.D. Geotech Engg
25 +
Years
7 Engineers Tunneling
6 ME /BE
15+ Years
8 Chief Engineer
1 ME /BE Mech.
25 +
Mechanical Engg.
9 Engineers Mech.
10 Chief Engineer Electrical
Years
4 ME / BE Mech.
15+ Years
1 ME / BE Elect.
25 +
Engg.
Years
11 Engineers Elect
4 ME / BE Elect
15+ Years
12 Sr. Engr. Instrumentation
1 ME / BE Instru.
15+ Years
13 Jr. Engr. Instrumentation
1 ME / BE Instru.
10+ Years
14 Senior Quantity Surveyor
1 ME / BE Civil
25 +
Years
15 Quantity Surveyors
4 BE Civil
10 15
Years
16 Planning Engineers
2 ME / BE Civil
15+ Years
17 Procurement Specialists
4 BE Mech / Elect
15 +
Years
18 Senior Safety Engineer
1 BE Elect / Mech / Civil
20 +
Years
19 Safety Engineers
6 BE
15 +
years
20 Survey Engineers
4 BE Civil
10 +
Years
21 Support Engineers and

Staff
As required and approved by

the Owner
PAGE 8 of 30
30 of 2461
2.4
MMRDA
Programme
In accordance with Clause 8.3 of the Conditions of Contract, the

Contractor shall within a time specified in the Appendix to the Tender,
submit a detailed contract programme for approval, which shall include
details of survey and geotechnical investigation works, all temporary
and permanent works, construction procedures and methodologies.
In addition to the requirements set down in the Conditions of Contract,

the programme shall include the following details:
(a)
Contractors organisational structures for the Contract including

details of all key staff and their responsibilities;
(b)
A statement giving the numbers and categories of supervisory

staff and skilled and unskilled labour to be employed on the
Works;
(c)
A list and type details of major constructional plant (including

vehicles) which the Contractor proposes to employ on the
Works, including programmed dates for order and delivery;
(d)
Details of the Contractor's methods of working for all operations;
(e)
A statement giving the proposals for location or locations and

sizes of offices, workshops and stores at the Site, pipe
manufacturing units and labour camps;
(f)
A complete resource allocation showing the number of units and

allotted times for each unit of constructional plant, materials and
labour allocated to each part of the Works;
(g)
Particulars to be shown on the programme shall include:
PAGE 9 of 30
31 of 2461
MMRDA
Submission of designs, drawings and documents
Employers representatives approval procedures / review

procedures
Re-submission of drawings etc. as necessary and review
Civil construction of each major structure
Placing of orders for Plant
Plant manufacture
Plant tests at place of manufacture
Plant deliveries to site
Plant erection
Plant tests at site
Tests on completion (commissioning tests)
The programme shall be co-ordinated to take into account the

requirements of climatic, groundwater and other conditions to provide
for the completion of the Works in accordance with the Contract.
The programme shall be prepared using MS Project software such as

primavera or equivalent and shall be submitted in both soft (editable
and PDF) and hard copies.
The programme shall be updated every month and as and when

requested by the Employers representative to show actual progress
and required revisions.
2.5
Milestones
Consistent prorata progress on all components of the Contract during

the entire Contract period shall be achieved. The key milestones set
out in Table 2.3, or such other Milestones as may be proposed by the
Contractor and agreed by the Employer at the time of bidding, are
proposed to be adopted for periodic review of the progress of various
components. These milestones will be the stages when the decisions
regarding any delay in the implementation will be taken with a view
towards the application of the provisions of Clause 8.0 of the
PAGE 10 of 30
32 of 2461
MMRDA
Conditions of Contract.
Table 2.3: Milestones of Works Description

S.
Work Description
Time from Date of Notice to proceed (months)
No
.
12
16
20
24
29
34
mont
mont
mont
mont
mont
mont
mont
mont
hs
hs
hs
hs
hs
hs
hs
hs
50%
75%
100
Mobilization
Establish site & Design
100
offices
Set up laboratory
100
%
Site surveys and
100
investigations
Finalization of work plan
100
%
Intake & raw water pumping station

Design
100
%
Civil works
50%
75% 100%
Mechanical Works
%
Electrical works
50 %
75%
100
%
Campus development
100
%
Trial Run and
100
Commissioning
Raw water pumping main from intake to WTP

Design
100
%
Supply of pipes valves
100
and allied equipments
Work completion
50% 100%
PAGE 11 of 30
33 of 2461
S.
Work Description
No
.
MMRDA
12
16
20
24
29
34
mont
mont
mont
mont
mont
mont
mont
mont
hs
hs
hs
hs
hs
hs
hs
hs
Surge control system
100
%
Hydraulic testing
100
%
Trial Run &
100
Commissioning
Water Treatment Plant

Hydraulic Design
100
%
Process design
100
%
Civil works
25%
50% 75%
100
%
Supply of equipment and
50%
machinery
100
%
Mechanical works
25%
50% 75%
100
%
Electrical works
25% 50%
Surya campus
50%
75% 100%
100%
development
Trial Run and
100
Commissioning
Clear water pumping station

Design
100
%
Civil works
25%
50
75%
%
Supply of equipment and
machinery
50%
100
%
100
%
Mechanical Works
25%
50% 75%
100
PAGE 12 of 30
34 of 2461
S.
MMRDA
Work Description
No
.
12
16
20
24
29
34
mont
mont
mont
mont
mont
mont
mont
mont
hs
hs
hs
hs
hs
hs
hs
hs
%
Electrical works
25% 50%
75% 100%
Surge control system
100%
Work completion
100
%
Trial Run &
100
Commissioning
Clear water pumping

main WTP to BPT
Design
100
%
Supply of pipes, valves
100
Laying & valve chambers
50% 100%
Hydraulic testing
100
%
Trial Run &
100
Commissioning
Break pressure tank

Design
100
%
Civil works
25%
50% 75%
100
%
100
Testing
100%
Trial Run &
100
Commissioning
Transmission main
a)
BPT to Kashidkopar
PAGE 13 of 30
35 of 2461
S.
MMRDA
Work Description
No
.
12
16
20
24
29
34
mont
mont
mont
mont
mont
mont
mont
mont
hs
hs
hs
hs
hs
hs
hs
hs
junction
Design
100
%
100
25% 50%
75% 100%
Hydraulic testing
100
%
Trial Run &

Commissioning
b)
Kashidkopar junction to
Kashidkopar MBR
Design
100
%
50%
100
25% 50%
75% 100%
Hydraulic testing
100
%
Trial Run &

Commissioning
c)
Kashidkopar junction to
Chene MBR
Design
100
%
25%
50% 75%

100
%
25% 50%
Hydraulic testing
75% 100%
100
%
PAGE 14 of 30
36 of 2461
S.
MMRDA
Work Description
No
.
12
16
20
24
29
34
mont
mont
mont
mont
mont
mont
mont
mont
hs
hs
hs
hs
hs
hs
hs
hs
Trial Run &

Commissioning
9
Tunnels (3Nos)
Design
100
%
Work completion
25% 50%
75% 100%
Trial Run &
100
Commissioning
10
River and creek crossings for piping
a)
Major crossings below bed level

Design
100
%
Supply of piping and
25%
50% 75%
allied valves
100
%
Laying & encasing
25% 50%
75% 100%
Hydraulic testing
100
%
Trial Run &

Commissioning
b)
Minor crossings below bed level

Design
100
%
25%
allied valves
Laying & encasing
50% 75%
100
%
25% 50%%
Hydraulic testing
75% 100%
100
%
c)
Trial Run &
100
Commissioning
Bridge & Civil works
PAGE 15 of 30
37 of 2461
S.
MMRDA
Work Description
No
.
Design
12
16
20
24
29
34
mont
mont
mont
mont
mont
mont
mont
mont
hs
hs
hs
hs
hs
hs
hs
hs
50%
100
100
%

allied valves
Work completion
50% 100%
Hydraulic testing
100
%
11
Trial Run &
100
Commissioning
Master balancing
reservoir
a)
MBR at Kashidkopar
Design
100
%
Civil works
25%
50% 75%
100
%
Rechlorination
100
%
Mechanical works with
50%
piping and allied valves,
100
%
equipments and electrical

works
Road
100
%
Testing
100%
Trial Run &

Commissioning
b)
MBR at Chene
Design
100
%
PAGE 16 of 30
38 of 2461
S.
MMRDA
Work Description
No
.
12
16
20
24
29
34
mont
mont
mont
mont
mont
mont
mont
mont
hs
hs
hs
hs
hs
hs
hs
hs
50% 75%
100
Civil works
25%
%
Mechanical works with
50%
piping and allied valves,
100
%
equipments and electrical

works
Rechlorination
50%
100
%
Roads
100
%
Testing
100%
Trial Run &

Commissioning
12
Other Buildings
Design
100
%
Civil works
50%
100
%
Work completion
100
%
13
132 kV/6.6 kV/415 V Substations

Design
100
%
Supply of material &
100%
equipments
Work completion
14
50% 100%
Trial Run &
100
Commissioning
Instrumentation and SCADA
PAGE 17 of 30
39 of 2461
S.
Work Description
MMRDA
No
.
Design
12
16
20
24
29
34
mont
mont
mont
mont
mont
mont
mont
mont
hs
hs
hs
hs
hs
hs
hs
hs
50% 75%
100
100
%
supply
50% 100%
Work completion
25%
2.6
Trial Run &
100
Commissioning
Monitoring of Progress, Progress Reports and Meetings
Each
month
the
Contractor
shall
submit
to
the
Employers
representative six copies of a written detailed progress report as per

Clause 4.21 of GCC and showing the stage reached in the execution of
the Works. The report shall show progress to the end of the preceding
month with respect to the approved Contract programme and output of
project management software. The reports shall be accompanied by
such additional information in approved form as may be required by the
Employers representative. The reports shall be forwarded promptly so
that on receipt the content is not more than seven days out of date.
The report shall show status of all activities required by the Contract
such as design, drawings, procurement, manufacture, works tests,
delivery, erection, testing and commissioning of all items of plant,
pipeline, tunnel and all other works.
Delays shall be detailed by the Contractor, with the proposed action to

overcome it.
The Employer or Employers representative may call meetings in his
office, at the Contractors office, or at the Site, to review the progress of
the Contract.
The Contractors representative shall attend such
PAGE 18 of 30
40 of 2461
MMRDA
meetings.
In addition to the above, the Employer shall Engineer convene

periodical meetings with Contractor and Employers representative for
reviewing progress and for necessary co-ordination among all parties
for smooth construction implementation and maintain the time
schedule.
2.7
Photographs / Videography
The Contractor shall arrange to take photographs and video films of all
important activities. These will include (but not be restricted to) virgin
sites and levels, existing trees and other buildings, obstacles and
utilities across / along the alignment of pipelines and /or plant
structures of this project. The video films shall be submitted for record
in duplicate to the Owners designated representative.
In accordance with the requirements of Clause 4.21 of the Conditions

of Contract the Contractor shall submit negatives of photographs and
unmounted positive colour prints not less than 250 x 200 mm of such
portions of the Works, in progress and completed, as may be directed
by the Employers representative and specified herein. The negatives
and prints shall not be retouched. The negative of each photograph
shall be the property of the Employer and shall be delivered to the
Employers representative with the prints. No prints of these negatives
shall be supplied to any other person without the written permission of
the Employers representative.
The photographs shall be of two categories:
progress photographs
record photographs
Both categories of photographs shall be properly referenced to the

PAGE 19 of 30
41 of 2461
MMRDA
approval of the Employers representative and on the back of each

print shall be recorded the date and time of the photograph, an
identifying description of the subject and the reference.
Photographs taken for record purposes as ordered by the Employers
representative or as specified herein shall be supplied with three prints,
having the reverse of one subscribed with the signatures of the
Contractor and the Employers representative (or their authorised
representatives) for the purpose of attestation. If required, the
Contractor may at his own expense have an additional print similarly
attested for his retention.
The Contractor shall supply one negative and three prints of each
progress photograph ordered by the Employers representative. The
Contractor shall supply two additional prints of progress photographs
selected by the Employers representative for incorporation in albums.
The Contractor shall supply two sets of albums, mount the prints, and
title the prints and albums all to the approval of the Employers
representative.
The Contractor shall also conduct video recording of important activity

at least once in a month and shall furnish the same.
The taking of photographs of the Works by the Contractor for any other
purpose whether for use in India or in any other country shall not be
carried out without written approval from the Employers representative.
2.8
Details and Data by the Employer
The Employer has the following data and used these in formulation of
the design and bid elements. They are listed below and shall be used
only as guideline. The Employer does not, however, guarantee either
the sufficiency or accuracy of the data provided. Contractor shall carry
out fresh survey, investigation and particular testing/and all other
details necessary for proper planning and detailed design. The
PAGE 20 of 30
42 of 2461
MMRDA
Contractor will be required to provide full details of the investigations

and analysis for approval of the Employers representative.
It is
expected that the surveys will be carried out with Total Stations and
necessary software will be used for creating the required drawings.
The employers details and data are as below;
Topographical surveys conducted and also established bench

marks along the transmission route. The corresponding L-Sections
are enclosed in tender drawing (Section 6D)
Geotechnical Investigations for tunnels and other works
Water quality analysis of raw water
Proposed Layout Plan of WTP, clear water pumping station, BPT

and MBRs and alignment of three tunnels
2.9
Sub-letting
The Contractor shall not sub-let the whole of the Works. Where any
design or manufacture is sub-let, the Contractor shall not be relieved of
his obligation under the Contract. The Contractor shall be responsible
for the acts, defaults and neglect in manufacture or design of any subcontractor, as if they were his own.
Where the Employers representative has consented to supply of Plant
or execution of work by manufacturers or sub-contractors proposed by
the Contractor, such manufacturers or sub-contractors shall not be
changed without the prior approval in writing of the Employers
representative.
A copy of every order shall be sent to the Employers representative at
the time the order is placed each clearly marked with the title of the
Contract and the Contract number.
PAGE 21 of 30
43 of 2461
2.10
MMRDA
Minimum Construction Equipment to be brought by Contractor on
Site
The Contractor is required to assign minimum equipment on site for

ensuring quality and timely progress of works. The minimum equipment
in adequate numbers, including but not limited to the equipment
described in this Subsection, shall be mobilized by the Contractor on
site in working condition. The Contractor should submit the equipment
mobilization program in the bid schedules.
Table 2.4: Minimum Equipment to be mobilized by Contractor on

Site
S.
Description of Equipment
No.
Minimum number
to be mobilized
Excavation, Transportation, Handling and Erection
Dozer
JCB
Crawler crane
Crane 10 T Hydra
Excavators
Tipping Trucks
10
Licensed Blasting Facility
Rock Breaker with Excavators
Ripper
1o
Compressors and jack hammers
11
Tripods and Chain Pulley Blocks
10
12
Dewatering Pumps
Concreting
Concrete Batching Plant
Concrete Mixers
10
Needle Vibrators
20
Plate Vibrators for Bedding
10
Portable welding and Gas cutting Equipments
PAGE 22 of 30
44 of 2461
S.
MMRDA
Description of Equipment
No.
Minimum number
to be mobilized
Welding set
Diesel Generating set
Gas cutting set
Pipe Manufacturing Equipment
Pipe forming Machinery
1 set at each
factory
Welding Equipment for submerged arc
1 set at each
welding for Pipe Fabrication
factory
Hydro Testing Equipment
1 set at each
factory
Gamma Ray Equipment
1 set at each
factory
Hydraulic testing equipments
1 set at each
factory
E
F
2.11
Pipe Lining and Coating Equipment
As required
Tunnel Boring Machine
As required
Field Laboratories
The Contractor shall establish a field laboratory as approved by the

Employers representative, suitably equipped to carry out tests as
stipulated in the QA/QC Manual, including all specialized equipment
which will be required for testing the material and equipment being
supplied under the Contract. Suitable trained laboratory staff will have
to be posted with full facility of computerized record keeping. The
minimum equipment to be provided in the laboratory shall be as listed
below. Additional equipment as may be deemed necessary may be
added to the same in due course on requirement of the Employer/or
Employers representative.
The laboratory shall have the following facilities required for sampling
and testing materials and concrete in the field. All such facilities shall
PAGE 23 of 30
45 of 2461
MMRDA
be provided by the Contractor at no extra cost to the Employer. The

following equipment with operators shall be made available at
Employers representative request.
Table 2.5: List of Equipment to be provided for Laboratory by the

Contractor
S.
Description
Quantity
No.
1
Hydraulic
Compression
Testing
Machine,
hand
1 No.
operated 100 tonnes capacity. Conforming to the

requirements
of
IS:
516-1959,
IS
:14858-2000
calibrated to an accuracy of 1% indicated load within

range.
2
Cube moulds 150x150x150 mm size conforming to IS:
24 nos.
516-1959, IS: 10086-1982.

3
Cube moulds 100x100x100 mm size conforming to IS:
12 nos
516-1959, IS: 10086-1982.

4
Slump apparatus conforming to IS: 7320.
Test sieve set IS: 460-1972, 30 cm dia frame of size
1
1 set
40mm, 20mm, 12.5mm and 10 mm and 20 cm dia

frame of size 4.75mm, 3.35 mm, 2.36mm, 1.18mm,
600 microns, 300 microns, 150 microns, 90 microns
and 75 microns.
6
Bulk density measure 3 and 15 liters capacity as per
One each
IS: 2386 (Part-III)- 1963.

7
Thickness and length gauge as per IS: 2386 (Part-I)-
One each
1963.
8
15 cm dia aggregate crushing value apparatus as per
1 no.
IS: 2386 (Part-IV)- 1963.

9
Graduated cylinder of glass 100, 250 and 1000 ml
3 nos. each
capacity.
10
Balances 1 kg, 5kg and 15 kg capacity.
11
Electric oven, thermostatically controlled upto 200 0C,
One each
1 no.
chamber space about 40x40x40 cm.
PAGE 24 of 30
46 of 2461
S.
MMRDA
Description
Quantity
Concrete Test Hammer (rebound hammer) of impact
1No.
No.
12
energy 2.207 N. m (0.225 Kgm) as per IS : 1331

(Part-2)- 1992.
13
Chemicals for water content determination of fresh
As required
concrete sodium chloride, nitric acid, nitrobenzene,

ferric
alum,
silvernitrate,
potassium
thiocyanate,
sodium hydroxide and HCl.

14
Vicat apparatus as per IS: 4031
1 no.
15
Vibration machine with 6 moulds as per IS: 4031.
1no.
16
Hot Plate
1 no
17
Apparatus
(HCl
heat
of
solution
method)
for
1 no.
estimation of cement content of fresh concrete

18
Glass ware for testing of S.No. 17
1 set
19
Pycnometer.
1no
20
Elongation index gauge
1No
21
Glass flasks and metal container
1 set
22
Sedimentation pipette
2 nos.
Arrangement can be made by the Contractor to have the cubes tested

in an approved laboratory in lieu of a testing machine at site at his
expense, with the prior consent of the Employers representative.
The outside laboratory shall also be used for routine testing of cement,
reinforcement, coarse and fine aggregate and other items.
In addition to the equipment in the laboratory, the Contractor will also

provide field testing equipment as directed by the Employers
representative on the various sites where work is in progress.
2.12
Settling up Factory for Pipe manufacturing in the Project Area
It is obligatory for the Contractor to establish at least one pipe

manufacturing and coating facilities in the Project area. He will have to
PAGE 25 of 30
47 of 2461
MMRDA
make his own arrangements for the required land, power and water
supply, access and the required permissions from relevant agencies.
The Employer will make efforts to help the Contractor in his efforts by
providing him with the necessary recommendation letters and whatever
other assistance may be possible.
2.13
Materials: General Requirements and Manufacturers Experience
The term materials shall mean all materials, goods and articles of every
kind whether raw, processed or manufactured and equipment and plant
of every kind to be supplied by the Contractor for incorporation in the
Works.
Except as may be otherwise specified for parts of the Works in

Employers requirements / particular specifications, the provision of the
Standard Specifications shall apply to materials general requirements
for any part of the Works.
All materials shall be new and of the kinds and qualities described in
the Contract and shall be at least equal to approved samples.
The Contractor shall as far as possible use materials available in India

for the completion of the Works, subject to compliance with the
Specification.
Materials shall be transported, handled and stored so as to prevent

deterioration, damage or contamination.
The Contractor shall procure pipes, specials, pumps and other

electrical equipments from approved manufacturers specified in tender
document with proven experience in the supply of similar items for at
least 10 years. Employer reserves the right to demand an additional
security upto 5% of the supply and construction value for considering
experience in manufacturing of less than 10 years.
PAGE 26 of 30
48 of 2461
2.14
MMRDA
Substances and Products
Substances and products used in the Works which may be applied to

or introduced into water supplied for drinking, washing or cooking shall
not contain any matter which could impart taste, odour, colour or
toxicity to the water or otherwise be objectionable on health grounds.
Only substances and products which have been approved by a
national or international regulatory body shall be used.
After award of Contract, from time to time, the Contractor shall submit
for the approval of the Employers representative a schedule of
substances and products he proposes to use in the Works giving the
following information as applicable:
Item of plant;
Substance/product in contact with water;
Manufacturer of plant/substance/product;
Point of use in the Works;
Name of the regulatory body if applicable, which has approved the

substance/product;
2.15
Delivery and Storage of Plant
2.15.1
Packing and Protection

Before any plant is despatched from a manufacturers factory it shall be
adequately protected and packed to ensure that it will arrive on the site
in an undamaged condition. The methods employed for protection and
packing must be suitable for rough handling and withstanding the
conditions which may be experienced during shipment, delivery to the
site and prolonged periods of storage in the open, whether the items
are shipped in packing cases, crates or only partially protected
according to their nature.
Packages containing dangerous or
breakable goods shall be packed and marked in accordance with any

statutory rules and orders applicable.
PAGE 27 of 30
49 of 2461
MMRDA
Bright parts and bearing surfaces shall be protected from corrosion by

applying a rust preventive lacquer, high melting point grease or similar
temporary protection. A sufficient quantity of solvent shall be supplied
with the plant to enable this coating to be removed on the site.
Electrical equipment shall be suitably protected against corrosion and

incidental damage to the satisfaction of the Employers representative.
Temporary leads shall be fitted to electrical equipment to enable anticondensation heaters to be energized when the plant is in store. The
heaters shall be energized by the Contractor when conditions require.
All machined flanges and other mating surfaces shall be protected by

means of wood templates. The bolts for securing these templates shall
not be reused in the final installation.
No crate or package shall contain items of plant intended for

incorporation in more than one part of the works.
All items of plant shall be clearly marked for identification against the
packing list, which shall be placed in a waterproof envelope inside
every packing case or crate. Every packing case and crate shall be
indelibly marked to show its weight, serial number, top and bottom,
shipping marks and handling instructions or sling marks.
2.15.2
Delivery to Site
The Contractor shall be responsible for the transporting and handling of

all the Plant.
The storage of all equipment and construction items at the Site shall be
the Contractor's responsibility.
The Contractor shall check all items against packing lists immediately
on delivery to the Site and shall also inspect for damage and
PAGE 28 of 30
50 of 2461
MMRDA
shortages. Damages and shortages shall be remedied with the

minimum of delay.
The Contractor may, with the prior approval of the Employers
representative and at no extra cost to the Employer, make
arrangements for any other contractor or agent to take delivery of,
unload and store the Plant on the Site on behalf of the Contractor.
All deliveries shall take place during the Contractor's normal working
hours.
2.15.3
Storage
An area and/or building on the Site for use by the Contractor for
storage of Plant prior to erection will be subject to the approval of the
The Contractor shall provide all other facilities for the safe and proper
storage of Plant, as recommended by the manufacturers, with
particular consideration being given to temperature, rain, sunlight, wind
and ground conditions. All electrical equipment for indoor installation
shall be kept in store building and dry condition shall be maintained.
The Contractor shall remain responsible to the Employer for the care
and insurance of the Plant and the provisions of this Clause shall not
relieve the Contractor of any of his liabilities under the Contract.
Stored Plant items shall be laid out by the Contractor to facilitate their
retrieval for use in the programmed order.
Stacked Plant items shall be protected from damage by spacers on

load distributing supports and shall be safely arranged. No metalwork
shall be stored directly on the ground.
Small Plant items shall be held in suitable bins, boxes or racks and be
PAGE 29 of 30
51 of 2461
MMRDA
clearly labelled.
Items of Plant shall be handled and stored so that they are not
subjected to excessive stresses and so that protective coatings are not
damaged.
Small plant items shall be held in suitable bins, boxes or racks and be
clearly labeled.
Items of plant shall be handled and stored so that they are not
subjected to excessive stresses and so that protective coatings are not
damaged.
The Contractor shall comply with the manufacturers
package and plant markings concerning the use and location of lifting
slings, chains and hooks.
2.15.4
Erection, Testing and Commissioning
Please refer a separate sub-section detailing specification for above

activities.
PAGE 30 of 30
52 of 2461
SUB-SECTION 6A.3
SITES AND SITE WORKS
53 of 2461
MMRDA
Table of Contents
SUB-SECTION 6A.3: SITES AND SITE WORKS ............................................................ 1

3.1 General.......................................................................................................................... 1
3.2 Access to the Site ...................................................................................................... 2
3.3 Camp and Campus .................................................................................................... 2
3.4 Facilities and Offices for Employers Staff and his Representative ........... 3
3.5 Areas Outside the Site .............................................................................................. 4
3.6 Road Works ................................................................................................................. 5
3.7 Maintenance of Existing Access Roads .............................................................. 6
3.8 Clearance of the Site ................................................................................................. 6
3.9 Clearance and Reinstatement of the Site on Completion ............................... 7
3.10
Site Records ............................................................................................................ 7
3.11
Access for the Employers Representative ..................................................... 7
3.12
Water Supply and Disposal on Site ................................................................... 7
3.13
Latrines and Washing Facilities ......................................................................... 8
3.14
Electricity for Contractor's Use on Site............................................................ 8
3.15
Compressed Air Use on Site ............................................................................... 9
3.16
Refuse Disposal on Site ....................................................................................... 9
3.17
Health, Hygiene and Contamination of Water Supplies............................... 9
3.18
Safety and Security on Site ............................................................................... 10
3.19
First Aid and Life-saving Apparatus on Site ................................................. 12
3.20
Electrical Safety on Site ..................................................................................... 12
3.21
Noise ........................................................................................................................ 12
3.22
Warning and Safety Signs.................................................................................. 13
3.23
Signboards ............................................................................................................. 13
3.24
Advertising ............................................................................................................. 13
54 of 2461
MMRDA
SUB-SECTION 6A.3: SITES AND SITE WORKS
3.1
General
Main sites are at Kawadas for Intake, Suryanagar for WTP,

Kashidkopar and Chene for MBRs, three tunnel sites and entire route
of transmission systems.
The Contractor will be allowed to use the spaces available with the
Employer after permission of the Employers Representative.
The
Contractor will be free to use them for establishing his offices,

laboratories, staff quarters, storage spaces and workshop as long as
they do not interfere with the layout of the works to be carried out under
the Project.
The Contractor will also be permitted to use the skeleton constructions
available on these spaces for his use after permission from the
Employers Representative.
There may be some encroachments on some of these spaces and
structures which may take some time in clearance, for which the
Employer will not be held responsible. However, the Contractor shall
settle the issues coming across the way of work.
The prospective
bidders are advised to familiarize themselves with the existing situation

and make their own evaluation / assessment before submitting the bid.
All the buildings and compound wall / fencing to be handed over by the
Employer will be handed over on as as-is, where-is basis.
The Contractor will be responsible to arrange and pay for whatever
modifications the structures may require for his use and also for
providing necessary facilities like access road, water, sanitation and
electricity.
He will be responsible to maintain a clean and healthy
environment at the locations taken by him and will be responsible for

conduct of his personnel there.
SECTION 6A.3: SITES AND SITE WORKS
PAGE 1 of 14
55 of 2461
MMRDA
The Contractor will have to hand over the spaces and structures in a
clean and intact condition at the end of the Contract or at an
intermediate stage when they may be required by the Employers
Representative on demand after one-month notice.
There shall be no charge for the use of such space or structures. The
Employer however does not undertake to provide any further space or
accommodation that the Contractor may require to fulfill his contractual
responsibilities.
The Contractor will be responsible to arrange the
same at his own cost. The Employer may assist the Contractor in
making his arrangements by giving suitable recommendation letters.
3.2
Access to the Site
The Employer will provide to the Contractor access to and possession

of the Site for carrying out the Works. The Contractor shall be deemed
to have inspected the Site including access before submitting his
Tender.
The Contractor shall ensure that all the Plant offered is of a size and
weight or can be divided into sections of a size and weight suitable for
access to the place of installation. Also, the equipment used for
installation purposes shall be able to have access and position for such
purposes.
The Contractor shall ensure that the operation of the existing facility,
MBR and piping should not be hindered any way due to mobilization of
the equipment, civil or any contract related work.
3.3
Camp and Campus
The Contractor shall construct and maintain to the Employers

representative satisfaction a camp to provide living accommodation for
all contractors staff who have no other local accommodation. The
Contractor's camp shall be located close to the Site itself and at a
PAGE 2 of 14
56 of 2461
MMRDA
location approved by the Employers representative. Responsibility for

acquiring land and providing all services to the living quarters and
compliance with all sanitary laws and other laws and regulations shall
be borne by the Contractor. Security and the fencing of these areas
shall be the responsibility of the Contractor.
3.4
Facilities and Offices for Employers Staff and his Representative
The Contractor shall provide and upkeep the following facilities for the
Employer and Employers Representative. The cost for these facilities
shall be borne by the Contractor.
Air conditioned offices at five locations of floor area not less than 100
square meters at Suryanagar and 75 square meters at remaining four
locations, with provision of pantry with cooking / catering arrangement
for food & snacks, tea & coffee vending machines, crockery and
cutlery. Bottled mineral water with dispensers shall be provided by
Contractor in all offices. The office at Suryanagar shall have
conference room and projector for power point presentation.
The layout of the offices shall be submitted to the Employer for
approval. The office building shall be equipped with office furniture (at
least 3 tables, 8 chairs, two filing and two drawing cabinets at each
location), and each location shall be provided with a canteen,
electricity, standby generator set, telephones, broadband internet
connectivity, fans etc. Maintenance and upkeep of the office shall be
contractors responsibility for entire period of the contract.
The locations shall be as under:
WTP site
MendhwanKhind tunnel site
Kashidkopar MBR site
PAGE 3 of 14
57 of 2461
MMRDA
Tungareshwar tunnel site

Chene MBR site
In addition, a small office shall be provided at Intake site.
The construction of all offices shall be completed within 60 days.
For the Employers representative, two numbers of desktop computers
with flat screens loaded with the latest versions of windows MS office,
MSP, AutoCAD and Inkjet printer and photocopy machine for A4 & A3
size and a plotter for taking copies of construction drawings. All office
shall be provided with adequate stationary for routine office work.
Four air-conditioned cars of INNOVA / SCORPIO or equivalent of 2016
make with drivers shall be provided for use of employers staff. This
shall be provided for 34 months or until completion of the 50% of
operation and maintenance works and shall provide for monthly
average 5000 k.m. per vehicle. Fuel and maintenance of cars shall be
responsibility of the contractor.
In addition to above, the Contractor shall provide suitable air
conditioned temporary offices along the pipe laying works while work in
progress.
The offices shall remain as the property of the Contractor at the end of
the Contract.
3.5
Areas Outside the Site
In the event of the Contractor making use of any special or temporary

wayleave or accommodation acquired by him or any tip for the disposal
of surplus materials, or any borrow pit or quarry, he shall obtain the
written consent of the owner, occupier or authority having charge of the
PAGE 4 of 14
58 of 2461
MMRDA
land in which such way leave, accommodation or tip is situated and

shall make agreement with the owner, occupier or authority as
aforesaid of the condition of the surface of that land before entering
thereon.
The Contractor shall permit the Employers representative and any
person authorised by him access for the purposes of the Contract to
any such special or temporary wayleave or additional accommodation.
In the event of the Contractor making use of any special or temporary
wayleave or additional accommodation made available to him by the
Employer for the purpose of the Contract, the land in which such
wayleave or accommodation is situated shall be deemed to be part of
the Site.
Under these circumstances the Contractor shall form a Working Area
extending
5m
from
the
edge
of
the
Permanent
Works
or
accommodation on all sides. The Contractor shall restrict his activities

to within this Working Area. On completion of the works in this area,
the Contractor shall reinstate the area by clearing the stuffs to its
original condition to the satisfaction of the Employers representative.
Private land or other land taken by the Contractor for disposal of debris
or other material or for any other purpose must be cleared and made
acceptable from health and environmental aspect before.
3.6
Road Works
The Contractor shall obtain all permits required for carrying out works
such as excavation on public roads and shall liaise with the appropriate
authorities with regard to the timing and execution of the road works.
The Contractor shall be responsible for establishing and maintaining
temporary road diversions for the duration of the road works. The road
shall be kept open at all times during the road works period, and the
PAGE 5 of 14
59 of 2461
MMRDA
work shall be carried out in such a manner as to minimise the

disruption to traffic.
3.7
Maintenance of Existing Access Roads
The Contractor shall only use existing access roads within the Site
boundary which are necessary for the execution of the Works. The
Contractor shall be solely responsible for the maintenance of the
existing site access roads.
Such maintenance work shall include
general up-keep, and any necessary repairs to damaged road

surfaces, pavement, drainage, associated slopes, etc. to original
condition. While carrying out such maintenance work, the Contractor
shall make arrangements to maintain through passage for the
Employer's and his staff's vehicles and also those of other contractors
over these access roads, which may comprise temporary diversions all
to the approval and satisfaction of the Employers representative.
The Contractor shall take every precaution while operating tracked or
unsprang vehicles on surfaced roads and shall use planking or some
other protective material to protect the road surface.
3.8
Clearance of the Site
The Contractor shall clear the Site to the extent required by the
Employers representative for the setting-out. Clearance of the Site
shall also include the demolition and removal of all articles, objects and
obstructions which are expressly required to be cleared to the
satisfaction of the Employers representative.
The Contractor shall remove the material arising from such clearance
and dispose of it in a manner and at a location, on or off the Site, to the
approval of the Employers representative.
PAGE 6 of 14
60 of 2461
MMRDA
The Contractor shall fill and make good with appropriate materials
those cavities and losses of soil which result from clearing the parts of
the Site not subsequently to be occupied by the Works.
The Contractor shall not clear the Site of any structure without the prior
written permission of the Employers representative. As far as possible
big trees shall be saved otherwise replanted at approved location.
3.9
Clearance and Reinstatement of the Site on Completion
On completion of the Works, the Contractor shall clear any temporary

works areas and temporary access roads and reinstate the areas to
their original condition and to the satisfaction of the Employers
representative.
3.10
Site Records
The Contractor shall make records of the position and extent in the
excavations of every type of service, stratum and obstruction
encountered during the construction of the Works.
3.11
Access for the Employers Representative
The Contractor shall permit the Employer and the Employers

representative and any person authorised by the Employer including
workmen of the Employer, other contractors or utility undertakings
access for the purposes of the Contract to all areas of the Site and to
any additional accommodation or temporary wayleave for the duration
of the Contract period.
3.12
Water Supply and Disposal on Site
The Contractor shall be responsible for arranging water for the

purposes of constructing the Works at his own cost and risk. The
PAGE 7 of 14
61 of 2461
MMRDA
Contractor shall ensure the quality of the water remains suitable for the
purpose for which it is intended.
Wastewater shall be disposed off clear of the Site to the satisfaction of
the Employers representative so as to cause no damage or complaint.
3.13
Latrines and Washing Facilities
Throughout the period of construction of the Works the Contractor shall

provide, maintain and cleanse suitable and sufficient latrines and
washing facilities for use by his employees. He shall ensure that his
employees do not foul the Site but make proper use of the latrines.
Where practicable the latrines shall be connected to the nearest sewer,
or if this is not practicable the Contractor shall provide an adequately
sized septic tank and soak away.
The Contractor is also to provide separate latrines for the employers
staff and Employers representative.
After Completion of the works, the latrines and washing facilities shall
be removed, all ground disinfected and the surface reinstated to the
3.14
Electricity for Contractor's Use on Site
The Contractor shall be responsible for arranging power supply and

distribution of an electrical supply for the purpose of constructing the
Works and making payment to the power supply authority.
The installation shall comply with all the relevant regulations, Indian
Standards and Codes of Practice, and Health and Safety requirements,
etc. The Contractor must take every possible precaution to ensure that
his installation is safe and injury to personnel or damage to plant and
PAGE 8 of 14
62 of 2461
MMRDA
buildings is avoided. The Contractor shall be fully responsible for all

safety and maintenance aspects.
The Contractor shall test the temporary site distribution system
including energy meter every 3 months for compliance with the relevant
standards.
3.15
Compressed Air Use on Site
The Contractor shall provide the necessary compressed air plant and
equipment required for construction of the Works.
Electrically driven compressors connected to the site electricity supply
shall not be used. Diesel engine driven compressors shall not be sited
within buildings or in a location that may cause a health hazard to
personnel owing to exhaust fumes or noise.
3.16
Refuse Disposal on Site
Refuse and rubbish of every kind shall be removed from the Site and
disposed off by the Contractor at his own expense, frequently and
regularly so as to keep the Site in an approved wholesome and tidy
condition to the satisfaction of the Employers representative.
3.17
Health, Hygiene and Contamination of Water Supplies
The Site shall be an area of `restricted operation'. Exemptions may be

granted at the discretion of the Employers representative for short term
operations involving no risk of contamination. The Contractor shall be
responsible to ensure the following:
-
All personnel shall be medically accepted.
Water supplies for drinking, cooking and washing is fit for use and
minimum drinking water quality standards
PAGE 9 of 14
63 of 2461
MMRDA
Strict discipline shall be maintained concerning personal hygiene.
Vehicles, plant, tools and protective clothing shall be kept clean and
may require regular disinfection.
The Contractor shall be responsible for regular medical check-up and

treatment.
Should any employee is infected with any looseness of bowels, gastric
disorder or contagious disease such employee shall be immediately
removed from the site.
3.18
Safety and Security on Site
The Contractor shall at all times maintain a safe system of working and
shall comply with all enactments, regulations and working rules relating
to safety, security, health and welfare of all persons who may be
affected by his work.
In particular, he shall ensure that only persons who are properly trained
for their duties are employed, and that the correct tools and procedures
are used.
Nothing which has been written into or omitted from this Employers
Requirements shall be taken to relieve the Contractor from his
obligations
under
this
clause.
No
clause
in
this
Employers
Requirements shall prevent the Contractor from drawing the attention

of the Employers representative to any feature of the Works which is
not consistent with normal safety practices nor prevent him putting
forward proposals at any time which would increase the safety of the
installations.
Not later than four weeks before work commences on the Site, the
Contractor
shall
submit
to
the
Employers
representative
his
PAGE 10 of 14
64 of 2461
MMRDA
comprehensive proposals relating to the safety, health and welfare of

all his personnel on the Site.
The Contractor shall appoint a suitably qualified representative as
Safety Officer who shall be responsible for the implementation of site
procedures as per relevant standards which shall include but not be
limited to:
-
safety;
working in hazardous areas;
permit to work;
fire and smoking regulations;
first aid;
warning signs;
trenching scaffolding and other construction structures;
safety barriers;
protective clothing and equipment;
safety training;
safety meetings and inspections;
health and welfare.
The proposals shall be appropriate for all grades of labour and

personnel who will work on or visit the Site on behalf of the Employer,
Employers representative or Contractor.
The Employers representative has the power to stop any activity or
work in any area where there is a breach of the published site safety
rules such that health or life is put at risk.
The Contractor shall ensure that all employees working on the Site are
not working in an unsafe manner so as to endanger themselves, the
Contractors personnel, other personnel or the Plant. The Contractor
shall bring any violation of Site safety rules by others to the attention of
Employers representative in writing.
PAGE 11 of 14
65 of 2461
3.19
MMRDA
First Aid and Life-saving Apparatus on Site
The Contractor shall provide on the Site such life-saving apparatus as

may be appropriate and an adequate and easily accessible first aid
outfit or such outfits as may be required in any government ordinances,
factories acts, etc., published and subsequently amended from time to
time. In addition, an adequate number of persons permanently on the
Site shall be instructed in their use, and the persons so designated
shall be made known to all employees by the posting of their names
and designations in a prominent position on Site.
3.20
Electrical Safety on Site
The Contractor shall be responsible for the electrical safety of all Plant
supplied and installed. Whilst any equipment is being installed or
tested, the Contractor shall ensure that all necessary precautions are
taken to safeguard personnel working on site. If necessary, this shall
include fencing off areas which are considered to pose a risk, and
erecting warning notices.
The Contractor shall be responsible for ensuring that the electrical
installation is carried out by suitably trained competent personnel and
that the work is carried out in a safe manner.
The Contractor shall be responsible for the operation on the Site of a
permit to work system during the period of electrical equipment
installation and testing. This system shall regulate the installation, the
energisation and the use of electrical Plant installed and the method of
work adopted.
3.21
Noise
The Contractor shall ensure that the operations entailed in the

construction of the Works do not cause annoyance to others working
on the Site or to persons living adjacent to the Site.
PAGE 12 of 14
66 of 2461
3.22
MMRDA
Warning and Safety Signs
During construction of the Works statutory safety signs, shall be

adequately provided throughout the Works, both indoors and outdoors.
These safety signs shall cover mandatory, prohibition, warning,
emergency, fire-fighting and general notices. All signs shall be
positioned around the Works at highly visible points. Provision of signs
and the positions of signs shall be subject to the Employers
representative s approval. Special attention shall be given to areas
designated hazardous.
3.23
Signboards
The Contractor shall supply and erect signboards at locations to be

specified by the Employers representative. The layout and dimensions
of the signboards and their construction shall be to the approval of the
Employers representative and the lettering in both Hindi and English
shall be black on a white background or any other colour combination
for
better
indications
subject
to
approval
of
the
Employers
representative.
3.24
Advertising
The Contractor shall not use any part of the Site for any form of
advertising without the prior written approval of the Employers
representative.
3.25
Fire Safety
All fire safety precautions against fire hazards shall be taken by the
contractor as per
I.S. Code of practice for fire safety of buildings
(general) & National Buildings code of India 2005 as applicable.

Accordingly, necessary fire equipments shall be provided in all the
buildings and site the fire extinguishers and all provisions shall be
PAGE 13 of 14
67 of 2461
MMRDA
suitable for fire fighting for general fire, fire for electrical equipment and
fire for chlorine house. Adequate numbers of sand buckets shall be
provided.
PAGE 14 of 14
68 of 2461
SUB-SECTION 6A.4
SYSTEM PERFORMANCE PARAMETERS AND
LIQUIDATED DAMAGES
69 of 2461
MMRDA
Table of Contents
SUB-SECTION 6A.4: SYSTEM PERFORMANCE PARAMETERS AND

LIQUIDATED DAMAGES ...................................................................................................... 1
4.1 General.......................................................................................................................... 1
4.2 Shortfall observed in Commissioning Test ........................................................ 2
4.3 Shortfall and Lapses during O&M Period............................................................ 3
4.3.1 Filtered Water Turbidity........................................................................................ 3
4.3.2 Residual Chlorine during O&M ........................................................................... 4
4.3.3 Water Loss in WTP Process during O&M ......................................................... 4
4.3.4 Short Supply during O&M .................................................................................... 5
4.4 Leakage Loss in Transmission System during O&M Period ......................... 6
4.4.1 Establishing Benchmark Losses ........................................................................ 6
4.4.2 Monitoring during Operation Period (O&M Period) ......................................... 7
4.4.3 Liquidated Damages for exceeding losses beyond Acceptable Tolerance . 7
4.5 Power Consumption in Pumping Stations and WTP at the time of O&M ... 8
4.6 Maintenance of Power Factor during O&M ......................................................... 9
70 of 2461
MMRDA
SUB-SECTION 6A.4: SYSTEM PERFORMANCE PARAMETERS AND

LIQUIDATED DAMAGES
4.1
General
Supply of safe drinking water of required quantity and quality at

optimum energy consumption and optimum leakage losses is essence
of the Contract.
This subsection specifies performance parameters for the quality and
quantity of water supply system, acceptable variations and tolerances
and liquidated damages to be recovered from the Contractor if
guaranteed
performance
parameters
are
not
achieved
within
acceptable variations and tolerances at the time of (a) Inception of the

scheme and (b) during operation and maintenance period.
The performance parameters are as follows.
(a)
The time of Inception of the scheme
i)
Treated water output from the scheme
ii)
Water quality turbidity at clarifiers output
iii)
Water quality turbidity at outlet of filter plant
iv)
Power consumption
(b)
During Operation and Maintenance
i)
Filtered water turbidity
ii)
Residual chlorine in treated water at two MBRs
iii)
Net water loss in WTP
SECTION 6A.4: SYSTEM PERFORMANCE PARAMETERS & LD REVISED
71 of 2461
PAGE 1 of 9
MMRDA
iv)
Bulk water quantity supplied daily to two MBRs (short supply)
v)
Leakage loss in transmission system
vi)
Cumulative power consumption at Intake, WTP and clear water

pumping station
vii)
4.2
Power factor at all electrical installations
Shortfall observed in Commissioning Test
In case the permissible parameters are not achieved during

commissioning test liquidated damage as under shall be applicable.
(i)
Failure to achieve treated water output from WTP with

pumping system working for 22 hrs., per day, Liquidated
Damages (LD) at the rate of 0.5% of the works contract
price for each 1.0% shortfall below the guaranteed
capacity shall be applicable. However, 1% per cent
tolerance shall be allowed.
Illustration: If output from WTP is short by 1% no LD shall be

applicable. If output is short by 3%, LD will be applicable for 2%
shortfall only and shall be 0.5 x 2 i.e. 1% of work contract price
as one-time LD.
(ii)
Failure to achieve water quality stipulated from outlet of clarifiers

i.e. 10 NTU with the most critical raw water parameters, 1% of
the works contract price for the water treatment plant component
for each additional 1.0 NTU, or part thereof, beyond the
stipulated requirement of 10 NTU shall be applicable.
(iii)
Failure to achieve water quality stipulated from outlet of filter

plant (< 1.0 NTU), 1% of the works contract price for the water
72 of 2461
PAGE 2 of 9
MMRDA
treatment plant component for each additional 0.2 NTU turbidity,

or part thereof, beyond the stipulated requirement of 1 NTU shall
be applicable.
(iv)
LD for excess consumption of electric energy for operating the

pumping stations, water treatment plant and related facilities at
the rate of one & half times the estimated cost of the excess
energy requirements for operating above units at their rated
capacity for a period of fifteen years above the maximum
consumption guaranteed by the Contractor under relevant
schedules and current rates charged by power supply company
for electricity consumed by the plant and facilities, discounted to
net present value at the rate 8% (eight percent) per annum shall
be applicable.
4.3
Shortfall and Lapses during O&M Period
4.3.1
Filtered Water Turbidity

Raw water will be provided within the permissible parameters and, in
general, there should be no lapse in it. The treated water will be
checked for turbidity at filter outlet. The turbidity should be as per
treated water quality stipulated at the filter plant.
(i)
In case of lapses for one day in a calendar month, liquidated

damages will be applied at the rate of 0.25% of the Contractors
monthly charges for O&M for one day of lapse.
(ii)
In case there are lapses in two days, liquidated damages will be

applied at the rate of 0.5% of the Contractors monthly charges
for O&M for each day of Lapse.
(iii)
In case the Contractor has continuous lapses beyond two days,

liquidated damages will be applied at the rate of 1% of the
Contractors monthly charges for O&M for each day of lapse. In
73 of 2461
PAGE 3 of 9
MMRDA
such case, the Contractor will be notified and the Employer will
have the option of making the necessary inputs to control and
improve the supply. All costs for such improvement, including
10% for overhead and administration, will be charged to the
Contractor, along with the liquidated damages for the lapses.
4.3.2
Residual Chlorine during O&M

Water
will
be
provided
within
the
permissible
bacteriological
parameters and, in general, there should be no lapse in it. The treated

water will be checked for free residual Inlet / Outlet chlorine at MBR at
Kashidkopar & MBR at Chene. The free residual chlorine at the MBR at
Kashidkopar and MBR at Chene should not be less than 0.2 mg/Liter.
In case the permissible parameters are not achieved:
(i)
In case of lapses of one day in a calendar month, liquidated

damages will be applied at the rate of 0.25% of the Contractors
monthly charges for O&M for one day of lapse.
(ii)
In case there are lapses in two days, liquidated damages will be

applied at the rate of 0.5% of the Contractors monthly charges
for O&M for each day of lapse.
(iii)
In case the Contractor has continuous lapses beyond two days,

liquidated damages will be applied at the rate of 1% of the
Contractors monthly charges for O&M for each day of lapse. In
such case, the Contractor will be notified and the Employer will
have the option of making the necessary inputs to control and
improve the supply. All costs for such improvement, including
10% for overhead and administration, will be charged to the
Contractor, along with the liquidated damages for the lapses.
4.3.3
Water Loss in WTP Process during O&M
74 of 2461
PAGE 4 of 9
MMRDA
Water loss due to sludge abstraction from clarifiers and washing of

filter beds is unavoidable feature of the process. In order to conserve
water, recirculation of waste water and reuse by returning part of
wastewater is specified.
The water loss in WTP will be measured by integrating the flow
measured by flowmeter on Raw Water Transmission Main minus
flowmeter on clear water main during 24 hours.
With above arrangement and with tolerance, the water loss shall not
exceed 2.5% of WTP output.
In case, the water loss exceeds 2.5% of WTP output;
i)
In case of lapses for one day in a calendar month, liquidated

damages will be applied at the rate Rs.5000/- per ML for one
day of lapse.
ii)
In case there are lapses in two days or more liquidated

damages will be applied at the rate of Rs. 20,000 per ML per
day.
4.3.4
Short Supply during O&M

The supply is to be measured for each day from 00:00 midnight to next
midnight. The Contractor is expected to meet the daily supply as per
requirement from the Employers Representative.
Liquidated damages (LD) shall be imposed on a daily basis,

taking into account the tolerances of various parameters
No LD shall be imposed for failure to supply due to nonavailability of power on the part of Electricity Supplier Company,
MSEDL
75 of 2461
PAGE 5 of 9
MMRDA
No LD shall be imposed for water supply being short by up to

1% of required quantity
In case the daily water supply is below the requirement, LD will be

imposed as follows:
More than 1%: Liquidated damages will be applied at the rate of

0.10% of the monthly O&M charges, per percentage of total
shortfall per day less 1% tolerance
Illustration: If the supply is short by up to 1% on any day, no LD
will be applicable. If it is 5%, LD will be 0.4% per day. If the
deficiency is 11%, LD will be 1% per day. If the deficiency
increases to 21%, LD will be 2% of the monthly charges for
O&M per day.
4.4
Leakage Loss in Transmission System during O&M Period
4.4.1
Establishing Benchmark Losses

Leakage losses in Clear Water Transmission System shall be
monitored.
Electro-magnetic flowmeters are provided at following locations.
First flowmeter on Raw water pumping main (FM-M1)
Second flowmeter adjacent to clear water pumping station (FM-M2)
Third flowmeter upstream of Kashidkopar junction on clear water

gravity main from BPT to Junction (FM-M3)
Fourth flowmeter at Inlet to Kashidkopar MBR (FM-M4)
Fifth flowmeter at Inlet to Chene MBR (FM-M5)
76 of 2461
PAGE 6 of 9
MMRDA
In addition to above, 7 Nos. of electromagnetic flowmeters on

tapings between Kashidkopar Junction to Chene MBR (FM-T1 to
FM-T7)
Leakage losses as shown by these twelve flowmeters as monitored

and recorded during test run shall be benchmark value for following
reaches of transmission mains.
(i)
CWPS to Kashidkopar Junction
(ii)
Kashidkopar Junction to Kashidkopar MBR
(iii)
Kashidkopar Junction to Chene MBR

The benchmark overall losses are given by,
Benchmark value:
Total Qty ( FM M 2) Total Qty ( FM M 4) Total Qty ( FM M 5) Total Qty( FM T1 to FM T 7)

100
Total Qty ( FM 2)
=
4.4.2
y%
Monitoring during Operation Period (O&M Period)

The values of above 12 Nos. of flow measuring devices will be
monitored on day to day basis and compared with benchmark values.
If the variation from benchmark values is within 1% for clear water
main, the same will be deemed within acceptable tolerance.
4.4.3
Liquidated Damages for exceeding losses beyond Acceptable

Tolerance
Acceptable tolerance from benchmark values as stated in sub clause
77 of 2461
PAGE 7 of 9
MMRDA
4.4.1.
Clear water main
1% variation from benchmark value in

percentage
Illustrations:
(i)
Benchmark value during test run was 5%. If average monthly

actual value during O&M is less than or equal to 6%, no
liquidated damage shall be applicable. If actual value increases
beyond 6%, liquidated damage shall be chargeable.
Liquidated damages shall be at following rates.

For Clear water main
Rs.20 lakhs per 1% overall excess losses per

month beyond acceptable tolerance of 1%
4.5
Power Consumption in Pumping Stations and WTP at the time of

O&M
(i)
The expected power consumption shall be decided initially on

the basis of Test run of Intake, Raw water pumping station,
Water treatment
plant, Clear water pumping station and
complete system up to MBRs for the continuous period of seven

days. This test run shall start prior to issuance Work completion
certificate and the permission from the Employer.
(ii)
The expected power consumption shall be calculated initially for

running the system to full capacity of water quantity 403 Mld with
desired water quality standards. The power consumption during
these seven days test run period shall be taken as benchmark
for comparison with the actual power consumption during
operation and maintenance period. If the actual power
consumption is higher than benchmark consumption with
acceptable tolerance of 1%, liquidated damages shall be
78 of 2461
PAGE 8 of 9
MMRDA
recovered from the Contractor at the rate of 1.25 times of the

charges for the extra power consumed and paid to power supply
company (MSEDCL / MSETCL)
Application
of
liquidated
damages
for
excess
power
consumption shall not be subject to any upper limit and shall be

applicable with consideration for 1% tolerance. Thus if power
consumption is less than 101`% of benchmark, no LD will be
levied.
If consumption is 101.5% LD for 0.5% shall be
applicable.
4.6
Maintenance of Power Factor during O&M
The Contractor shall maintain power factor above the lowest limit of
power supply company which is presently 0.90.
Power supply
company also grant incentive / bonus / benefit if power factor is higher

than lowest limit.
Following stipulations shall be applicable.
(i)
If any penalty is imposed by power supply company for not

maintaining power factor to lowest limit, liquidated damage @
1.25 times the penalty imposed.
(ii)
If any incentive / bonus / benefit is granted by power supply

company, 50% of the amount shall be passed on to the
Contractor.
79 of 2461
PAGE 9 of 9
SUB-SECTION 6A.5
DESIGN, DRAWINGS AND DOCUMENTS
80 of 2461
MMRDA
Table of Contents
SUB-SECTION 6A.5: DESIGN, DRAWINGS AND DOCUMENTS................................ 1

5.1 General.......................................................................................................................... 1
5.2 Drawings furnished by the Employer ................................................................... 1
5.3 Tenderers Drawings ................................................................................................. 2
5.4 Design Documents and Drawings by the Contractor....................................... 3
5.4.1 General ................................................................................................................... 3
5.4.2 Design ..................................................................................................................... 4
5.4.3 Documents in Electronic Format ........................................................................ 4
5.4.4 Drawing Standards, Format and Numbering .................................................... 5
5.4.5 Approval of Drawings by the Employer ............................................................. 6
5.5 Preliminary Drawings................................................................................................ 8
5.6 Construction Drawings........................................................................................... 10
5.6.1 Civil ........................................................................................................................ 10
5.6.2 WTP ...................................................................................................................... 12
5.6.3 Mechanical ........................................................................................................... 12
5.6.4 Electrical ............................................................................................................... 16
5.6.5 Control, Instrumentation and Monitoring System .......................................... 21
5.7 Control System Development ............................................................................... 23
5.8 As-Built Drawings .................................................................................................... 23
5.9 Operating and Maintenance Manual ................................................................... 24
5.9.1 General ................................................................................................................. 24
81 of 2461
MMRDA
SUB-SECTION 6A.5: DESIGN, DRAWINGS AND DOCUMENTS
5.1
General
Following 3 categories of Design and Drawings are involved in the bid

process and contract.
i)
Design and drawings furnished by the Employer with bid

documents
ii)
Tender drawings and documents furnished by the Tenderer with

his tender
iii)
Design, drawings and documents submitted by the Contractor

for the works
This subsection describes intent and implications of three categories

of design and drawing and stipulates employers requirements for
design and drawings for the works included in this contract.
5.2
Drawings furnished by the Employer
Drawings submitted as part of the Employers Requirements are

enclosed as Folder 4 Drawings. The drawings illustrate an overall
conceptual layout of the Works, and are not binding on the Contractor.
These drawings shall not be taken as the limiting responsibility of the
Contractor for the detailed design of the works. The tenderer may also
refer paragraph 2.8 of Sub-Section 6A.2.
The Contractor shall carry out such surveys, studies and analyses of
any kind as are necessary for the purpose of his general and detailed
designs and to verify the information shown on the Tender drawings
and other data furnished by the Employer. The Employer shall not be
liable for any claim by the Contractor on account of incompleteness or
SECTION 6A.5: DESIGN DRAWINGS & DOCUMENTS
PAGE 1 of 26
82 of 2461
MMRDA
inaccuracy of the data furnished by the Employer irrespective of when

the Contractor shall discover such incompleteness or inaccuracy.
All levels indicated except specified as obligatory or mandatory are
provisional, and may need to be revised subject to the results of survey
and site investigation that may be carried out by the Contractor, in
addition to the survey / investigation details furnished with tender
documents.
The Contractor shall note the constraint in terms of land available for
the works as shown in the drawings. The work including access roads
and pipework, shall be located within the area shown on the drawings
and in accordance with the overall conceptual design layout shown.
No additional land than that shown in the drawing will be provided. The
tenderer may also refer site constrains stated in Subsection 2A.3 and
various particular specifications.
5.3
Tenderers Drawings
The Tenderers drawings and documents are those furnished by a

tenderer with his tender for the purpose of illustrating and clarifying his
proposals. These include,
-
Layout Plans
Design of Intake and selection of raw water pumps
Design of clear water sump for vortex-free operation of pumps and

selection of pumps
Description of the proposed Water Treatment Plant and Treatment

Process offered
Hydraulic and Process Flow Diagram
PAGE 2 of 26
83 of 2461
MMRDA
Process and Instrumentation Diagram (P&IDs)
Hydraulic design of pipeline including shell thickness
Preliminary design of BPT
Electrical Load list
Chemical Uses
Design and drawing showing rock profile, tunnel profile and

associated works
Design and drawings for crossings and tappings
Such other drawings and documents so as to illustrate and explain

tenderers proposal
5.4
Design Documents and Drawings by the Contractor
5.4.1
General
The Construction Documents are design and certified Drawings
submitted by the Contractor to the Employer during the course of the
Contract for approval. The Contractor shall supply to the Employers
representative 5 (Five) copies each of the initial design calculations
and sizing of all components of the System including architectural,
structural,
process
hydraulic,
mechanical,
electrical
and
instrumentation equipment, supported by design calculation (Excel

spread sheets), flow diagrams and general arrangement drawings for
approval. It is a matter of high priority that the Contractor ensures the
submission and finalization of such designs and drawings in the
stipulated time schedules as stipulated elsewhere. It is the intention of
the Employer to ensure that the approval of such submissions is made
expeditiously and in time.
PAGE 3 of 26
84 of 2461
MMRDA
The Contractor shall be fully responsible for the content of all

submissions to the Employer irrespective of the source or origin of
information
contained
in
such
submissions.
All
submissions
irrespective of the source or origin of information shall be checked by

the Contractor and endorsed as such before submission to the
Employer. The Employer will not accept submissions for review unless
these requirements have been met.
Approval by the Employer of a submission by the Contractor shall
mean that the Employer has no objection in principle to the content of
the submission, drawings, calculations, certificates, samples and the
like and that the Employer finds the content of the submission good
enough to allow the work relating to the submission to proceed.
Approval by the Employer shall not relieve the Contractor of his
responsibility under the Contract. Approval will be given only on the
basis of information available at the time to the Employer on the
understanding that subsequent event may require withdrawal or
modification of such approval.
5.4.2
Design
The design of the works shall be an integral part of the Contract. Such
design shall include site investigation, temporary works designs and
drawings, functional plans and general designs, diagrams, detailed
designs and working drawings for all aspects of the works together with
any and all other studies, investigations, computations, analyses and
evaluations necessary to comply with the requirements of the
Specification.
Functional plans and designs shall be based on the proposals
submitted with the Contractor's Tender, subject to such modifications
as the Employer may require.
5.4.3
Documents in Electronic Format
PAGE 4 of 26
85 of 2461
MMRDA
All documents submitted for approval shall be provided in both electronic

format as well as paper copies of sufficient number as specified
elsewhere.
Each electronic submission shall be provided on
read/writable softcopy clearly marked with the project title, submission

reference and a description of the contents.
The Contractor shall provide the following electronic formats as a
minimum:
Word-processing documents
Microsoft Word / Adobe

acrobat
Spread sheet documents
Microsoft Excel / Adobe

acrobat
Databases
Programme of works
Drawings
Microsoft Access
-
Primavera or equivalent
AutoCAD
The Contractor shall submit details of the proposed software versions for
the Employers approval.
5.4.4
Drawing Standards, Format and Numbering

Drawings submitted by the Contractor shall be clearly printed with black
lines on white paper, and shall be resistant to fading on exposure to
light. Prints shall be on durable paper of good quality. Sheet sizes shall
be in accordance with A series to ISO 216, and be drawn electronically
at A1 size unless otherwise stated in the Contract or agreed with the
Employer.
All drawings submitted by the Contractor shall use SI units.
PAGE 5 of 26
86 of 2461
MMRDA
All drawings shall be clearly and fully cross referenced to the

Specification and the Employers drawings as relevant.
All drawings shall be prepared using an identical title block format. This
shall be approved by the Employer and shall identify the project,
drawing title, the Employer, the Contractor, Sub-contractor, if
applicable.
A formalised drawing numbering system shall be adopted with digits of
each number, referencing location, revision, drawing type and size.
The numbering format and allocation of drawing number blocks shall
be approved by the Employers representative The Contractor shall
provide a sequential numbering system for all Construction Documents
All drawings shall be submitted to a formalised checking procedure
prior to submission to the Contractor. Drawings not so checked will not
be approved.
Where drawings are revised, the revision letter or number shall be
incorporated in the title block and the revision shall be clearly indicated
on the drawing with the revision letter or number shown in an adjacent
triangle. When drawings are revised, this shall be done electronically
and not manually, and softcopies containing the revised files of all
drawings, which have been supplied in electronic format shall be
submitted at the same time as the paper prints.
5.4.5
Approval of Drawings by the Employer

The Employer representative shall arrange to send observations if
necessary within 21 (Twenty-One) days of submission of the design
and drawings for modifications to the Contractor. The Contractor shall
incorporate all necessary comments in the above design and drawings,
if any, and shall re-submit further 5 (five) copies each of the revised
design and drawings within 10 (Ten) days for final approval of the
PAGE 6 of 26
87 of 2461
MMRDA
Employer. The Contractor shall thereafter submit 7 (Seven) copies

each of the approved design and 7 (Seven) copies each of the
approved drawings together with one softcopy. The Employers will
return 2 (two) approved copies to the Contractor and retain 5 (five) for
his office and field use.
If the submissions require more than one round of revision on account
of incomplete compliance from Contractor, the delay will be on account
of the Contractor. If new observations are given by the Employers
representative, the Contractor will be entitled to take an additional 10
(ten) days period for compliance but without any impact on contract
period / time limit for completion of works. Further design calculations
and drawings shall be submitted in sequence as per a schedule to be
drawn and agreed upon mutually, immediately after submission of the
general arrangement drawings.
Category for drawing approval as follows shall be adopted.
Category I
Fully approved; no observation
Category
Good
II
Category
for
construction
after
compliance
of
observations
-
Not approved, need major revision
III
A blank space 90 x 50 mm shall be provided immediately above the
title block for the approval stamp. If required in the document
elsewhere, the detailed design and the execution drawings shall be
submitted only after verification by an institute approved by the
Employer or his representative. The Contractor shall be responsible for
preparation of working drawings and the construction documents for
works, as specified in the Contract.
The Employer may require the Contractor to submit for approval
PAGE 7 of 26
88 of 2461
MMRDA
additional drawings if they are necessary to enable him to satisfy

himself that the items are well designed, that they comply with the
Employers Requirements and that they are suitable for their intended
purpose. These drawings shall form the agreed basis for the execution
of the Works. If an approved drawing is revised, revised copies shall be
submitted for approval as above and no such revised drawing shall be
used for the purposes of the Contract until it has been approved in
place of the earlier issue of the drawing.
Approval of drawings by the Employer shall not be held to relieve the
Contractor of his responsibilities under the Contract.
The Employer will not permit construction to start on a part or section of
the Works unless Construction Documents for that part or section have
been approved.
5.5
Preliminary Drawings
Drawings for approval shall be submitted in two Phases both in hard as

well as in soft (editable) formats. The first phase shall be the
Preliminary Drawings. Drawings submitted during this phase shall be
of sufficient detail for the Employer and his representative to
understand outline the Contractors proposals for the design and
construction of the Works.
The Preliminary Drawings shall inter alia comprise:
-
Entire system design and hydraulic flow diagram
General arrangement of Intake and clear water pumping station

including hydraulic design of pump well and screen, gates etc.
Control philosophy;
Treatment works hydraulic profile including hydraulic calculations;
PAGE 8 of 26
89 of 2461
MMRDA
Process design;
Treatment works flow diagram including details of flows in each

area of the plant;
Preliminary process and instrumentation diagrams (P&ID s); the

diagrams shall indicate in symbolic form the process, plant and
systems of measurement, control and automation;
Site layouts for Intake, WTP, MBRs including information on levels

detailing the location of:
Buildings;
Process plant;
Storage tanks;
132 kV / 6.6 kV / 415 V transformer substation
Roadways;
Buried pipelines;
Main cable routes;
Civil works plans, elevations and main sections of all reservoirs and
buildings showing location and sizes of plant, equipment and panels
etc.;
Site drainage details;
General arrangements and main sections of all plant areas;
Pipeline L-Sections, major and minor crossings, bridge
Tunnel profile including founding level, arrangement of shafts,

methodology for drilling and disposal of water and muck, MS end
pieces, thrust block
PAGE 9 of 26
90 of 2461
MMRDA
Electrical Single line diagram based on approved Mechanical and

Process load list showing C.T & P.T details, Starter details, Cable
sizes, Feeder metering and protection details, Equipment capacity
and sizes, Feeder Interlock operation logic, D.G set Starting and
Stopping operation logic, Panel cable entry details, Panel Busbar
Capacity and Sizes etc.
A description of building services provisions proposed for the

Works;
Control system architecture;
Load schedule;
Instrument schedule;
The Preliminary Drawings shall be submitted by the Contractor for

approval preferably as a single or maximum three submissions.
5.6
Construction Drawings
The second phase shall be the detail design phase and shall comprise
the submission of the Construction Documents. These shall be
submitted after approval of the Preliminary Drawings.
The Construction Documents shall be used for the construction of the
Works and shall inter alia comprise:
5.6.1
Civil
The Contractor shall comply with the provisions of the requirement of
the Specifications for Civil Works, as applicable.
The civil construction drawings shall comprise the following;
PAGE 10 of 26
91 of 2461
MMRDA
Site layouts for Intake, WTP, MBRs including information on levels

detailing the location of:
Buildings;
Process plant;
Storage tanks;
132 kV / 6.6 kV / 415 V transformer substation
Roadways;
Buried pipelines;
Main cable routes;
Civil works plans, elevations and main sections of all reservoirs and
buildings showing location and sizes of plant, equipment and panels
etc.;
Site drainage details;
General arrangements and main sections of all plant areas;
Pipeline L-Sections, major and minor crossings, bridge
Tunnel profile including founding level, arrangement of shafts,

methodology for drilling and disposal of water and muck
General arrangement drawings showing the location of each Plant

item;
Detail drawings of:
Cable and pipework chambers;
Buried pipework;
Pipework connections;
Contract interface;
Reinforcement drawings;
PAGE 11 of 26
92 of 2461
MMRDA
Bar bending schedules.
The structural design calculation with computer input & output files
for the design package program such as STAAD etc.
5.6.2
5.6.3
WTP
-
Hydraulic profile;
Hydraulic calculations
Calculations for process
Process flow diagram;
Comprehensive P&ID s including details of:
Pipeline sizes and materials;
Valve size and type;
instrumentation;
Identification of controlling PLC.
Mechanical
A) Drawings
i) Vertical Turbine pumps (Both Raw water and Clear water)
-
Sectional Assembly drawing including MOC and dimensions
Installation drawing with dimensions and levels
pump mounting with sole plate
Accessories, valve and instrumentation drawing
ii) Piping and fabrication items

-
General arrangement of plant and pipe work including

valves, sections.
detailed drawings of proprietary and fabricated plant items
PAGE 12 of 26
93 of 2461
MMRDA
iii) EOT Crane and lifting equipments

-
iv) Sluice valves / Non return valves / Butterfly valves

-
v) Ventilation system
-
General arrangement drawing
Layout & duct mounting
vi) Stop logs

-
General arrangement of stop logs
Frame for stop logs with foundation and grouting details
Individual stop log fabrication drawing
Lifting arrangement for lifting stop logs with lifting beam and
chain pulley block
Installation drawing
vii) Screen
-
Frame for screen
Screen drawing with dimensions
installation drawing with grouting details for frame with

dimensions and levels
viii)Sluice gates at intake and WTP

-
Frames for sluice gates
Individual sluice gate fabrication drawing with dimension
PAGE 13 of 26
94 of 2461
MMRDA
Installation drawing including Thimble arrangement
ix) Water hammer control devices

-
Surge analysis without and with water hammer control

device.
General arrangement drawing with levels
Overflow, collection and disposal arrangement
Tank and its draining arrangement
access to control devices for maintenance
Details of devices with MOC
x) Manual and electric operated actuators for valves, gates

-
Sectional assembly drawing with MOC
Arrangement with on valve mounting
xi) Rechlorination
-
General arrangement drawing
Detail drawing for chlorination equipments
xii) Water treatment Plant

-
General arrangement of Flash Mixer
Details of Flocculator
General arrangement of plates in Clarifier
wash water pump system and air blower system details
Pre and Post chlorination system general arrangement and

details with description
Chlorine tonner mounting, Chlorine piping arrangement
Details of Leak absorption system with layout
Details of ventilation system in chlorine house and other

areas
PAGE 14 of 26
95 of 2461
MMRDA
B) Schedules / equipment data sheets

-
Pump characteristic Curves
Selection of combination of pumps (working + standby)
Plant performance details
Pipeline Schedules
Valve schedules
C) Calculations
-
Hydraulic design for pump wells and approach bays for vortex
free operation of pumps detailing required dimensions kept
Details of correction measures proposed for preventing vortices

e.g. Cone underneath bellmouth, back wall at rear of pump
Pump sizing
Pump head calculation and calculations for operating head

range
selection and sizing of motor for pumps, Blowers
Pipeline sizing
Air Blower and compressor sizing
Required ventilation rate for air supply fans and exhaust fans to
restrict temperature rise
Sizing of duct
Sizing of Air supply fans and exhaust Fans
Torque calculation for selection of manual and electric operated

Actuator for operating valves, gates
sizing of lifting equipments
Dynamic load on pump, blower foundation structural members
Calculation for G value and power requirement for flash mixer
Selection and sizing of wash water pump and air blower
Calculations for chlorinator, chlorine dose, booster pump and

leak absorption system
PAGE 15 of 26
96 of 2461
5.6.4
MMRDA
Electrical
General requirements are as follows:
Schematic drawings shall include a comprehensive schedule of the

components used in each switchboard, MCC and control panel
including details of the type, manufacturer and rating of each
component.
The external arrangement of each switchboard, MCC and control

panel shall show the arrangement of all components including
details of panel section, switch and instrument labels.
Electrical control schematics, loop diagrams and schedules shall

where practical be A3 size drawings; all other drawings shall be A1
size.
(a) 132 kV / 6.6 kV / 415 V switchgear

i) Dimensional Layout Drawing.
ii) Complete assembly drawings of the Switchgear showing plan,
elevation and typical sectional views and location of cable boxes
and
control
cable
terminal
blocks
for
external
wiring
connections, etc.
iii) Foundation plan showing the location of
channel sills,
foundation, anchor bolts and anchors, floor plans and openings.

iv) Schematic power and control wiring diagrams with control,
interlocks, relays, instruments, space heaters, bus bar rating
with material, Current transformers, potential transformers etc.
PAGE 16 of 26
97 of 2461
MMRDA
(b) 132 V / 6.6 kV / 415V Transformers

i) General arrangement
drawing
shall
indicate
the
overall
dimensions, net weights, quantity of oil, crane requirements for

assembly and dismantling of transformers and the general
constructional features.
ii) General arrangement drawing of the transformer, showing plan,
front elevation and side elevation complete with all accessories
and fittings, detailed dimensions, net weights, quantity of, crane
lift for un-tanking, size of lifting lugs and eyes, clearances
between HV terminals, between LV terminals, between HV and
LV terminals, between HV & LV terminals and ground etc.
iii) Rating, diagram and terminal marking plates, complete with
polarity and vector group.
iv) Control wiring diagram for marshalling box.
v) Foundation drawing with position of foundation bolts and depth.
(c) RTCC Panel for Main Transformer
i) General arrangement
drawing
shall
indicate
the
overall
dimensions, net weights, and the general constructional

features.
ii) Wiring diagram with tap position details and logic for on line
operation.
(d) Panels, Distribution Boards, Power Control Centres, Motor Control
Centres etc.
i) Dimensional layout drawing.
PAGE 17 of 26
98 of 2461
MMRDA
ii) Complete assembly drawings of the switchboard/distribution

board / MCC showing plan, elevation and typical sectional views
and location of cable boxes and control cable terminal blocks for
external wiring connections, etc.
channel sills,

interlocks, relays, instruments, space heaters, starter details Bimetallic relay ratings and contactor ratings, bus bar rating with
material, current Transformer, potential transformer etc.
(e) Capacitor bank with Automatic Power Factor Correction Relay
i) Dimensioned general arrangement drawings of capacitor and

capacitor control panel.
ii) Justification for number of steps for switching.
iii) Fully dimensioned general arrangement drawings of capacitor

and capacitor control panel with elevation, side view, sectional
view and foundation details.
iv) Complete schematic and wiring diagrams for capacitor control

panel.
(f) Diesel Generator
i) Dimensional layout drawing.
ii) Complete assembly drawings showing plan, elevation and

typical sectional views and location of cable boxes and control
cable terminal blocks for external wiring connections, etc.
PAGE 18 of 26
99 of 2461
MMRDA
channel sills,

interlocks, relays, instruments, space heaters, starters with Bimetallic relay ratings and contactor ratings, busbar rating with
material, start stop philosophy etc.
v) Exhaust system with piping layout.
vi) Day oil tank sizing with mounting arrangement details.
vii) Fuel bulk storage tank sizing with mounting arrangement details.
viii) Fuel supply system with pipe arrangement.
(g) Battery and Battery Charger with D.C. Distribution board
i) Dimensioned general arrangement drawings.
ii) Fully dimensioned general arrangement drawings of battery and

battery charger with elevation, side view, sectional view and
foundation details.
iii) Complete schematic and wiring diagrams.
(h) Cabling System
i) Details of Installation of Cables in Trenches, on cable trays,

directly buried etc. at all locations inside the treatment plant.
ii) Cable routing lay out inside and outside the plant.
iii) Bill of quantities of cables, lugs and glands.

PAGE 19 of 26
100 of 2461
MMRDA
iv) 132 kV / 6.6 kV Cable termination and mounting kit Layout

drawing.
(i) Lighting system
i) Detailed Room Wise Lighting Layout with Type of fixture details

and Circuit diagram showing phase wise load distribution and
interconnection between switches, fixtures, Lighting panel,
receptacles etc.
ii) Conduit layout showing room wise routing of wires from lighting
panel to lighting fixtures, receptacles etc.
iii) Internal road Lighting and area lighting layout with type of
mounting details and fixture details.
iv) Street Light pole details with Foundation details.

(j) Earthing System
i) Details such as material, sizes, etc. of the earth conductor and

electrode pits.
ii) Earthing layout drawing showing natural ground resistor, routing

of main grid inside and outside the plant with interconnection of
equipment earthing to the grid and earth pits.
iii) Substation
Building
Layout
showing
Panel
locations,
Transformer locations and Trench Layout.
iv) Electrical Equipment and Panel Layout inside and outside the
plant.
(k) Schedules
PAGE 20 of 26
101 of 2461
MMRDA
cable schedules;
load and power consumption schedule;
junction box schedule;
protection relay setting schedule
(l) Calculations for:

-
Cable sizing;
Fault level and Voltage drop Calculations;
Co-ordinated protection study;
Standby generator sizing based on equipments finalized by

Mechanical and Process;
Transformer
Sizing
Based
on
equipments
finalized
by
Mechanical and Process;

-
Room wise Lighting Calculation as per Lux level given in the

specification;
5.6.5
Earthing Sizing Calculation;
Panel Busbar Sizing Calculation
Control, Instrumentation and Monitoring System

(a) Drawings
-
power supply distribution single line and schematics diagrams

(see note 1) for each control panel;
internal and external (see note 2) general arrangement for each

control panel (dimensional);
control and instrumentation loop drawings (see note 3);
instrument installation detail drawing (hook up, see note 4);
cable block diagrams;
PAGE 21 of 26
102 of 2461
MMRDA
cable routing/installation drawings;
foundation and fixing details and trenches drawings;
schematic diagram for system configuration of PLCs, operator

stations, engineering stations, large screen, multi-plexer, training
station, report station, printers etc.;
screens of process flows, diesel generator set and HV power

incoming panels etc.;
format of reports, alarms etc.
(b) Schedules
-
cable schedule;
cable interconnection schedule;
control and instrumentation load schedule for each control

panel;
I /O schedule for each PLC;
control and monitoring item schedule for each PLC and operator
station
alarm schedule
junction box schedule;
instrument schedule;
instrumentation, process control set point schedule;
instrument data sheets;
(c) Documentation
-
functional design specification (FDS);
factory acceptance test document (FAT);
site acceptance document (SAT)
PAGE 22 of 26
103 of 2461
5.7
MMRDA
Control System Development
This activity is specified in Subsection 2C1.2 of particular specification.

5.8
As-Built Drawings
These drawings shall be compiled by the Contractor and shall

constitute a permanent record of the Works as executed. These shall
include all such drawings, schedules, documentation and calculations
as necessary for a complete understanding of the Works design,
operation and maintenance.
Draft As-Built Drawings shall be submitted 60 days prior to the
commissioning. The Employer will signify his approval or disapproval
of the As-Built Drawings within 28 days of submission.
The Contractor shall supply to the Employer 5 (Five) copies of the AsBuilt drawings. The Contractor shall incorporate all necessary
comments of the Employer in the above drawings, if any, and shall resubmit further 5 (five) copies each of the revised drawing within 10
(Ten) days for final approval of the Employer. The Contractor shall
thereafter submit 7 (Seven) copies each of the approved As-built
drawings with softcopies. The Employer will return 2 (two) approved
copies to the contractor and retain 5 (Five) for the Employers office.
A3 and smaller sized As-Built Drawings shall be provided on durable
paper for reproduction by photocopier. As-Built Drawings larger than
A3 shall be provided as a paper copy and also produced in the form of
black lines on a durable translucent film from which further paper prints
can be taken by others as required. In addition, drawings shall be
provided as an AutoCAD Revision (latest version) software copy
(Editable).
Text shall be provided in an industry standard word processing,
spreadsheet or database format as appropriate
PAGE 23 of 26
104 of 2461
MMRDA
5.9
Operating and Maintenance Manual
5.9.1
General
The Contractor shall compile, operating, maintenance and overhauling
instructions for the whole of the Plant, and shall consist of separate
volumes. The manual shall consist of:
(a)
general descriptive text (including drawings for illustration) of the

Works described section by section.
(b)
comprising the complete operational instructions for the system,

equipment and plant. This shall be termed the Operators
Manual. It shall be aimed at the operational staff and shall be
written in clear unambiguous text complete with drawings were
necessary for clarification of any issues. The manual shall
comprehensively detail what to do on a day to day basis and
also what to do in the event faults developing. It shall in addition
provide a complete list of the maintenance tasks the operator
should carry out including the intervals between these tasks.
(c)
the
essential
instructions
for
mechanical
and
electrical
maintenance of the Plant. These instructions shall be short and

concise and set out in a consolidated schedule the inspection,
lubrication, cleaning and any other type of servicing operations
required. The Contractor shall prepare typical maintenance log
sheets that the Employer can subsequently use for daily,
weekly, monthly or other periodic maintenance and shall form
record sheets of plant maintenance operations.
(d)
instructions for use of skilled maintenance personnel in fault

location,
carrying
out
routine
replacements,
withdrawing,
dismantling, overhauling, re-assembling and testing the various

items of Plant.
PAGE 24 of 26
105 of 2461
(e)
manufacturers
MMRDA
Technical
Documentation
subdivided
into
categories for:
-
civil;
mechanical;
process;
electrical;
electrical building services;
mechanical building services;
instrumentation and control.
(f)
civil As-Built Drawings
(g)
comprising the FDS and PLC code
(h)
electrical As-Built Drawings. The electrical drawings shall be

complete
sets
including
all
information
necessary
for
maintenance and spares replacement

(i)
control and instrumentation As-Built Drawings. The electrical

drawings shall be complete sets including all information
necessary for maintenance and spares replacement
(j)
mechanical As-Built Drawings. The mechanical drawings shall

be complete sets including all information necessary for
maintenance and spares replacement
(k)
electrical and mechanical building services As-Built Drawings.

The drawings shall be complete sets including all information
including performance curves necessary for maintenance and
spares replacement
(l)
FAT records for the Works
PAGE 25 of 26
106 of 2461
MMRDA
(m)
SAT records for the Works
(n)
Any other requirement stated in Subsection 2A.9:
Operation
and Management Requirement

Each volume shall be subdivided (relating to areas of plant) into sub
sections or sub-volumes in order to ease the location of plant details.
Each volume or sub volume shall be provided with a comprehensive
index for the volume or sub-volume concerned and the O & M manual
as a whole.
Draft copies of the O & M manuals shall be submitted to the
Employers representative for his approval at least 60 days prior to the
commencement of Tests on Completion. The Contractor shall initially
supply to the Employer 5 (five) draft copies.
The Contractor shall
incorporate all necessary comments of the Employer in the above

manuals, if any, and shall resubmit further 5 (five) copies each of the
revised manuals within 10 (Ten) days for final approval of the
Employers representative. The Contractor shall thereafter submit 7
(Seven) copies each of the approved manual together with one
softcopy. The Employer will return 2 (two) approved copies to the
Contractor and retain 5 (Five) for the Employers representatives
office.
Each volume shall be enclosed within A4 and A3 ring binders have
tough grease resistant covers suitable for use on site and designed to
permit the easy removal and insertion of the contents. The front cover
and spine of each volume shall show details of the project, Employer,
Employers representative and a volume title.
Text shall generally be enclosed in A4 ring binders, A3 drawings shall
be enclosed within A3 ring binders except where it accompanies A4
text in which case it shall be folded. A1 drawings shall generally be
folded and enclose in A4 box files. Where A1 drawings accompany text
they shall be folded and enclosed in an A4 plastic wallet, one wallet per
drawing.
PAGE 26 of 26
107 of 2461
SUB-SECTION 6A.6
QUALITY ASSURANCE AND QUALITY
CONTROL
108 of 2461
MMRDA
Table of Contents
SUB-SECTION 6A.6: QUALITY ASSURANCE AND QUALITY CONTROL ............................. 1
6.1
General...................................................................................................................................... 1
6.2
QC Tests of Material for Civil Works................................................................................. 1
6.3
QC Tests for MS Pipeline - Factory Checks/Tests ........................................................ 8
6.4
QC Checks for Handling, Transportation and Storage at Factory / Site ............... 18
6.5
QC Tests for MS Pipeline Field Checks / Test ......................................................... 18
6.6
Plant and Equipment ........................................................................................................... 21
6.6.1
Extent & Procedure for Submission for Pre-Construction Testing & Review Data ..
........................................................................................................................................... 21
6.6.2
Contractors Quality Assurance System ..................................................................... 21
6.6.3
Inspection Call and Quality Assurance Plan (QAP) .................................................. 22
6.6.4
Inspection Categories for Plant and Equipments ...................................................... 23
6.6.5
Conditions for Supply and Inspections........................................................................ 27
109 of 2461
MMRDA
SUB-SECTION 6A.6: QUALITY ASSURANCE AND QUALITY CONTROL
6.1
General
The Quality Assurance/Quality Control requirements shall be followed

for ensuring strict compliance of the specifications and for ensuring the
highest standards of quality of material and work. All Inspections and
Testing shall be carried out in accordance with the specifications and in
absence of specifications relevant Indian Standard shall be used.
6.2
QC Tests of Material for Civil Works
The tests on the construction material received on site shall be carried

out as follows. The test report in triplicate shall be submitted to the
Employers Representative before use. The Employers Representative
shall return one copy to the contractor duly approved or disapproved.
Material will be used only after receipt of above approval.
S.
Material & Tests
Acceptance Criteria
No
Frequency of
Test/Remarks
.
1
Cement (OPC) [Reference: IS 8112 and IS 12269]

i) Initial setting time
Not less than 30 minutes
For each
ii) Final setting time
Not more than 600 minutes
consignment of
iii) Fineness by dry
Residue not more than 10% 50 M.T. or part
sieving
on 90 micron sieve
iv) Specific gravity
3.10 to 3.15
v)
Compressive
thereof
33
43
53
Grade
Grade
Grade
a) 3 days
160
230
270
b) 7 days
220
330
370
c) 28 days
330
430
530
Strength in kg/cm
vi) Soundness by
Expansion not more than 10
Lechatlier
mm
SECTION 6A.6: QUALITY CONTROL & QUALITY ASSURANCE
110 of 2461
PAGE 1 of 29
S.
MMRDA
Material & Tests
Acceptance Criteria
No
Frequency of
Test/Remarks
.
apparatus
Note: Sulphate resistant cement as per IS 12330 wherever required

as per instruction of Employers representative shall be used.
Generally, tests specified for OPC shall be applicable for
Sulphate resistant cement with acceptance criteria given in the
IS.
S.
Material & Tests
Acceptance Criteria
No
Frequency of
Test/Remarks
.
2
Sand [Reference IS 2116, IS 1542]

i) Particle Size
Tests should be
carried out in the
a) For Masonry
Mortar
b) For Walls &
90-100 % passing through
beginning and if
2.36mm I.S. sieve
there is a change
90-100
passing
Plaster
1.18mm I.S. sieve
ii) Silt content
Not more than 4%
iii) Fineness
modulus
through in source.
a) For concrete 2.6 to 3.6

b) For masonry and first coat of
plaster, not more than 3
c)For pointing & second coat of
plaster shall not exceed 1.6
iv) Bulkage
Bulkage will have to be

determined for applying correction
to the quantity of sand as and
when necessary.
Steel (Reference: IS 432 Part1)

i) Manufacturers
Review
Test
111 of 2461
PAGE 2 of 29
S.
Material & Tests
MMRDA
Acceptance Criteria
Frequency of
No
Test/Remarks
.
Certificates per
Lot
ii) Size
Check for actual diameter
Per Lot
iii) Mass
Check for theoretical weight in Per Lot

kg/m
Water for Construction work [Reference IS 3025]

i) pH value
Not less than 6
Once
ii) Sulphate and
Sulphate content-500mg/L (Max)
approval
Chloride content Chloride Content-2000mg/L (Max)
for
of
source of supply
for PCC, 1000mg/L (Max) for RCC subsequently

every six months
5
Coarse Aggregate [Reference IS 383]

i) Gradation
Size of metal
One test per

100% passing
100%
through sieve size
Retained
100m
on sieve
size
80mm
100mm
50mm
60mm
80mm
50mm
50mm
60mm
40mm
40mm
63mm
40mm (35 to 70%)
40mm (30
to 65%)
12.5 mm (0 to 5%)
12.5mm
(95to
100%)
40mm to 50mm
63mm
25 mm
50mm
25mm
For Bituminous
works
40mm crushed
metal
112 of 2461
PAGE 3 of 29
S.
Material & Tests
MMRDA
Acceptance Criteria
No
Frequency of
Test/Remarks
.
25mm crushed
40mm
20mm
25mm
12.5mm
20mm
10mm
12.5mm
6.3mm
10mm
4.75mm
For Concrete
For Road
At the beginning
Work
and if there is
Shall not exceed
Shall not
change in source
45%
exceed
metal
20mm crushed
metal
12.5mm crushed
metal
10mm crushed
metal
6.3 mm crushed
metal
ii) Impact Value
30%
iii) Crushing value
Shall not exceed
Shall not
45%
exceed
17%
iv) Los Angels
Shall not exceed
Shall not
Abrasion
16%
exceed
Value
50% (for
WBM) and
17% for
(B.T.
works)
v) Flakiness Index
Shall not exceed
Shall not
35%
exceed
15%
vi) Water
Shall not exceed 5%
Absorption
Shall not
exceed 5%
for WBM
113 of 2461
PAGE 4 of 29
S.
Material & Tests
MMRDA
Acceptance Criteria
Frequency of
No
Test/Remarks
.
and 1% for
BT work
Bricks [Reference IS 2212]

Class 1
Class 2
A set of 15 bricks
i) Water
Shall not exceed
shall not
for
Absorption
20%
exceed
consignment
22%
part thereof.
ii) Compressive
or
32.8kg/cm minimum 29.52
strength
kg/cm
(wet condition)
7
50000
minimum
Soil/Earth /Subgrade material [Reference IS 1498, IS 2720]

i) Proctor density
Shall not be less than
One test per
a) 1.52 gm/cc for embankment up 1000m

to 3 m height
b) 1.60 gm/cc for subgrade and
earthen
shoulders
verges
/backfill
c) 1.65 gm/cc for top 0.5 m height
of embankment
ii) CBR value
The
Embankment
shall
be
designed on ascertaining the CBR

value.
8
Soft Murum
i) Plasticity Index
Below 8
One
test
for
compaction
of
one layer in 1 km
and
every
change in source
or type of Murum
9
Hard Murum
114 of 2461
PAGE 5 of 29
S.
Material & Tests
MMRDA
Acceptance Criteria
Frequency of
No
Test/Remarks
.
i) Gradation
ii) Plasticity Index
95% passing through 80mm sieve One
test
for
size and 2% passing through 25 compaction
of
mm sieve size
one layer in one
Below 4
km
and
every
change in source
or type of Murum
10
Size Stone
Each lot
i) Quality of stone
Visual check
ii) Dimension
As per Drawing
iii) Water
Maximum 5%
Absorption
iv) Compressive
Minimum 1530 kg/cm
Strength
v) Specific Gravity
11
Not less than 3
Cement Flooring Tiles

Water absorption
Shall not exceed 10%
6 Tiles shall be
tested for a lot of
2000 tiles or part
thereof.
12
Glazed Tiles
Water Absorption
Shall not exceed 18%
One set of 5 tiles

for every 5000
tiles
or
part
thereof.
13
Bitumen [Reference IS 1220]

Grade
30/40
60/70
80/100
Two samples per
i) Softening Point
50-65
40-55
35-50
lot
ii) Flash and Fire
175
175
175
0.99
0.99
0.99
Point(Min)
iii) Specific
115 of 2461
PAGE 6 of 29
S.
Material & Tests
MMRDA
Acceptance Criteria
Frequency of
No
Test/Remarks
.
Gravity(Min)
iv) Ductility(min)
50cm
75cm
75cm
v) Mastic hardness 60 to 80 at 25C without coarse

no.
aggregate and 10 to 20 at 25 C
after adding coarse aggregate
14
Cement Mortar Cube [Reference IS 2250]

Compressive
Proportion
28 Days
One sample for
Strength
every 2 m of
127 to 211
mortar subject to
kg/cm
a minimum of 3
84 to
samples per day
Strength
1:3
1:4
126kg/cm
1:5
56 to 84
kg/cm
1:6
35 to 56
kg/cm
15
Cement Concrete Cube [Reference IS 516]

Compressive
Grade
Strength
7 Days
28 days
Quantity (m)
(Min
(min
and minimum
kg/cm)
kg/cm)
number of
samples
M10
70
100
1-5 m
M15
105
150
6-15m
M20
135
200
16-30
m
M25
170
250
31-50
m
M30
200
300
50&abo
4 plus
ve
M35
235
350
Additional
samples for each
116 of 2461
PAGE 7 of 29
S.
Material & Tests
MMRDA
Acceptance Criteria
Frequency of
No
Test/Remarks
.
addition of 50 m
or part thereof.
(1
sample=6
cubes)
M40
16
270
400
Bituminous Mix
i) Extraction
To check correct binder content 2 test for each

as per the tender.
100
tonnes
of
Minimum stability 820kg for SDBC mix subject to a

(Semi
dense
Bituminous minimum of two
Concrete)
tests per day per

plant
ii)
Marshall Minimum
Stability & Flow DBM/BC
measurements
stability 900
kg for For
each
Bituminous tonnes
(Dense
of
100
mix
Macadam/ Bituminous Concrete)
produced, a set
Flow 2-4 mm
of
moulds
prepared
Marshall
to
be
and
tested
6.3
QC Tests for MS Pipeline - Factory Checks/Tests
The following table on Quality control requirements in factory shall be

followed by the Contractor during the project execution. The
Checks/Tests
shall
be
conducted
in
presence
of
Employers
Representative.
117 of 2461
PAGE 8 of 29
MMRDA
Factory Testing All Tests

S.
Material /
Tests
No Equipmen
.
Size of
Witness to
Remarks /
Sample/
Test/Review
Acceptance
Frequency of
by
criteria
Test/Certificat
Employers
es
Representati
ve
1 Material for i)
Pipes
Each Lot
Review of
documents
Identification
of
grade of
material
(Fe 410 as
per IS 3589)
ii)
Test Certificate Review

Certificat
Per Heat No.
e of
Test
of As per IS 3589/
IS 5504
Certificates
Chemical
Compositi
on (Ladle
Analysis)
iii) Visual and 100%
Checking to
Dimension
Witness
al
Checking
Shell
thickness
Tolerance
- +20%
and
-0% (No
negative
118 of 2461
PAGE 9 of 29
S.
Material /
Tests
No Equipmen
.
MMRDA
Size of
Witness to
Remarks /
Sample/
Test/Review
Acceptance
Frequency of
by
criteria
Test/Certificat
Employers
es
Representati
ve
tolerance)
iv) Tensile
Strength,
One sample per Test to be
a) UTS - 410MPa
lot of 200MT
b) Elongation -
Witnessed
Elongation
20% (As per IS
test,
3589)
Guided
bend test
as per IS
3589 &
IS 5504
(Whicheve
r is higher)
2 Welding
Procedure
SAW /SMAW Before
Examination
for production Production
and Tests will 817
Qualificatio and
n
As Stated in IS
be witnessed
S MAW f o r
repair works
3 Checks on i) Edge Fabricated
bevel angle
Pipe
30 +5
100%
Checks to be
As per IS 3589/
witnessed
IS 5504
-0
and
thickness of
root face
1.50.8(mm
119 of 2461
PAGE 10 of 29
S.
Material /
Tests
No Equipmen
.
MMRDA
Size of
Witness to
Remarks /
Sample/
Test/Review
Acceptance
Frequency of
by
criteria
Test/Certificat
Employers
es
Representati
ve
ii) Welding
100%
and
Checks to be
Height of inside
witnessed
weld bead shall
Dimensiona
not exceed 60% of
l Check.
Shell Thickness.
iii) Outside
100%
Checks to be
diameter
Tolerance 0.75%
witnessed
at both
ends.
iv) Ovality
v)
100%
100%
Straightness
Checks to be
Max 1% of
witnessed
diameter.
Checks to be
Max 0.2% of Total
witnessed
length.
Test to be
As per IS 4853
4 Radiography (Reference: IS 4853)

a) Pipes
Weld Defects 10%
witnessed
b) Fittings
Weld Defects 100%
Test to be
As per IS 4853
witnessed
5 Ultrasonic Test (Reference: IS 7343)
a) Pipes
Weld Defects 100%
Test to be
As per IS 7343
witnessed
b) Fittings
Weld Defects 100%
Test to be
Only for seams
witnessed
which are
inaccessible to
Radiography
120 of 2461
PAGE 11 of 29
S.
Material /
Tests
No Equipmen
.
MMRDA
Size of
Witness to
Remarks /
Sample/
Test/Review
Acceptance
Frequency of
by
criteria
Test/Certificat
Employers
es
Representati
ve
6 Hydro
Pressure
100%
testing of
Test to be
As per IS 5504 /
witnessed
Tender document
Pipes at
a) 2235x16mm-
Factory
2.348MPa
b)2235x12.5mm
-1.834MPa
c)
1829x12.5mm
-2.241MPa
7 Cement Mortar Lining (IS 2116 and IS 11906)

i) Sand
a) Grading of Each lot
Test to be
Sieve
%Passin
sand
Witnessed
size
g by
Weight
2mm
100
850
95-100
micron
s
600
85-95
micron
s
425
45-60
micron
s
250
121 of 2461
5-25
PAGE 12 of 29
S.
Material /
Tests
No Equipmen
.
MMRDA
Size of
Witness to
Remarks /
Sample/
Test/Review
Acceptance
Frequency of
by
criteria
Test/Certificat
Employers
es
Representati
ve
micron
s
150
2-5
micron
s
b)
Each lot
Checking
Total
weight
of
Deleterious
such
substances
and
shall not exceed
calcareous
3%
of
the
material
combined
weight
and
of substances and
Organic
sand.
materials
as under
Limitation
a) Shale Max 1% by
Weight.
b) Clay Lumps Max1%
by
weight.
c) Mica Max 2% by
Weight.
ii)Ceme
Test with
At least two test Review of
nt
Mortar test
Cylinders for
Test
Mortar
Cylinders or
7days and
Certificates
Centrifuge
28days test (IS
As per IS 3589
test Cylinder 3589)

(at option of
122 of 2461
PAGE 13 of 29
S.
Material /
Tests
No Equipmen
.
MMRDA
Size of
Witness to
Remarks /
Sample/
Test/Review
Acceptance
Frequency of
by
criteria
Test/Certificat
Employers
es
Representati
ve
Manufacturer
)
iii) Lining
a) Visual
100%
Checking
a) Surface
Inspection
should be
for Surface
uniformly
finish
smooth and
free from
voids.
b) No waves,
grooves
allowed.
b) Visual
100%
Checking
a) Temperature
Inspection
and
for Cracks
shrinkage
and
cracks less
Disbandm
than 1.5mm
ent
width need
not be
repaired.
b) Disbandment
not accepted.
c) Thickness Minimum at 4
[12mm
Checking
places per Pipe
+3mm
Thickness shall
be determined by
steel pins of dia
less than 1.5mm
0mm]
at Four Equidistant points on

two cross
123 of 2461
PAGE 14 of 29
S.
Material /
Tests
No Equipmen
.
MMRDA
Size of
Witness to
Remarks /
Sample/
Test/Review
Acceptance
Frequency of
by
criteria
Test/Certificat
Employers
es
Representati
ve
sections.
d) Check
100%
Checking
Whether
both end is
free upto
100mm
(for
handling)
iv) Curing
of Lining
a) Time gap
Checking and Time gap shall
between
Review of
not exceed 30
Lining and
Registers
minutes
commenci
ng of
Curing
b) Total
4days
Curing time
c) Overall
Curing
Procedures
8 External Coating of Pipeline for Buried Length
i) Coating
Review of
material
test
Each Batch
Review of
As per
Documents
AWWA C 214
Checking
Test as per
certificates of
manufacturer
for
tapes/primers
ii) Surface
a) Pre
100%
Preparation cleaning prior
AWWA C 214
124 of 2461
PAGE 15 of 29
S.
Material /
Tests
No Equipmen
.
MMRDA
Size of
Witness to
Remarks /
Sample/
Test/Review
Acceptance
Frequency of
by
criteria
Test/Certificat
Employers
es
Representati
ve
to abrasive
blasting
b) Abrasive
Blast
100% - 2
Checking
locations /pipe
Test as per
AWWA C 214
Cleaning
c)
100% - 1
Surface
Checking
location / pipe
Test as per
AWWAC 214
Rough
ness
iii) Inner
a) Storage
100%
Checking
As per
Tape &
temperatu
Manufacturers
Outer
re of the
recommendation.
Tape
Rolls
prior to
applicatio
n
b) Usage of
Each Lot
Checking
Tape Rolls
Manufacturers
(Time limit)
recommendation.
iv) Applying a) Tensioning
Checking to
Inner
Witness
Layer
Tape
As per
Procedure
As per IS 3589
b) Overlap
width and
length at
change of
Tape
v) Total
a) Holiday
100%
Tests to be
125 of 2461
No Holiday at 12KV,
PAGE 16 of 29
S.
Material /
Tests
No Equipmen
.
MMRDA
Size of
Witness to
Remarks /
Sample/
Test/Review
Acceptance
Frequency of
by
criteria
Test/Certificat
Employers
es
Representati
ve
Coating
Test
Witnessed
System
As per
AWWAC214.
Test
b) Adhesion
One in every
Test of the ten pipes
Tests to be
2190N/m width -
Witnessed
As per
inner layer
AWWAC214.
to steel
c) Thickness 100% at 4
Tests to be
Min :1.854mm
Test
Witnessed
Max :2.235mm,
locations per
pipe
As per
AWWAC214
d) Impact
Resista
One
in
every Tests to be
ten pipes
Witnessed
nce
e)
vi) Checking
AsperAWWAC214
.
One
Penetra
4370 N/m -
in
every Tests to be
ten pipes
Witnessed
25% reduction in
thickness and
tion
No Holiday -
Resista
As per
nce
AWWAC214
100%
Checking
Whether
both ends
are free
for about
100mm
(for
Handling)
126 of 2461
PAGE 17 of 29
S.
Material /
Tests
No Equipmen
.
MMRDA
Size of
Witness to
Remarks /
Sample/
Test/Review
Acceptance
Frequency of
by
criteria
Test/Certificat
Employers
es
Representati
ve
9 Marking
Stenciling
100%
Checking
and
As per
Requirement
Stamping
6.4
QC Checks for Handling, Transportation and Storage at Factory /

Site
Objective of the checks is to ensure that hooks, slings and other

attachment used for lifting and lowering during handling does not cause
any damage to LINING AND COATING.
Secondly the Pipes in trucks / trailer shall be kept / stacked such that
stipulations for cushioning etc. are followed and no damage to coating
occurs.
6.5
QC Tests for MS Pipeline Field Checks / Test
All tests/Checks shall be conducted in presence of Employers

Representative
S.
Material /
No
Equipment
.1 Pipeline Trench
i) Check depth
Tests
Size of
Witnes
Remarks /
Sample/
s to
Acceptance criteria
Frequency of
Test
Every Day
with reference
before Pipe
to working
Laying.
127 of 2461
As per Drawing
PAGE 18 of 29
S.
Material /
No
.
Tests
MMRDA
Size of
Witnes
Remarks /
Equipment
Sample/
s to
Acceptance criteria
ii) Width of trench
Frequency
Every
Day of
Test
As per Drawing
before Pipe
iii) Stablility of
Laying.
Every Day
slope
iv) Whether
before Pipe
Fortnightly
shoring and
As per Drawing
Review
planking are
required and if
v) Whether sheet
As per Site
piling is
Requirements
required and if
vi) Whether Weld-
Every day
Width of Weld Pit to
pits for welding
be D+1500mm.
joints are
Depth to be 300mm
provided and
and breadth
dimension are
2 Checking damage
Check damage Checkin
To pipe before
lowering
3 Gradient/Slope of
Laid Pipe
4 Check for Weld Fit Gap
Up
5 Welding
i) Visual
to Lining and
Coating
100%
Checkin Gradient in working
100%
g
drawing
Checkin Not exceeding 3mm
100%
g
Checkin No Pockets, Voids
inspection
and discontinuity in
weld.
both inside
6 Field Joint
adequate for access.
and
ii)Radiograp 10%
Inside Weld bead

Checkin As per IS 4853
iii)
100%
Checkin As per IS 7343
Holiday
100%
Checkin As per AWWAC216
Coating (Heat
Test
Shrinkable)
over
entire
length of
Pipe
128 of 2461
PAGE 19 of 29
S.
Material /
No
Equipment
Tests
.7 Handling at
MMRDA
Size of
Witnes
Remarks /
Sample/
s to
Acceptance criteria
Frequency of
100%
interior of Pipes
Test General finish and

Checkin
8 Bedding &
Thickness
Zone Zone Zone
Backfilling
i) Check Concrete
One test for

each 100m of
base (Wherever
ii) Check layer
1
Checkin 100m
2
-
m
200m 150m 250m
compacted area
thickness
iii) Proctor Density
m
90%
after
9 Valve Chamber
i) Size
ii) Depth
iii) Provision and
As per drawing
before and
fixing of
during the
Ladder/Rungs
Construction
(Material
work.
m
95%
m
95%
Checkin
Checkin
Checkin
iv)Length,
Class and
Checkin
fixing of
Manholes and
v) Provision of
Checkin
Soak pit at
vi) Inside Clean
g
After Completion Checkin
vii)Leakage/Seap
Zero Leakage
Checkin
age
viii)
on completion
g
Checkin
ix) Puddle
3
-
Checkin
Flanges in Wall
x) For Wash out
a) Disposal Compare with
Checkin
Pipeline Type Drawing

b) Outfall
arrangemen
xi) Slope on top of
Check
Chamber to
negotiate with
10 Road
129 of 2461
PAGE 20 of 29
S.
Material /
No
Equipment
Tests
MMRDA
Size of
Witnes
Remarks /
Sample/
s to
Acceptance criteria
Frequency
of
-
i) Check Road
Test
Check
Reinstatement
is as per
6.6
Plant and Equipment
6.6.1
Extent & Procedure for Submission for Pre-Construction Testing &

Review Data
All goods and materials to be incorporated into the Works shall be new,
unused, of the most recent or current models, and shall incorporate all
recent improvements in design and materials.
The Contractor shall place orders for the material and the equipment
only after approval of the Employer's Representative. The Contractor
shall submit the detailed drawings from the approved Manufacturer and
the procedure of submission, review and revision shall be as
specification.
6.6.2
Contractors Quality Assurance System

Major features of the Quality Assurance System practiced by the
Contractor and detailed in his Quality Assurance Manual shall
include:
(a)
The Contractor has defined all staff responsibilities and the QA

systems operating within the Organization for the purpose of
ensuring adequate quality of the end product.
(b)
Regular and systematic programs of testing are carried out for

all incoming raw materials.
(c)
Regular calibration checks are carried out on all measuring
130 of 2461
PAGE 21 of 29
MMRDA
equipment used in the Manufacturing operations.

(d)
All production operations and test functions are properly

documented and available to any relevant member of the
Contractor's workforce.
(e)
All checking activities, test results, etc. are recorded on

appropriate standardized forms and these are verified, certified,
recorded and filed in a systematic manner.
(f)
A detailed inspection and test plan is prepared for the whole

manufacturing operation.
(g)
Statistical analyses are carried out regularly on appropriate test

results to confirm that all processes are performing within the
specified tolerances.
(h)
Adequate procedures are planned for corrective action in the

event that quality checks show that performance is not
satisfactory.
(i)
The Contractor has a senior officer with the authority to resolve

matters of quality to the satisfaction of the Employer's
Representative.
(j)
The Contractor has adequate facilities under the control of

properly trained staff to perform the quality control duties.
6.6.3
Inspection Call and Quality Assurance Plan (QAP)

The Contractor shall inform the Employer's Representative about the
likely dates of manufacturing, testing, and dispatching of any material
and equipment to be incorporated into the Permanent works and notify
the Employer's Representative for inspection and testing, at least
twenty-eight (28) days prior to packing and shipping and shall submit
131 of 2461
PAGE 22 of 29
MMRDA
the following
Copy of Purchase Order placed on Manufacturer (Prices may be

blanked)
Manufacturers test results and Quality Control Certificates
QAP incorporating inspection details and tests to be conducted on

basis
of
relevant
IS
and
requirements
stated
hereunder
subsequently
Authenticated Characteristics curves for Pump and Motor
The Employer's Representative will decide whether he or his

representative will inspect and test the material / equipment or whether
he will approve it on the basis of the manufacture's certificate.
6.6.4
Inspection Categories for Plant and Equipments

The following inspection and test categories shall be applied prior to
delivery of the equipment, of various categories as indicated in the
technical specifications for each type of the equipment:
Category A: -The drawing and QAP (Quality Assurance Plan) for
testing has to be approved by the Employer's Representative before
manufacture and testing. The material has to be inspected by the
Employer's Representative or a third party inspecting agency approved
by the Employer's Representative at the manufacturer's premise
before packing and dispatching. The Expenses of two Representatives
of the Employer for travel and stay will be borne by the Contractor
including Air fare. The Contractor shall provide the necessary
equipment and facilities for tests and the cost thereof shall be borne by
the Contractor.
Category B: - The drawings of the equipment have to be submitted
132 of 2461
PAGE 23 of 29
MMRDA
and approved by the Employer's Representative prior to manufacture.

The material has to be tested by the manufacturer and the
manufacturer's test certificates are to be submitted and approved by
the Employer's Representative before dispatching of the equipment.
Notwithstanding the above, the Employer's Representative, after
examination of the test certificates, reserves the right to instruct the
Contractor for retesting, if required, in the presence of the Employers
representative.
All
cost
for
visit
and
travel
of
Employers
Representative will be borne by the Contractor.

Category C: - Samples of the materials and/or equipment shall be
submitted to the Employer's Representative for pre-construction review
and approval. Following approval by the Employer's Representative,
the material may be manufactured as per the approved standards and
delivered to the site.
The categorization of the various material, equipment and plant for
purpose of inspections is as below. However, this list can be altered
and additions or subtractions done or categories changed in due
course during the implementation of the Contract by the Employer's
Representative.
6.6.4.1
Mechanical Work / Plant
S.
1.
Items
a) Vertical Turbine Pumps
Category of
Category A
b) Horizontal Centrifugal Pump

Sluice Valves with / without Actuators
Category B
2.
a) Diameter 600mm and above
Category A
b) Diameter below 600mm

Butterfly valve with the actuator
Category B
Category A
4.
b)
Diameter
600mm
Non
Returnbelow
Valve/Dual
Plate Check Valve
Category
Category B
A
5.
Pipe work
3.
Category A
b) Diameter below 600mm
Category B
133 of 2461
PAGE 24 of 29
MMRDA
S.
6.
Items
Sluice gates
Category of
Category A
7.
E.O.T Crane
Category A
8.
Monorail and other lifting equipments
Category B
9.
Air vessel
Category A
10.
Air compressor
Category B
11.
Chlorination Equipment (Except Pump)
Category A
12.
Motor 90kW and above
Category A
13.
Motor below 90kW
Category B
14.
Blower
Category B
15.
Metallic bellows, Expansion Joints and
Category A
16.
Dismantling
Air valves joints
Category A
17.
Drain and dewatering Pump sets
Category B
18.
Ventilation Equipments
Category A
19.
Portable Fire Extinguisher
Category B
20.
Air Conditioners
Category B
21.
Scrubber System
Category A
22.
23.
Screen
Flash Mixer, Flocculator Equipment, Rotating
Category A
Category A
Bridge, Centrifuge, Tube Modules (For Tube
6.6.4.2
24.
Settler),
Nozzle,
Clarifier
Plates (For Plate
ScrubberFilter
system
for chlorine
Neutralisation
Category A
25.
Stop log Gates
Category A
Electrical Works
S.
No.
1.
2.
3.
4.
5.
6.
7.
8.
Items
HV Outdoor Current Transformer
HV Outdoor Switch Disconnector/ Isolator
/HV Outdoor Lightning Arrester
Category of Inspection
Power Transformer (including OLTC, RTCC

MV and LV Capacitors and APFC Panel
Category A
Category A
Category A
Category A
Category A
Category A
HV, MV and LV switchboards, Relay control panel

LV Variable Frequency Drive and Soft Starter
Category A
Category A
Gantry/ Structure for Switchyard/ Transmission
134 of 2461
PAGE 25 of 29
MMRDA
S.
Items
No.
9.
10.
11.
12.
Starters (Other than Soft Starters)

Battery and Battery Charger and DCDB
Cathodic protection- Transformer/ Rectifier (T/ R)
Outdoor 132kV accessories for substation (i.e.
Category B
Category A
Category A
Category B
Fuse, ACSR Conductor, Clamps and connectors,

hardwares,
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Cathodic Protection equipment other than T/ R

Neutral Grounding Resistor
Sub-Distribution Boards, Lighting Panels and

Lighting System, illumination
UPS System
HV, MV and LV Power and Control Cables
MV/LV Cable Termination
Motors MV & LV
Printers
Earthing System and lightening protection
Local Push Buttons, local distribution n boards
Category B
Category B
Category B
Category B
Category B
Category B
Category B
Category B
Category B
Category B
Category C
24.
Cable tray and accessories
Category B
25.
LV DG Sets, Diesel Storage tank
Category A
6.6.4.3
Instrumentation Control and Automation
S.
Items
No.
B)
Instrumentation Works
1.
Instrument Control Panel for RWPS comprising of
Category A
PLC system, digital indicators, digital flow indicator

2.
and
integrator,
alarm
annunciator,
pushbuttonsof
Instrument
Control
Panel
for CWPS comprising
Category A
PLC system, digital indicator, alarm annunciator,

3.
Instrument Control Panel for Water Treatment
Category A
Plant along with PLC System.

4.
Local SCADA Systems (Integrated testing with

PLC
system
including
ICP
and
Category A
wireless
communication equipment) for RWPS, WTP

5.
6.
Temperature scanners
Flow switches
Category A
Category A
135 of 2461
PAGE 26 of 29
S.
No.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
6.6.5
MMRDA
Items
Digital panel meters

Conductivity level switches
Control panel for surge protection system
Full Bore Electromagnetic Flow meters
Pressure Switches
Differential pressure Transmitters
Ultrasonic type level measuring systems
Float type Level Switches
Instrumentation and Control cables
Instrumentation Control Panel
Radar type level meter
Pressure transmitter
Alarm Annunciator
Open channel flow meter
Turbidity meters
Residual chlorine meter
PH meter
Laboratory instruments and equipment
Pressure Gauges
Portable temperature monitor
Portable sound level meter
Portable vibration meter
Laptop Computers
EPABX System
Category A
Category A
Category A
Category A
Category B
Category B
Category B
Category B
Category B
Category A
Category B
Category B
Category A
Category B
Category B
Category B
Category B
Category B
Category B
Category B
Category B
Category B
Category B
Category A
Conditions for Supply and Inspections

For material/equipment under Category "A" and "B", the Employer's
Representative will provide an authorization for packing and shipping
after inspection and review of Manufacturers Certificate for Category A
and Category B.
The testing and approval for dispatching shall not absolve the
Contractor from his obligations for satisfactory performance of the
System.
The Employer or his duly authorized representative shall have access
to the Contractor/Manufacturer's premises at suitable time to inspect
136 of 2461
PAGE 27 of 29
MMRDA
and examine inspections (including testing for chemical analysis and

physical properties) the material and workmanship of the material,
plant and equipment during manufacture. The Contractor will be
responsible for obtaining permission for such at the manufacture's
premise if he is not the manufacturer. The testing will be carried out by
the
Contractor/Manufacturer
and
certificates
submitted
to
the
Employer's Representative, who will have the right to witness or

inspect the above mentioned inspection/testing at any stage desired by
him. The Contractor shall forward to the Employer 3 Nos. duly certified
copies of the Test Certificates and Characteristics Performance Curves
for all Equipment.
If any material or any part of the works fails to pass any inspection/test,
the Contractor shall either rectify or replace such materials or part of
the works and shall repeat the inspection and/or test upon giving a
notice. Any fault or short coming found during any inspection or test
shall be rectified to the satisfaction of the Employer's Representative
without any extra cost before proceeding with further inspection or
wiring of that item. Any circuit previously tested, which may have been
affected by the rectifications work shall be retested.
Where the Plant and Equipment is a composite unit of several
individual pieces manufactured in different places, it shall be
assembled and tested as one complete working unit at the
Manufacturer works.
Neither the Inspection / Testing of the material or any part of the works,
nor the attendance by the Employer's Representative(s), nor the issue
of any Inspection Test Certificate shall relieve the Contractor from the
responsibilities under the Contract.
The test Equipment, Meters, Instruments etc., used for testing shall be
calibrated at recognized test laboratories at regular intervals and valid
certificate shall be made available to the Employers Representative at
the time of testing. The calibration instruments used as Standard shall
137 of 2461
PAGE 28 of 29
MMRDA
be traceable to National/International Standards. The calibration

certificates for the test instruments shall be produced for Employer's
Representative consent in advance of testing and if necessary
instruments
shall
be
recalibrated
or
substituted
before
the
commencement of the test.
138 of 2461
PAGE 29 of 29
SUB-SECTION 6A.7
ERECTION, TESTING AND COMMISSIONING
139 of 2461
MMRDA
Table of Contents
SUB-SECTION 6A.7: ERECTION, TESTING AND COMMISSIONING ....................... 1
7.1 Erection General......................................................................................................... 1
7.2 Erection of Plants and Equipment ........................................................................ 3
7.2.1 Levelling and Grouting of Machinery ................................................................. 3
7.2.2 Vertical Turbine Pumps........................................................................................ 4
7.2.3 Air Blower ............................................................................................................... 5
7.2.4 Electric operated Crane / Manually operated Crane ....................................... 5
7.3 Records, Procedures and Reports ........................................................................ 6
7.4 Completion of Erection............................................................................................. 6
7.4.1 Plant Erection ........................................................................................................ 6
7.4.2 Safety Procedure and Practice ........................................................................... 8
7.4.3 Documentation ...................................................................................................... 9
7.5 General Preparations for Pre-Commissioning and Commissioning Tests
....................................................................................................................................... 11
7.5.1 Technical Documents ......................................................................................... 11
7.5.2 Procedures ........................................................................................................... 12
7.5.3 General and Coordination Documents ............................................................ 12
7.5.4 Manpower............................................................................................................. 13
7.6 Pre-Commissioning Checks and Commissioning Tests .............................. 13
7.6.1 General Requirements ....................................................................................... 13
7.6.2 Mechanical Equipment ....................................................................................... 15
7.6.3 Pump Motors ....................................................................................................... 20
7.6.4 Instrumentation Testing Requirements ........................................................... 21
7.7 Electrical ..................................................................................................................... 24
7.7.1 Sub-Station Installation ...................................................................................... 25
7.7.2 Commissioning Tests / Completion Checks ................................................... 40
7.8 Instrumentation and Control ................................................................................. 52
7.8.1 Site Calibration .................................................................................................... 53
7.8.2 Instrumentation Installation and Pre-Commissioning Checks ..................... 53
7.8.3 Instrumentation Commissioning ....................................................................... 55
7.8.4 Programmable Logic Control (PLC) ................................................................. 55
7.8.5 Control Panel ....................................................................................................... 57
7.8.6 Tests for Local SCADA ...................................................................................... 59
7.8.7 Tests for UPS ...................................................................................................... 59
7.9 Commissioning......................................................................................................... 60
7.9.1 Commissioning Tests ......................................................................................... 62
7.10
Pipeline Works ...................................................................................................... 64
7.10.1
Hydraulic Testing of Pipeline ......................................................................... 64
7.10.2
Tests on Completion of Pipeline Works....................................................... 67
7.10.3
Cathodic Protection System Test ................................................................. 69
7.11
Tests for Water-Retaining Structures ............................................................ 69
7.12
Water Treatment Plant ........................................................................................ 70
7.12.1
General ............................................................................................................. 70
7.12.2
Dry Test Requirements .................................................................................. 70
7.12.3
Hydraulic Wet Test Requirements ................................................................ 71
7.12.4
Filter Wet Tests................................................................................................ 72
7.12.5
Process Wet Tests .......................................................................................... 75
7.13
Trial Run of the entire System .......................................................................... 77
140 of 2461
MMRDA
Commissioning of the entire System.............................................................. 78

7.14
7.15
Tests after Completion........................................................................................ 78
7.15.1
Employers Obligations................................................................................... 79
7.15.2
Retesting on Failure ........................................................................................ 79
7.15.3
Test during Mansoon ...................................................................................... 79
7.15.4
Treated Water Quality Criteria ...................................................................... 81
141 of 2461
MMRDA
SUB-SECTION 6A.7: ERECTION, TESTING AND COMMISSIONING
7.1
Erection General
The contractor shall obtain all statutory, legal permissions, and

Licenses as applicable to Lay out & construction of the complete plant
and systems including 132 kV HT Substations & Chlorination system
(at WTP & MBR), from appropriate Central Government, State
Government, Municipal Corporations and other agencies. The
contractor shall obtain all prior approvals from the concerned authority
including lay out drawings before execution and after completion of
work of plant wherever necessary.
The cost, fees etc. as applicable for obtaining all the statutory, legal
permissions, Licenses, approvals shall be borne by the contractor
during the execution and operation & maintenance of project work.
The Contractors staff shall include adequate and competent (holding
license from competent authority) erection engineers with proven, &
adequate experience on similar Contracts to supervise the erection of
the Works and sufficient skilled, semi-skilled and unskilled labor to
ensure completion of Works in time and with quality. The Contractor
shall not remove any supervisor, erector or skilled labor from the Site
without prior approval of the Employers Representative.
The Contractors key supervisor responsible for erection shall be an
erection
engineer
who
is
conversant
with
the
erection
and
commissioning of the complete Works. If there are more than one

erector, one of them will be in charge and the Contractor shall inform
the Employers Representative in writing which erector is designated as
his representative and is in charge
The contractor shall submit the erection methodology stage-wise and
stepwise, QAP (Quality Assurance Plan) and name of the erection
SECTION 6A.7: ERECTION, TESTING & COMMISSIONING
PAGE 1 of 81
142 of 2461
MMRDA
engineer with qualification and experience for approval of Employers

Representative. The Contractor shall ensure that no installation or
erection work shall commence until full and unconditional approval to
working drawings, erection method and QAP signed and stamped by
the Employers Representative are available at Site.
The Contractor shall be responsible for setting up and erecting the
plant to the line and levels of reference and of the positions, levels,
dimensions and alignment, and provision of appliances and labor in
connection therewith. The checking of setting out of any line or level by
Employers Representative shall not in any way relieve the Contractor
of his responsibility for the correctness thereof.
Erection of Plant shall be phased in such a manner so as not to
obstruct the work being done by other contractors or operating staff
who may be present at the time. Before commencing any erection
work, the Contractor shall check the dimension of structures and
pockets for foundation and holding down bolts and other erection aids,
anchors, cutouts where the various items of Plants are to be installed
and shall bring any deviation from the required position, lines or
dimensions to the notice of the Employers Representative. Plant shall
be erected in a neat and workman like manner on the foundations and
at the locations shown on the approved drawings. Unless otherwise
directed by the Employers Representative, the Contractor shall adhere
strictly to the aforesaid approved drawings.
The Contractor shall align all equipment and holding down bolts and
shall inform the Employers Representative before proceeding with
grouting-in the items concerned. The Contractor shall ensure that all
equipment is securely held and remains in correct alignment and levels
before, during and after grouting-in. The contractor shall also ensure
that adequate number of air vents are provided so as to ensure no
probability of air trapping in the grout. The approval by the Employers
Representative of the Contractors proposals for rigging and hoisting
any items of the Plant into their final positions shall not relieve the
PAGE 2 of 81
143 of 2461
MMRDA
Contractor from his responsibility for damage to completed structures,

parts or members thereof or other installed equipment. He shall at his
own cost make good, repair or replace any damaged or injured items,
whether structural, electrical, architectural, or of any other description,
promptly and effectively to the satisfaction of the Employers
Representative. No Plant, equipment or other loads shall be moved
across the floors of structures without first covering the floors with
timber of sufficient size so that applied loads will be uniformly
transferred to floor beams and girders. If it is required to reduce
bending stresses and deflection, the beams and girders shall be
provided with temporary supports. During erection of the Plant the
Employers Representative will inspect the installation from time to time
in the presence of the Contractors Site representative to establish
conformity with the requirements of the Specification and good
engineering practice. Any deviations flaw and deficiencies found or
evidence of unsatisfactory workmanship shall be corrected as
instructed by the Employers Representative.
7.2
Erection of Plants and Equipment
7.2.1
Levelling and Grouting of Machinery

Contractor shall undertake, sufficiently in advance, chipping of any
unevenness of concrete on foundations, anchor bolt pockets, cutouts
etc., to achieve uniform level of reference for erection. All concrete
surfaces receiving grout shall be chipped as required to ensure better
bonding with the grouting. Contractor shall undertake the inspection of
all components to be erected sufficiently in advance to check their
soundness and conformity to drawings and the inspection records shall
be signed by the Employers Representative as approval for
undertaking the installation of the components. Any damage, shortfalls
etc. shall be made good to the satisfaction of the Employers
Representative. All grout for equipment shall be carried out using nonshrinkable continuous grout materials with suitable framework of at
least 12mm thickness. Surfaces to receive the grout shall be chipped
PAGE 3 of 81
144 of 2461
MMRDA
and roughened and laitance shall be removed by wire brush or blast of

air. Concrete surface shall be blown off by compressed air before
commencing grouting. Before commencing grouting it shall be
conformed that air displaced by pouring grout has way out to
atmosphere Grouting shall be done in one continuous operation from
one side such that grout flows in a single wave until grout reaches all
confined spaces with no air pockets and air from all confined spaces is
expelled. A hydrostatic head of 150 mm shall be maintained during
grouting operations. All grouting shall be carried out in the presence of
the Employers Representative. All lines and levels shall be checked
after grout is set. Block outs shall be closed using cement concrete of
the same grade as that of the parent structure.
7.2.2
Vertical Turbine Pumps

(i)
Check the surface of location of pump to be grouted and surface

of sole plate for cleanliness and level.
(ii)
Check the foundation bolts
for fixing sole plate are rigidly
anchored and sufficiently projected above sole plate for rigid

tightness.
(iii)
Check the matching of sole plate holes and discharge head

plate by assembling before erection of sole plate.
(iv)
Check all the special tools & tackles and lifting arrangement are
in working condition.
(v)
Check with high precision spirit level that the sole plate and
discharge head plate assembly are at correct horizontal level
and the flange at exact vertical level.
(vi)
Check the alignment of pump set for tolerance limit set by

manufacturer of pump.
PAGE 4 of 81
145 of 2461
(vii)
7.2.3
MMRDA
Check free rotation of pump.
Air Blower
(i)
Check the grouted foundation anchoring bolts, base frame holes

for matching.
(ii)
Check the manufacturers recommended Anti-vibration pad

mounting to base frame.
(iii)
Check level of base frame with high precision spirit level
and
grouting / foundation place.

(iv)
Check manufacturers recommendation for size of foundation.
(v)
Check
alignment air blower set
before and after assembly of
suction and discharge silencer.

(vi)
Check for alignment of air blower set which shall be within

tolerance limit set by the manufacturer.
(vii)
7.2.4
Check free rotation of air blower set.
Electric operated Crane / Manually operated Crane

(i)
Check the horizontal and vertical mounting plates of suitable

structural strength perfectly welded to RCC steel bar on Corbel
and column.
(ii)
Check all the plates installed on RCC column and corbel are
aligned in level by water tube.
(iii)
Check girder level individually and in parallel for perfect

horizontal level before welding to plates on corbel and column.
PAGE 5 of 81
146 of 2461
(iv)
MMRDA
Check rail level by tack welding to girder and joints for correct
horizontal level.
(v)
Check the safety equipments, lifting equipments for placing EOT

assembly on rails.
(vi)
Check that longitudinal travel and lateral travel covers all

equipment to be handled.
(vii)
7.3
Check Crane for rated load capacity after successful erection.
Records, Procedures and Reports
The Contractor shall maintain records pertaining to the progress and

quality of installation / erection work and inspection, testing,
compliance with all technical requirements in respect of all his works as
described in the previous paragraphs. The reporting shall be in the
approved formats. The Contractor shall submit such records to the
Employers Representative after the erection of any particular work
before submitting the bill of supply / progress of work. Such report shall
comprise shop inspection reports, shop testing reports, material test
reports, and all the quality control reports of welding, erection and
alignment records. All the above mentioned records shall be submitted
in the final form duly countersigned by the Employers Representative
attesting conformity to specifications and his approval of installation,
and duly incorporating all the additions, alternations, and information as
required by the Employers Representative, on the basis of preliminary
reports giving the progress of the work. Such records notwithstanding,
any records submitted earlier with bill of supply / progress, etc., shall
be duly bound and submitted to the Employers Representative in six
copies by the Contractor on completion of erection.
7.4
Completion of Erection
7.4.1
Plant Erection
PAGE 6 of 81
147 of 2461
MMRDA
The completion of erection by the Contractor shall be deemed to occur

if all the units of the Plant are structurally and mechanically complete
and will include, among other such responsibilities, the following:
Plant in the Scope of the Contract has been erected, installed and
grouted as per specifications
Stage-wise and stepwise erection checks are completed and

approved by the Employers Representative
Erected Plants are totally ready for commissioning checks
At the stage of completion of erection, the Contractor shall ensure that

all the physical, aesthetic and workmanship aspects are totally
complete and the Plant is fit and sound to undergo tests on completion
and subsequent pre-commissioning checks.
Upon achieving the completion as described above, the Contractor
shall, after having given 21 days advance notice of the expected date
for carrying out the inspection, notify the Employers Representative by
a written notice intimating completion of erection and notify the
Employers Representative for inspection along with equipment-wise
and item-wise check list submitted and instruments and gauges such
as water tube precision spirit level, feeler gauge, dial gauges, torque
wrenches, etc. are kept ready for erection checks. The Employers
Representative shall proceed with the inspection of such units within 7
days.
The Employers Representative shall certify completion when there are
no defaults in the Works or provide the Contractor with a list of
deficiencies for rectification, hereinafter referred as the Punch List.
The Contractor shall complete the rectification work within a jointly
agreed period before pre-commissioning activities and obtain the
Employers
Representatives
acceptance
or
approval
before
PAGE 7 of 81
148 of 2461
proceeding
with
MMRDA
pre-commissioning
checks.
The
Employers
Representative may inform the Contractor that the works are accepted
with the Punch List (items which do not hamper operability, safety or
maintainability) and allow the Contractors to proceed with the precommissioning checks when the Contractor undertakes to complete
such outstanding works within an agreed time prior to completion of
commissioning. Taking over shall be based on rectification of all
deficiencies which are to be completed before acceptance as
mentioned in the Punch List.
7.4.2
Safety Procedure and Practice

a) Mechanical
For all rotating equipment coupling guard shall be provided
Lifting equipment for various items shall be of suitable capacity
All floors / tiles at work and other places shall not be slippery
Safety signboards shall be displayed at works
At all places for alighting in trenches, passages and deep site

works ladders, safety belts shall be used
Barricading and danger boards shall be provided wherever

necessary
Chain, Wire ropes, other tiding apparatus condition shall be

checked
b) Electrical
PAGE 8 of 81
149 of 2461
MMRDA
Following safety procedure and practice should be provided by the

Contractor in the switchboard room/substation as per latest edition
of I.S. 5216.
(i) Rubber matting in front of HV, MV and LV switchboard and other
panels in switchboard room
(ii) Shock treatment chart in switchboard / electrical equipment
room
(iii) Caution/Danger Board on
HV, MV and LV switchboard and other LV panels
Lighting distribution board
Transformer yard
(iv) Sand bucket in switchboard / electrical equipment room/

transformer yard
(v) Fire extinguisher in switchboard/ electrical equipment room
(vi) Four sets of hand gloves in switchboard room of each location
(vii)
First aid box in switchboard / electrical equipment room/
Chlorination plant /pumping plant

(viii) Fire Safety
The requirement of hand appliance in switchboard room,
electrical equipment room shall be as per the latest edition of
Fire Protection IS code of practice and National Building code.
7.4.3
Documentation
PAGE 9 of 81
150 of 2461
MMRDA
Set of documents shall be prepared and maintained by the Contractor

and one set of the latest revised documents shall always be kept at site.
The following documents shall be prepared by the Contractor:
(i) All latest approved L-sections and alignment drawings
(ii) All up-to-date as built drawings as well as approved drawings in
Category I for all mechanical, electrical, instrumentation and civil
works
(iii) Data sheets for instrument specification and selection
(iv) List of all equipment along with data sheet/ literature
(v) Erection/ Instruction manual for all equipment
(vi) Commissioning manual for all equipment
(vii)
Instrument Schedule
(viii) Electrical cable schedule and inter-connection diagram

(ix) Instrumentation schedule
(x) Instrumentation cable schedule
(xi) Loop drawings for instruments in the field and control panel
(xii)
Instrument test and calibration report
(xiii) Instrument installation drawings

(xiv) The Contractor shall keep on site two sets of the latest revised
Operation, Maintenance and Calibration manuals for all field
PAGE 10 of 81
151 of 2461
MMRDA
instruments and sub systems, annunciation system, data loggers,

indicating controllers and PLC system etc.
7.5
General Preparations for Pre-Commissioning and Commissioning

Tests
The commissioning period as notified by the Contractor shall include all

periods of pre-commissioning, trial runs and tests on completion. It is in
the
Contractors
interest
to
offer
the
section/units/systems,
progressively under Identified milestones within overall erection and

commissioning period, duly completed for rectification of any
deficiencies pointed out by the Employers Representative and to
achieve mechanical completion before undertaking the tests on
Completion within the specified period. The Employers Representative
also reserves the right to withhold the cost is estimated to be
equivalent to the rectification of deficiencies pointed out to the
Contractor until such a time as the deficiencies are rectified by the
Contractor to the satisfaction of the Employers Representative.
The documents listed in Sub-clauses 7.5.1, 7.5.2, 7.5.3 and 7.5.4 shall
be completed in accordance with the Contract schedule before
commencement of pre-commissioning and commissioning tests. The
Employers Representative and the Contractor shall preserve and
control these documents in a safe and appropriate place on Site in
order that both parties personnel can make use of them at any time.
7.5.1
Technical Documents
Operation and Maintenance manual
Design documents including the Contractors design data, drawings

and Specifications
Tools and test equipment list
PAGE 11 of 81
152 of 2461
7.5.2
Spare parts list
Lubricant list
MMRDA
Procedures
Mechanical testing procedure
Electrical testing procedure
Instrumentation testing procedure
Detailed pre-commissioning and commissioning procedures and

tests
7.5.3
Detailed Performance Test procedure
General and Coordination Documents
Detailed
organization
charts
for
pre-commissioning
and
commissioning tests showing lines of authorities and responsibility,

and functions of all key personnel
Job description of the members of the team
Scheduled dates of assignment of each member to precommissioning and commissioning works
Detailed schedule showing the time sequence which the Contractor

anticipates to follow for the various steps in completion of trial run,
pre-commissioning and commissioning of each unit and equipment
Regulations for safety, hygiene and discipline
PAGE 12 of 81
153 of 2461
MMRDA
Practical organization of the relationship (meetings, reports, etc.)

between the Contractor and the Employers Representative at the
phases of pre-commissioning and commissioning
7.5.4
Emergency communication route
Manpower
Required manpower shall be provided as agreed between the
Contractor and the Employers Representative in a Manpower
Mobilization Plan, which shall include the number and qualifications of
the operator and maintenance personnel to be furnished by the
Employers Representative for the Plant.
7.6
Pre-Commissioning Checks and Commissioning Tests
7.6.1
General Requirements
After the completion of erection, pre-commissioning activities listed
below shall be carried out to make the Plant ready for commissioning.
All instruments, materials and provisions necessary for conducting site
tests shall be provided by the Contractor at his own cost. Upon
completion of erection of each piece of equipment, facility or discrete
part of the plant, mechanical checks and tests shall be carried out
according to the Contractors checklist. The mechanical checks and
tests shall be to establish that:
The Plant is erected in accordance with the Contractors

construction drawings, pipe work drawings, instrument diagrams,
etc., issued for the Plant;
Materials are installed and mechanically function in accordance with

the Contract; and
PAGE 13 of 81
154 of 2461
MMRDA
Applicable codes as listed in the Contract are followed for materials

and workmanship
Items such as painting, thermal insulation and final cleanup which do

not materially affect the operation or safety of the Plant will be
excluded. All these items shall be listed and completed after precommissioning but before acceptance.
The Contractor shall prepare and maintain at Site test forms and
records, which shall include:
Check list details in the tests and checks;
Date and times of test or check;
Identification of equipment and facilities;
Test pressure, test data and results, including remarks, if any; and
Signature of the Contractors personnel attesting to data recorded;

if any. The Contractors construction forces thereof shall carry out
checks, tests and records
Wherever the Employers Representatives is witnessing or attesting of

the check or test is required, the Employers Representatives
personnel shall attend such check and test. For this purpose, the
Contractor shall keep the Employers Representative informed of a
day-to-day test plan schedule. The test plan schedule may be revised
from time to time to reflect the actual progress of the work and test.
Any items found incomplete or requiring rectification repair or
adjustment shall be marked as such on the test records and reported
by the Contractor to the Employers Representative and the
Contractors personnel in-charge of the relevant unit. Checking
procedures shall be repeated until all the items on the checklist are
cleared. A complete set of test records shall be handed over to the
PAGE 14 of 81
155 of 2461
MMRDA
Employers Representative on completion. The tests on the different

mechanical and electrical equipment shall include but not be limited to:
7.6.2
Mechanical Equipment
A)
Pumps, Piping and Valves and other mechanical plant
i)
Leakage tests shall be carried out on all erected pipe

work, pumps and valves and immediately after erection
where possible before being built in
ii)
Operating tests shall be conducted on valves and

actuators
iii)
The pumps shall be tested for mechanical performance.

The vibration and noise levels shall be checked to be
within the specified limits
iv)
Pump performance tests shall be conducted for all raw

water and clear water pump sets. Each pump shall be
tested one pump at a time
v)
Check and verify efficiency of each pump and vibration of

pump
vi)
Check the running of different combinations of pump sets

and verify the various parameters within permissible limits
vii)
To check the sequential start and stop of pumps with

level control and automation scheme
viii)
Check suitability of dismantling joint by working on nutbolts and sliding flange
ix)
Check whether motor current is within safe limit
PAGE 15 of 81
156 of 2461
x)
Check
MMRDA
feasibility
of
access
for
lubrication
and
maintenance to all bearings

xi)
Check operation of EOT crane current drawn limit and

position switch for pendants
B)
Stop Log Gates
The frames for stop logs gates shall be properly grouted and
level and inner gap suitable to stop log gate shall be checked,
stop log gates rubbers shall be checked for rigid fixing with
gates. Chain pulley block shall be checked for proper load
capacity and load chain travel for required depth. The structural
members for lifting arrangement levels and its grouting
foundation shall be checked. The lifting arm for stop logs shall
be checked by lifting the gates with lifting arm outside before
insertion of gates.
Operation, function of complete stop log
arrangement shall be checked for water leakage at site

C)
Screen and its Lifting Arrangement
Check frame for screen insertion for proper grouting and levels
with inside tolerance suitable for screens. Check the dimensions
of screen suitable for frame which shall cover complete area for
screening function. Check lifting arrangement for removing
screen for cleaning and other maintenance purpose. Structural
members of lifting arrangement grouting and level of chain /wire
rope shall be aligned so that screens can be easily inserted in or
removed from location. Chain pulley block shall be checked for
proper load capacity and load chain travel for required depth.
Operation of all complete screen shall be checked
D)
Sluice Gates & Manual Actuators and Lifting Arrangements
PAGE 16 of 81
157 of 2461
MMRDA
Check the erection & level of frames of all sluice gates as per
requirements. The shaft of sluice gate shall be checked for
intermediate supports for smooth operations. Gearbox / lifting
arrangement shall be exactly in vertical position. Operation of
all the gates shall be checked one by one. All the gates shall be
checked for function open and closure.
E)
1.
Chlorination System and Equipments
Pre-Commissioning
After the completion of erection, pre-commissioning activities

listed below, checks shall be carried out to make the Plant ready
for commissioning.
i) The Plant is erected in accordance to statutory requirements

& with the Contractors construction drawings, pipe work
drawings, instrument diagrams, etc., approved for the Plant;
ii) Necessary statutory permissions are obtained for inception

of the system as well as maintaining it, viz factory act
Environmental clearance, public liability insurance, major
hazard rules etc.
iii) Materials and equipments used in accordance with the

Contract; and
iv) Applicable codes as listed in the Contract are followed for

materials and workmanship
v) Chlorine carbon steel chlorine header successful testing and

ready for use.
PAGE 17 of 81
158 of 2461
MMRDA
vi) Chlorine tonner changeover system, instruments and control

system ready for working
vii) Chlorine leak arresting kits are available and ready for use
viii) Scrubber system and neutralization system successful

testing at site and ready for use
ix) Ventilation system, complete safety equipments, first aid etc.

are ready.
x) Chlorine
tonners
sufficient
quantity
and
Spares
for
chlorination system are available
xi) Training is imparted to operators and Engineers for

chlorination system.
xii) All chlorine gas piping from chlorine drums to chlorinator

shall be pressure tested with dry air/nitrogen to a pressure of
15 kg/sq.cm.
xiii) The chlorine gas piping from the chlorinators up to injectors

shall be pressure/vacuum tested with dry air/nitrogen to a
pressure/vacuum
equal
to
1.5
times
the
maximum
pressure/vacuum to be encountered during operation.
xiv) The motive water piping shall be hydrostatically tested for a

pressure of 1.5 times the operating pressure or the maximum
pump discharge pressure at pump shut off whichever is
higher.
xv) After the chlorine system has been completely tested as

above, leak proofness tests shall be conducted admitting
chlorine gas.
Leakages if any shall be identified using
ammonia stick. During this test all chlorine leak detectors

PAGE 18 of 81
159 of 2461
MMRDA
shall be in place and all safety procedures shall be adhered

to.
2.
Commissioning
General public surrounding the area shall be made aware for

commissioning of hazardous system of chlorination for safety
purpose.
Following Commissioning tests shall be conducted during
commissioning test.
1. Motive water pressure test and vacuum observation
i. Testing of system Chlorine gas by using
full container in
service
ii. Testing of system Chlorine gas by using maximum possible
full tonners in service
iii. Full capacity test of Chlorinator and vacuum observation
iv. Minimum capacity of chlorinator and vacuum observation
v. Tonner Automatic changeover test
vi. Residual chlorine test
vii. Test for Electrical supply failure in chlorination plant for no
cl2 leakage
F)
Surge Protection Test
The effectiveness of the surge protection system shall be

checked as follows,
PAGE 19 of 81
160 of 2461
MMRDA
Install pressure gauges at the pressure gauge points such as

immediately after pumps, at summits, at valleys, at critical
points, etc.
Run all the pumps at a time at least for one hour and then
shut off all the pumps at a time
Record the pressure gauge readings before and after shut

off
Inspect working of the various equipment of the surge

protection system
The pressure gauge readings at any point should show the

pressure increase less than as specified for design of surge
protection system given in Employers requirement surge
control and Break pressure tank Vacuum pressure of -3.0 m
(minus three meters) is allowed in the system. No leakages
should occur other than the places observed above in the
leakage test. The surge protection system shall work smoothly
without any visual distress, failing which the Contractor shall
take necessary measures to rectify the surge protection system.
G)
Load Testing of Lifting Equipment
The Contractor shall carry out all the tests to the satisfaction of
the Employers Representative. The Contractor shall be
responsible for coordinating the Programme of site testing of all
items methodology for testing shall be submitted to Employers
representative for prior approval.
7.6.3
Pump Motors
PAGE 20 of 81
161 of 2461
MMRDA
Condition of winding insulation be tested and insulation values shall be

restored to required level by suitable heating arrangements locally.
7.6.4
Instrumentation Testing Requirements

(a)
Tests on Cables
i.
Check details are in accordance with the specification
ii. Check for physical damage

iii. Megger test between each core and armour / sheath
iv. Continuity check
v. Connections
(b)
Continuity of Signal/Control/Power Supply Cables
After laying of the field signal/control/power supply cables and

prior to connection up to the control panels/instruments, the
following procedures shall be adopted:
i.
The
signal/control/power
supply
cables
shall
be
disconnected from each termination point in turn when the

wires shall be 'rung-through' for identification and tagged.
ii. The signal/control/power supply cables shall be reconnected
to the termination points and again 'rung-through'.
(c)
Loop Test
After testing and calibration of individual instruments forming the

various loops, simulated functional test of the whole loop shall
be performed before pre-commissioning. The procedure for
PAGE 21 of 81
162 of 2461
MMRDA
conducting these tests shall be decided by the Employers

Representative and results shall be recorded. During loop test, it
is the Contractor's responsibility to ensure that the calibration of
instruments is intact and in order and if any instrument is found
defective in calibration, he shall recalibrate the same without any
extra cost. After the loop test is over, he shall connect back all
the terminations and connections removed for loop test.
(d)
Tests on Electrical Installation
i.
Check all closing, tripping, supervision and interlocking of

control devices.
ii. Check operation of all alarm circuits.

(e)
Test on Complete Control System
i.
On completion, the functioning of the complete control

system shall be tested to demonstrate its correct operation in
accordance with the Specification.
ii. For control system testing, the Contractor may provide

temporary means to simulate operating conditions, but the
system will not be finally accepted until correct operation has
been demonstrated to the satisfaction of the Employers
Representative when all the Plant is operating.
iii. The system shall be shown to operate correctly whatever the
selection of duty and standby equipments may be.
iv. Conditions to be tested shall include:
Normal automatic operation
Normal manual operation
PAGE 22 of 81
163 of 2461
(f)
MMRDA
Emergency manual operation
System Validation
i) The services of factory trained and field experienced

instrumentation engineer(s) shall be provided to validate
each system and verify that it is operational and performing
its intended function within system tolerance. System
tolerance is defined as the root-mean square sum of the
system component published specified accuracy from input
to output.
ii) Each system shall be validated by simulating inputs at the

first element in loop (i.e. sensor) of 10 %, 50 % and 90 % of
span, or on/off and verifying loop output devices (i.e.
indicator, alarm etc. except controllers).
iii) During system validation, provisional settings shall be made

on levels, pressure, alarms etc.
iv) Correct operation of controllers shall be verified by observing

that the final control element moves in the proper direction to
correct the process variable as compared to the set point. All
logic sequences shall be verified to operate in accordance
with
the
specifications.
All
defects
and
malfunctions
disclosed by tests shall be corrected immediately. New parts

and materials shall be used as required and approved and
tests shall be repeated.
v) A report certifying completion of validation of each instrument

system indicating calculated system tolerances, verification
that the system meets these tolerances and any provisional
settings made to devices shall be provided. The report shall
be made in the format required by the Employers
PAGE 23 of 81
164 of 2461
MMRDA
Representative and shall be certified by the Employers

Representative when he approves it.
(g)
Final Operational Testing and Acceptance
i) Upon completion of instrument calibration and system

validation, all systems shall be tested under process
conditions.
ii) The testing shall include, but not limited to all specified
operational modes, taking process variables to their limits
(simulated or process) to verify all alarms, failures, interlocks
and
operational
interlocks
between
systems
and/or
mechanical equipment.
iii) Any defects or malfunctions shall be immediately corrected

using approved methods and materials and the tests shall
then be repeated.
iv) Upon completion of final operational testing, a report shall be

submitted, indicating that the total control system provided
meets all the functional requirements specified herein. This
report shall be made in the format required by the
The Employers Representative shall certify this report when he
approves it and it shall constitute final acceptance of the control
system.
7.7
Electrical
The commissioning engineer shall verify any commissioning tests /

completion checks to satisfy him with suitable and calibrated testing
kits as required, that the plant is fit and sound. The commissioning
tests / completion checks to be carried out shall include, but not be
PAGE 24 of 81
165 of 2461
MMRDA
limited to, those described in subsequent paragraphs, as applicable to

the individual equipment / system.
7.7.1
Sub-Station Installation
Installation work should be divided in two broad categories.
a)
Indoor installation work preconditions for commencing
Civil works should be complete
Material, equipment should be available
Essential interface work should be complete
Indoor work can be conducted during rainy season

b)
Outdoor work preconditions for commencing
Civil work in that area including foundations, cable trenches,

approach roads etc. should be complete
Material and equipment should be available
Planned sequence should be followed
Rainy season should be avoided for final assembly work of

equipment like circuit breakers, transformers
c)
Preliminary Preparation
The preliminary preparations include study of drawings,
acceptance reports, checking certificates and test reports of the
equipment. Completion of civil engineering works, arranging the
tools, lifting gears etc. organizing the labour, prepare the
PAGE 25 of 81
166 of 2461
MMRDA
schedule of installation, preparing sequences cards for erection

major items etc.
d)
Drawings for erection

The drawings include:
Circuit diagrams of the plant
Civil engineering plans, foundation plans etc.
Dimensions drawings of equipment
Equipment assembly, subassembly, component drawings
Interface
drawings
(inter
relationship
between
varies
auxiliaries)
e)
Field Quality Plans (FQP)

Each
equipment
should
have
FQP
for
erection,
pre-
commissioning and final testing. The instructions for field quality

checks, formats for test records etc. shall be prepared for
monitoring.
f)
Safety Procedures
Procedures and paper works for the following should be
enforced from the beginning.
(i) Permit to work
(ii) Access to work
(iii) Entry passes
PAGE 26 of 81
167 of 2461
MMRDA
(iv) Material gate pass etc.

(v) Follow the safety rules faithfully
(vi) Take permission from authorized person for doing specific
work
(vii)
Place condition notice and danger notices
(viii) Make sure to switch off the supply from both ends
g)
Installation
The erection sequence may differ somewhat from site to site
depending on various circumstances. After the erection of the
steel structures comes the erection of the insulators and the
phase conductors, bus bars etc. Thereafter follows excavation
for the underground earth matt.
(i)
Erection of Galvanized Steel Structures

Structure shall be built by bolting of section from gro0und
to top. Skilled erection personnel shall be provided to
build up the upper portion step by step. The construction
should be complete and final lightning shall be done after
adjustment into straight position.
The structures shall be provided with identification marks
to enable proper and speedily assembly at site.
The
vertical axis shall be maintained. Alignment in vertical

position shall be ensured by use of theodolite, plumb line,
spirit level on horizontal members.
PAGE 27 of 81
168 of 2461
MMRDA
Cross beams shall be erected on the ground and hoisted

up by means of a derrik or a mobile crane.
(ii)
Insulators
All insulators shall be checked immediately upon arrival
at site.
Post insulators shall be installed on respective support
structures by using suitable crane.
Correct galvanized
hardware and torque spanners of specified torque shall

be used.
String insulators shall be then raised up to gantry holding
point and installed by using correct galvanized hardware.
The main problem with insulators is protection against
damage during transportation, handling and erection.
Insulators shall be protected by wooden cages during the
entire erection period.
(iii)
Rigid Aluminium Tublor or ACSR Busbars

After installing post insulators, the bus bars shall be
erected. The length of tubes shall be cut to size, edges
are filed for perpendicularity and removal of byros and
sharp corners. Edges are prepared for welding.
The tubular busbars shall be fastened on to the rigid
insulators by using correct hardware. Mating surfaces of
clamp and tube shall be cleaned by energy paper prior to
tightening the nut bolts anti-oxidation jelly shall be applied
immediately.
PAGE 28 of 81
169 of 2461
MMRDA
When connecting conductors etc. care must be taken not

to introduce stresses such as bending forces, pull etc.
The erection of ACSR conductors of flexible bus is
stringing and connection for all conductors. Erection of
connectors and clamps is a very critical activity and must
be done as per instructions. Necessary quality checks
shall be made. Connectors shall be handled carefully to
avoid scratches, dirt, damage to threads etc. Preparation
for connections and tightening of bolts shall be done
carefully.
(iv)
CTs, VTs
These shall be installed on respective structures. The
porcelain shall be closely observed for cracks.
Small
chops up to 8 mm diameter shall be rectified by means of

epoxy resin. Larger chips shall not be allowed.
When erecting current and voltage transformers, the oil
level shall be checked and it should be checked that the
insulator etc. has not oil leakage.
The connections of
secondary earth, primary shall be checked twice.

Lifting equipment, slings etc. must be applied at the
correct places.
Lifting by slinging on the primary
connection must not be done under any circumstances.

The following tests shall be done before the erection to
verify the healthiness of CT / VT.
(i) Ratio test (ii) Insulation measurement (iii) Continuity
(iv) DC resistance
(v)
Surge Arrestors
PAGE 29 of 81
170 of 2461
MMRDA
Surge arrestor shall be lifted and assembled on the

structure. The correct functioning and protective ability of
the surge arrestors shall be ensured by:
The erection of the arrestor as close as possible to the

object to be protected, usually a power transformer
Connection of the arrestors lower main earthing

terminal shall be made with the shortest possible
conductor to the earth mat
The transformer tank shall be connected to the same

ground point as the arrestor lower main earthing
terminal
Separate earthing of arrestor and transformer tank

must not be made under any circumstances, as the
arrestor cannot protect the transformer in such case
(vi)
Disconnectors (Isolators)
The
manufacturers
instructions
shall
be
carefully
followed for erection of isolators, operating mechanism

etc.
The insulator columns shall be assembled on the
structure. The contact arms, operating mechanism, the
linkages between three poles shall be assembled.
Correctness of alignment, simultaneous closing of all
contacts shall be checked by manually and electrically
operation.
(vii)
Outdoor Circuit Breakers
PAGE 30 of 81
171 of 2461
MMRDA
The breaker shall be assembled by trained personnel of

the erector or manufacturer. The breaker is dried out by
hot air circulation followed by evacuation. Breaker is kept
in vacuum for at least 20 hours to ensure removal of
water drop lets and moisture completely. Thereafter SF6
gas is filled. The leakage test shall be carried out by
means of soap solution, SF6 leakage detector and by
monitoring pressure gauge. Leakage free performance
should be ensured before commissioning.
The auxiliary systems of mechanism, gas monitoring
system, operating pressures of compressed air or
hydraulic mechanism etc. shall be verified. Settings of
pressure switches and their functioning shall be verified.
The reaction of the circuit breaker is a comprehensive job
shall be carried out in accordance with the erection
manual.
Outdoor circuit breakers shall be mounted on prefabricated galvanized steel structures.
Structures shall
be supplied by the manufacturer of breakers.

(viii)
Installation of Transformers
The tank filled with dry nitrogen gas shall be unloaded
near the final plinth or in nearby concreted floor of
adequate bearing capacity by sliding on the wooden
sleepers.
Sufficient number of hydraulic jack shall be
used for unloading.

After unloading the tank on the plinth, the following
activities are carried out:
Assembly of tap changer
PAGE 31 of 81
172 of 2461
MMRDA
Assembly of bushings
Installation of control cabinet
Power cables
Fitment of accessories
Filtered oil is filled into the transformer tank. The oil is

circulated through the filtering plant.
The filtration
continued till the following is achieved
Enough breakdown value of the oil sample from the

tank
Enough dryness of oil from the tank
Designed chemical composition (purity)
Insulation
resistance
and
polarization
index
of
transformer
(ix)
Tans measurement
Earthing System
Earth resistance shall be measured during dry season
and wet season. These values shall be within permitted
limits.
The earth mat work includes burying of earth rods and
earthing copper plates, earthing mat, risers.
All
recommended parts are connected to earth mat to

eliminate the danger of step and touch potentials. The
earth mat must be made with great care to ensure
PAGE 32 of 81
173 of 2461
MMRDA
personnel safety from dangerous touch potential and step

potential. The part of the earthing system above ground
must be carefully laid and connected. Follow strictly the
erection documentation for:
Structure earthing
Tower earthing and earthing of overhead earthing

shold
(x)
Apparatus and cabinet earthing
Earthing switches terminal
Disconnector with switch terminal
Equipment earthing
Transformer neutral earthing
Transformer tank earthing
Surge arrestor terminal earthing
Cable racks earthing
Capacitor neutral earthing
Earthing of fencing, doors, screens, lamp post etc.
Commissioning of substation
Commissioning activity follows erection and involves final
checks, subsystem tests, system tests and load tests.
PAGE 33 of 81
174 of 2461
MMRDA
The commissioning organization includes:
Commissioning incharge
Control room engineers
Test engineers for AC yard
Test engineers for auxiliaries etc.
Supervisors and electricians, mechanics etc. for quick

repairs
(xi)
Documentation and field quality engineers
Documentation
Test records of every equipment shall be verified and

signed
If test results show abnormal or doubtful values the

hold points shall be identified and corrective actions
are taken before continuing the further work in that
apparatus
After
completing
all
the
equipment
tests,
the
subsystem tests shall be carried out. These involve a

group of equipments i.e. a switchgear bay with circuit
breakers, isolators, earthing switches, CTs, protection
system etc.
Final system tests shall be performed as per agreed

schedule and sequence
PAGE 34 of 81
175 of 2461
MMRDA
Commissioning shall be carried out from control room

in liaison with all the sub system engineers
The sequence of operations of earthing switches,
isolators, circuit breakers is listed, before commencing
the charging operations.
After each operation from control room, the position of
indicating mark on mimic board is observed.
Meanwhile,
the
observers
in
yard
inspect
the
equipment from nearby location and inform the status

about operation to control room engineer over walkietalkie / phone.
The sequence of operations is completed and the
system is energized.
All the equipments in yard are observed for corona,
hot-spots leakage, flashovers, sparking etc.
Hot-spots on clamp and connectors are observed by
means of remote sensing binoculars.
During commissioning, control board is closely
observed for meter readings, indication by relays etc.
If alarm or tripping occurs, investigation and corrective
actions are taken before proceeding further.
(xii)
Commissioning Tests
These are divided in the following categories:
i) Equipment functional checks and tests
PAGE 35 of 81
176 of 2461
MMRDA
ii) Sub system checks and tests

iii) Complete system tests at low voltage; without voltage
iv) Commissioning tests before and after system HV
energization
v) Performance tests
(xiii)
Equipment Tests
The equipment tests on each individual equipment are
performed in accordance with the site testing plan, site
tests are with all the associated equipment, auxiliaries,
sub system etc.
The equipment tests include the following (as applicable)
Insulation resistance measurements
Resistance measurements
Phase sequence tests
Polarity tests
Ratio tests
Operating timing tests
Continuity tests
Insulation resistance of auxiliary circuits
PAGE 36 of 81
177 of 2461
MMRDA
Mechanical operation tests
Sequential operation tests
Applied voltage tests
Primary injection tests
Secondary injection tests
Functional operation tests
Performance characteristics tests
Site tests shall be carried out on individual equipments as

per manufacturers recommendations.
The site test
results shall be compared with the shop tests results to

confirm that the equipment has been assembled correctly
and is in proper functioning state.
(xiv)
Sub-Systems Tests
The
sub-system
associated
comprises
electrical
and
several
equipments,
mechanical
connections,
controls, interlocks etc.

The sub-system tests are performed as per schedule.
These include:
Tests on main circuits
Tests on auxiliary circuits
Tests on protective and control circuits
PAGE 37 of 81
178 of 2461
MMRDA
Tests from local points
Tests from control room
Current injection tests
Applied voltage tests
Insulation resistance tests
Functional tests
(xv)
Tests on Protection Systems
Tests before energizing the secondary equipment
Tests before energizing primary equipments
Synchronising tests
Tests on each protection zone
Tests on overlapping of protective zones
Test by initiating protection from the control room
Staging fault tests by artificial fault in protective zone
Secondary Injection Tests:

These tests consist of injecting current through the
secondary circuits and checking operation of relays.
Primary Injection Tests:
PAGE 38 of 81
179 of 2461
MMRDA
These tests shall be conducted by injecting currents

through primary circuits of CTs.
Tripping and closing tests on circuit breakers
These shall be conducted from:
Local kiosk near the CB
By initiating the protective relay from the protection

panel
By initiating the push button from the control panel
Indications and Alarms
Each indication and alarm on the annunciation panel

should be checked
(xvi)
Phasing Tests
Before paralleling a transformer, the following shall be
checked
The phase sequence
The polarity
The ratio, etc.
(xvii) On Load Tests

The voltage is applied initially for a fraction of second to
one second under close observation.
PAGE 39 of 81
180 of 2461
MMRDA
After satisfying healthy installation, the voltage is applied

for a little longer duration under close observation. Relay
panels, instrumentation panels.
Auxiliaries, outdoor
years are observed closely for flashovers, corona, noise

etc.
After ensuring no flashovers and tripping, the voltage is
applied for a longer period.
During commissioning close observation is necessary for
several hours, days etc. as per field quality norms.
After loading, the busbars and connectors should be
observed for hot spots if any.
(xviii) Handing over to the operating staff
After successful commissioning and trial period, the
installation is handed over to the trained operating staff.
Sufficient maintenance spares, consumables, operating
instructions and maintenance instructions shall be made
available to the trained operating staff.
7.7.2
Commissioning Tests / Completion Checks
7.7.2.1
Preliminary Checks
In general, the following checks shall be carried out on all the
equipment/systems, as applicable.
a) Name plate details according to approved drawings / specifications
b) Any physical damage or defect and cleanliness
c) Tightness of all bolts, clamps and connections
PAGE 40 of 81
181 of 2461
MMRDA
d) Oil leakages and oil level

e) Condition of accessories and their completeness
f) Clearances
g) Earthing connections
h) Correctness of installation with respect to approved drawings /
specifications
i) Lubrication of moving parts
j) Alignment
k) Correctness and condition of connections
l) Operation test for all protection relay for protection of motor
7.7.2.2
General Tests
a)
Commissioning Tests of Motor
Insulation resistance test of motor windings and cables.
Continuity check for power and control cables
Winding resistance measurement in case of motors rated 55

kW and above
Control, interlock and protection schemes
Operation and setting of timer, in case of Star Delta starters

(LT Motors)
PAGE 41 of 81
182 of 2461
MMRDA
Phase sequence and rotation
No load trial run for observation of vibrations, noise and

temperature of bearings etc.
On load operation, starting and running load current (also

observe vibrations, noise and temperature of bearing and
winding)
Starting current shall be checked whether its specified limit

or not
Relay setting as per relay co-ordination chart
Simulation check of motor control circuit by local/ remote

closing and tripping
b)
Commissioning Tests of Transformer:
i) Test oil for dielectric strength, and resistivity, Insulation

resistance test of windings.
ii)
IR for bushings, before assembly.
iii)
Test the transformer for the following:
iv)
Winding resistance at all the taps
Short circuit impedance (at low voltage)
Core loss at normal tap at low voltage
IR and PI
Vector group test.
PAGE 42 of 81
183 of 2461
MMRDA
v)
Phase sequence test.
vi)
Test the current transformers for following:
Continuity test
Polarity test
Insulation resistance test
Measurement of secondary winding resistance
vii)
Line connection as per phasing diagram.
viii)
Winding resistance.
ix)
Insulation resistance of control wiring.
x)
Buchholz relay operation (for alarm and trip).
xi)
OLTC control indicating and alarm circuit.
xii)
Operation test of all protective devices (electrical and

mechanical) and interlocks.
xiii)
Calibration of temperature indicators (oil and winding)

and temperature relays.
c)
Commissioning Tests of Switchboard (HT / LT):
i)
Checks on relays.
ii)
Insulation resistance test
PAGE 43 of 81
184 of 2461
MMRDA
iii)
High voltage test
iv)
Millivolt drop test for busbar joints
v)
Checks on motors/ simulation check.
vi)
Setting of relays, other alarms, tripping devices and

interlocks as per scheme.
vii)
Phase angle checks, measurement of magnitude and

phase angle of current transformer secondary currents
and potential transformer secondary voltage.
viii)
Functional checking of all power and control circuits e.g.

closing, tripping, control, interlock, supervision and alarm
circuits including proper functioning of the component
equipment.
ix)
d)
Earthing Terminals.
Commissioning Checks of Relay:
i)
Check operating characteristics over the entire range by

secondary injection.
e)
ii)
Check minimum pick up voltage.
iii)
Check operation of electrical / mechanical targets.
iv)
Relay settings.
Commissioning Checks of Energy Meter:
i)
Check calibration (Test certificates).
PAGE 44 of 81
185 of 2461
MMRDA
ii)
Megger all insulated portions.
iii)
Check CT and VT connection with particular reference to

their polarities for relevant
iv)
f)
Meters
Commissioning Test of Circuit Breaker:
i)
Check control wiring for correctness of connections,

continuity and IR values.
ii)
Manual operation of breaker.
iii)
Power closing / operating manually and electrically.
iv)
Breaker tripping and closing time (Test certificates).
v)
Trip free and anti-pumping operation.
vi)
IR Values- resistance
vii)
Contact resistance.
viii)
Simultaneous
closing
and
mechanical
interlocks
provided.
ix)
Check electrical and mechanical interlocks provided.
x)
Checks on spring charging motor, correct operation of

limit switch and time of charging,
xi)
Checks on CTs.
xii)
High voltage test (LT breakers only)
PAGE 45 of 81
186 of 2461
xiii)
g)
h)
MMRDA
All functional tests.
Commissioning Tests of Voltage Transformer:
i)
Insulation resistance test.
ii)
Polarity test.
iii)
Ratio test on all cores.
iv)
Line connections as per connection diagram.
Commissioning Tests on Current Transformer:
i)
Megger between windings, winding terminals and body.
ii)
Polarity test.
iii)
Ratio identification checking of all ratios on all cores by

primary injection of current.
iv)
Magnetization
characteristics,
secondary
winding
resistance.
i)
v)
Capacitance and tan delta test (Test certificates).
vi)
Dielectric test of oil (wherever applicable).
Commissioning Checks of Cable:
i)
Megger test between each core and armour / sheet.
ii)
Continuity check.
PAGE 46 of 81
187 of 2461
iii)
vii)
j)
k)
l)
MMRDA
Connections.
High voltage test for cables above 1.1kV.
Commissioning Checks of Capacitor:
i)
Measurement of capacitance
ii)
Capacitor loss tangent measurement (for above 1000V)
Commissioning Checks of Neutral Grounding Resistor:
i)
High voltage test
ii)
Ohmic value test, Insulation resistance measurement test
Lightning System
Commissioning tests stipulated in applicable standards and code

of practice covering all lightning system equipment
m)
Earthing System
Continuity of all conductors and joints shall be checked. The

Employers Representative may ask for earth continuity tests,
earth resistance measurements and other tests, which in his
opinion are necessary to prove that the system is in accordance
with design, specification, code of practice and Indian Electricity
rules (1956). Earth grid resistance value should be not greater
than one ohm.
n)
Commissioning Checks for Battery:
i)
Specific gravity test.
PAGE 47 of 81
188 of 2461
o)
MMRDA
ii)
Cell voltage test.
iii)
Capacity test.
iv)
Initial charging/ discharging cycle.
Commissioning Checks of Battery Charger:
i)
Functional check of auxiliary devices, such as alarms,

indicating lamps etc. and operational checks.
ii)
Insulation test of all circuits.
iii)
Measurement of voltage regulation and efficiency.
iv)
No load current and voltage (AC) and voltage and current

(both AC and DC) at different points.
v)
Voltage at tap cell (While boost Charging)
Test for Battery and Battery Charger
All tests shall be conducted as per the relevant standards. Tests shall
include following:
Type & Acceptance tests.
i)
Type Tests: Performed at manufacturers works
ii)
Acceptance Tests: Performed at site after installation and

commissioning of the battery.
All tests shall be witnessed by the Employers representative

Commissioning Test.
PAGE 48 of 81
189 of 2461
a.
MMRDA
The following routine tests shall be conducted at site at no extra

cost.
i.
Visual checks for dimensions and general arrangement.
ii.
Wiring checks
iii.
Functional checks
iv.
Voltage regulation for rated input supply for loads from 0-100%.
v.
Load test to show the charger can serve the rated duty without
the current limiter device operating.
vi.
Calibration of potentiometer vis-a-vis the DC output for float and

boost chargers.
vii.
Ripple and harmonics measurement by oscilloscope at different

loads.
viii.
Demonstration of guaranteed efficiency and power factor.
ix.
Insulation test (with 500 V megger)
x.
Hipot test, excluding electronic controller, at 2 kV AC for one

min.
b.
The following type tests shall be conducted at the factory. Extra

cost, if any, shall be specifically stated by the manufacturer.
Heat run test with both float and boost chargers on full load
especially for float and boost charger schemes/systems and if
housed in same/adjacent panel/ cubicle with or without dividing
partitions.
PAGE 49 of 81
190 of 2461
c.
MMRDA
Vendor shall ensure use of calibrated test equipment having

valid calibration test certificates from standard laboratories
traceable to National Standards.
Acceptance Test of Batteries
Acceptance tests shall be conducted at site on completion of

installation and commissioning and immediately prior to putting the
battery in service. These tests shall comprise of:
i.
Visual inspection
ii.
Dimensional check
iii.
Ampere hour Capacity test
iv.
Retention of charge
v.
Insulation resistance
Routine Test
i.
Physical examination.
ii.
Dimension, mass and layout
iii.
Marking
iv.
Polarity.
Test reports
A copy of routine and type test results shall be submitted for approval
before the dispatch of batteries. Specified number of bound copies of
complete test results shall be furnished with the batteries.
PAGE 50 of 81
191 of 2461
p)
MMRDA
DG Set
Acceptance tests shall be conducted at site on completion of

installation and Commissioning and immediately prior to putting the DG
Set in service. These tests shall comprise of:
Functionality check:
Manufacturers standard tests:
H.V (High Voltage Test)
Megger test Insulation Megger test
Phase sequence
Change over test with LT Auxiliary Transformer along with AMF

Panel.
All functional interlocking test at No-load test shall be done before

charging the transformers.
Indicating, Metering, closing, tripping circuits as per approved

drawings.
Load Test
Run set for 2 hours at full load (all critical Loads as approved)
step load acceptance and rejection tests using the maximum step
loads
q)
Building Services
PAGE 51 of 81
192 of 2461
MMRDA
Contractor has to check and test the illumination and ventilation system
shall be erected and commission as per approved drawings for point
wiring, lighting fixtures exhaust fans, ceiling fans, power sockets, etc.
After installation each point wiring and equipments shall be tested as
required before handover.
7.8
Instrumentation and Control
i.
The list of tests to be carried for SAT along with test instruments
to be used shall be furnished for review by the Employers
Representative.
ii.
The testing of all the equipment and accessories shall be carried

out as per latest applicable Indian/International standards
recommendations.
iii.
Prior to testing, all relevant documentation and sufficient briefing

about the tests shall be given to Employers Representative who
would witness the testing.
iv.
After installation and commissioning, the Contractor shall

demonstrate, by tests in the field, compliance of the values,
functionalities, quality and reliability of the complete system and
its components, both hardware and software, as specified and
as per guarantees.
v.
Contractor shall be fully responsible for interfacing to the

equipment of Others as indicated in the scope of works. It shall
be Contractor's responsibility to ensure satisfactory functioning
of the system in conjunction with related equipment like
exchanges,
data
equipment
and
other
communication
equipment of the Employers Representative. Problems relating

to such interconnections shall be mutually resolved.
PAGE 52 of 81
193 of 2461
vi.
MMRDA
After tests as above, the complete system shall be on

continuous uninterrupted service with all functionalities and
interconnections without any failures or manual interventions for
correction, modification, rectification or replacements in the
Contractor's system.
vii.
Additional specific tests, if required, would be decided mutually.

SAT on local SCADA, UPS systems shall include the all tests
covered under FAT documents except tests such heat run test
and those tests which cannot be conducted at site (such tests
shall be approved by the Employers Representative) in addition
to integrated local SCADA, UPS systems testing at site with all
field equipments/instruments
7.8.1
Site Calibration
Standard calibration procedures shall be used for calibrating all field
instruments. All reference equipment, used for calibration, shall be
certified from an authorized certifying agency, to be arranged by the
Contractor at his own cost. At the time of calibration, standard
calibration norms shall be adopted and the same will be documented
for record purposes. Calibration shall be performed in the presence of
the Employers Representative. The instrumentation shall be calibrated
while being commissioned in order to verify that the high quality
calibration carried out during FAT is not being disturbed (No undue
adjustments shall be made for minor deviations). The Contractor will
monitor and check the instrument calibration throughout the Operation
and Maintenance period.
7.8.2
Instrumentation Installation and Pre-Commissioning Checks

a)
Check the exact location of the instrument with reference to the

pipe
and
instrumentation
diagram
and/or
the
General
Arrangement drawing.
PAGE 53 of 81
194 of 2461
b)
MMRDA
Check that tag plate with tag no. and description is provided for
each instrument.
c)
Check the model No. and instrument type with reference to the
technical specification requirements.
d)
Check all mounting and fixing arrangements and required

accessories such as isolation valve, nuts and bolts, siphon etc.
e)
Check that the instrument installation is as per the installation

drawing.
f)
Check the cable type, connections for power supply as well as

signal cables.
g)
Check that cable shields for the instruments are properly

terminated.
h)
For the flow meters, check that the flow rate and totalized flow
reading on the various displays match.
i)
Check
that
the
earthing
is
as
per
manufacturers
recommendation.
j)
Check that there are no leakages.
k)
For the level switches check that the level electrodes are
connected to the correct level control units.
l)
For the temperature scanners, check that the communication

port of temperature scanner is properly configured and
interfaced with the PLC system. Also check that the alarm and
trip signals for various channels of temperature scanner are
properly configured.
PAGE 54 of 81
195 of 2461
m)
MMRDA
Check the loop continuity for every circuit. While this is being
done, the power supply to the instrument shall be cut-off.
n)
Calibration checks of the instruments shall be carried out to

ensure integrity with the manufacturers factory test reports. (No
undue adjustments shall be made for minor deviations
o)
After switching on the instrument/system, it shall be monitored

hourly and the data obtained shall be recorded and compared
with the reference norms to ascertain whether any recalibration
is required. If recalibration is required it shall be carried out
using standard reference equipment/instruments at no extra
cost.
7.8.3
Instrumentation Commissioning
a)
Each control loop and interlock shall be tested independently, in

manual mode first and then in auto mode from the PLC and
local SCADA system. The operation shall be checked for
conformity with the approved logic in both modes. All pump
control ON/OFF shall be checked in manual mode first.
b)
Annunciation system shall be checked as performance testing

by simulating the condition and bypassing in actual mode and
then individual loop will be checked for annunciation system.
c)
All motorized valves shall be checked in manual mode first, from

controls on the control panel, and feed-back from the field for
valve on/off shall be checked on the panel.
7.8.4
Programmable Logic Control (PLC)

a)
The PLC system and software shall be loaded by the

representative of the PLC manufacturer.
PAGE 55 of 81
196 of 2461
b)
MMRDA
Testing, commissioning and stabilization of the software shall be

carried out by the authorized representative of the PLC
manufacturer. The following checks shall be carried out:
All indicators and indicating controllers will be put in manual

mode after independent checking
Check that the PLC is properly configured and installed as

per the approved drawings
Check that the PLC wiring is as per approved drawing
Check that the cables terminating in the PLC are properly

dressed
Check that the PLC is earthed as per manufacturers

recommendations
Check that the PLC on-line battery is functioning properly
Check that the PLC is correctly time synchronized with the

local SCADA system
Check that the signals and events are getting correctly time
stamped
Check the PLC response when input signal is out of range
Check that the correct ladder program is loaded in the PLC
Check the PLC ladder program by simulating various normal

and abnormal conditions
PAGE 56 of 81
197 of 2461
MMRDA
Check that the data sheets and drawings are updated to

reflect the as-built status
All analogue inputs shall be connected to the PLC system

first. All digital inputs shall be checked at terminals before
connecting to the I/O card of PLC system. PLC system shall
be installed and checked first, before connecting any control
signals/cables. Software shall be loaded in the PLC first,
before connecting I/O cards with signal cables. After
complete checking of the system in manual mode, system
shall be put in Auto mode
c)
The PLC system manufacturer/supplier shall provide assistance

/commissioning support at the time of commissioning, to be
arranged and coordinated by the Contractor. Details regarding
commissioning shall be provided prior to commissioning and any
required modifications or changes shall be advised in advance.
7.8.5
Control Panel
a)
Check name plate details of every piece of associated

equipment for conformity with the specifications.
b)
Check the tightness of all bolts, clamps, connecting terminals.
c)
Check for physical damage.
d)
Check cleanliness
e)
Check switch development
f)
Each wire shall be traced by continuity tests and it should be

confirmed that wiring is as per the relevant drawings. All
interconnections between panels/equipment shall be checked
PAGE 57 of 81
198 of 2461
MMRDA
g)
Megger test on all wires.
h)
Check on meters
i)
Check that the primary devices are set as per the system
requirements.
j)
Checks on the control circuit for the functional requirements
k)
Check that the control panel front fascia layout is as per

approved drawings.
l)
Check that the panel and all the panel equipment (viz. panel
indicators, alarm annunciators, etc.) are connected to the proper
earth.
m)
Check that spare cutouts on the control panel are blanked.
n)
Check that the panel indicator tag plates reflect the tag no. and
the correct service description.
o)
Check whether the panel meters are fixed properly in their

cutouts.
p)
Check that the instruments are identified inside the panel.
q)
Check that the panel meter instrument ranges are as per

approved data sheets.
r)
Check that panel meters are provided with password protection

facility.
s)
Check that the alarm inscription details are as per approved

drawings.
PAGE 58 of 81
199 of 2461
MMRDA
t)
Check that the MCBs are identified by their function.
u)
Check that safety guards are provided for power supply

terminals.
v)
Check the cables terminating in the control panel are properly

dressed.
w)
Check that proper node addresses are given to the panel

meters/ scanners connected on the communication bus.
x)
Check that the communication bus is terminated properly.
y)
Check working of alarm annunciator by simulating alarm

conditions.
z)
Check that the panel meter readings match with other displays.
aa)
Check that the no. of decimal places and unit of measurement

are same for all the displays.
bb)
Check that the data sheets and drawings are updated to reflect
the as-built status.
7.8.6
Tests for Local SCADA

SAT on local SCADA systems shall include all the tests covered under
FAT documents except tests which cannot be conducted at site (such
tests shall be approved by the Employers Representative) in addition
to integrated local SCADA, communication system and UPS systems
testing at site with all field equipment/instruments.
7.8.7
Tests for UPS
PAGE 59 of 81
200 of 2461
MMRDA
SAT on UPS systems shall include the all tests covered under FAT
documents except tests which cannot be conducted at site (such tests
shall be approved by the Employers Representative) in addition to
integrated local SCADA, UPS systems testing at site with all field
equipments/instruments.
7.9
Commissioning
After the completion of pre-commissioning activities, the final checks

and preparations necessary for startup of the plant shall be carried out.
The Contractor shall submit to the Employers Representative a written
Notice of Mechanical Completion, which shall include:
1.
Identity part of the Plant considered mechanically complete.
2.
Copies of all relevant completed test reports.
3.
Date on which the completion of the tests was achieved.
4.
Check list& commissioning data formats.
5.
Request for issuance of a Mechanical Completion Certificate in

respect of that part.
6.
Within fourteen (14) days from the date of receipt of the

Contractors written Notice, the Employers Representative shall:
In the case of acceptance, issue a Mechanical Completion

Certificate
In the case of objection, submit a rejection statement setting

forth-remaining items to be completed or defects or
deficiencies to be corrected before Mechanical Completion
status
can
be
accepted.
When
the
Employers
Representative rejects the Contractors Notice the Contractor

PAGE 60 of 81
201 of 2461
MMRDA
shall take any necessary action to complete or correct the

items marked and give the Employers Representative a
second Notice of Mechanical Completion
7.
After the issuance by the Employers Representative of a

Mechanical Completion Certificate, commissioning activities
listed below shall be carried out to enable the start-up and
operation of the Plant. Procedures are described as below:
A) Commissioning procedure shall be carried out in a methodical
sequence as follows
8.
Warming up
Start-up
Initial running
Operability adjustment
Stable operation
Final adjustment
At all stages of commissioning sequence, the Plant shall be

operated at optimum Plant conditions. To ensure this, the
Contractor may make minor adjustment to the conditions
indicated in the Operation and Maintenance Manual as
necessary.
9.
The Contractor shall check the operating conditions of the Plant

by constantly monitoring operating data.
PAGE 61 of 81
202 of 2461
10.
MMRDA
The Contractor shall specify for each discrete part of the Plant
the operational data to be recorded and the manner in which the
data is to be taken.
11.
The Employers Representative on the forms to be mutually

agreed shall record all the operating data. The Employers
Representative shall make a copy of the operating log and
analytical data from initial operation through to the completion of
Performance Test available to the Contractor for evaluation.
12.
The Contractor shall carry out commissioning tests in the

presence of the Employers Representative. The evaluation of
test results and decision passed by the Employers
13.
Representative regarding the test results will be final and

binding on the Contractor. Any additional tests or repetition of
tests to establish satisfactory operation of any equipment shall
be carried out by the Contractor, if so desired by the Employers
Representative, at no extra cost.
14.
All checks and tests shall be as per the Manufacturers drawing

manuals,
relevant
codes
of
installation
and
as
per
commissioning checklists.
15.
Among other commissioning tests, the following shall be carried

out at site after completion of installation. Contractor shall
ensure to use calibrated test equipment having valid calibration
test certificates from standard laboratories traceable to National
Standards / International Standards. All tests to be carried out in
the presence of Employers Representative.
7.9.1
Commissioning Tests
Following commissioning tests are to be carried out on all the
equipment/systems, as applicable.
PAGE 62 of 81
203 of 2461
MMRDA
Insulation resistance measurement of equipment, accessories,

cabling / wiring etc.
Dielectric tests on equipment, accessories, cabling/ wires etc.
Phase sequence and polarity
Voltage and current ratios
Vector group
Resistance measurement of winding, contacts etc.
Continuity tests
Calibration of indicators, meters, relays, etc.
Control and interlock checks
Settings of equipment and accessories
Checking of accuracy/error
Checking of operating characteristics, pick-up voltages and

currents, etc.
Operational and functional tests on equipment, accessories,

control schemes, alarm/trip/indication circuits, etc.
Measurement of guaranteed/approved design values including

lighting levels, earth resistance measurement, etc.
Complete commissioning checks of the system
PAGE 63 of 81
204 of 2461
MMRDA
7.10
Pipeline Works
7.10.1
Hydraulic Testing of Pipeline
7.10.1.1
Testing Procedure
Pipelines and fittings shall be subjected to hydraulic pressure tests in
the presence of the Employers Representative which shall comply with
IS 5822 unless otherwise specified.
Testing shall be carried out in two stages:
Test of sections as pipeline laying proceeds
Tests on completion of the entire pipeline as-a-whole, including

the intermediate sections that were not included under the
sectional testing stage
The Contractor shall provide all plant, equipment, fittings and water
necessary for the hydraulic tests. The Contractor shall submit to the
Employers Representative, well in advance of the time of tests, details
of his proposals, including the supply of adequate quantity of water and
its supply arrangement. No connections from the existing pipelines will
be allowed, nor will any connections to the pipeline and pipe work be
allowed which would involve cutting, offtakes, or otherwise altering the
Permanent Works. Test gauges shall be of approved manufacture
having dials of at least 200 mm diameter, graduated such that the test
pressure is at least 75% of the full scale reading. If necessary, different
gauges shall be supplied for different pipeline sections. Two gauges
shall be provided for the sole use of the Employers Representative
and shall remain in the Employers Representatives possession for the
duration of the Contract. All gauges shall be dead weight tested and
calibrated from testing institutions approved by the Employers
PAGE 64 of 81
205 of 2461
MMRDA
representative at the commencement of work and at regular intervals

as required by the Employers Representative.
The Contractors arrangements for testing shall include a suitable
means for quick
installation
and
removal of
the
Employers
Representative gauges and any replacement gauges required during

testing.
7.10.1.2
Sectional Testing
Sectional hydraulic tests shall be carried out after the pipeline section
to be tested has been laid, jointed and backfilled to a depth sufficient to
prevent floatation, the sections to be tested shall not be longer
5000 m unless otherwise approved by Employers Representative.
In addition to the above requirements, the Contractor shall perform an
initial hydraulic test on the first 500 m length of pipeline to be laid under
the Contract. This test shall be undertaken within one month of the
Contractor commencing the laying of pipes Should the pipeline fail the
test, or should the Contractor fail to undertake the test, all laying and
welding work shall come to a halt until that section of pipeline passes
the hydraulic test. Any delay which may occur as a result of this will be
to the Contractors account, and will not be a cause for any variation.
Each length of the pipeline to be tested shall be capped or blanked off
at each end and securely strutted or restrained by means of adequately
designed and provided thrust block to withstand the forces which will
be exerted when the test pressure is applied. Testing against closed
valves will not be permitted. Washout valves shall be fitted with blank
flanges and these, together with in-line valves, shall be left open. Air
valves already fitted shall be permitted to function during the test.
Proposals for testing where thrusts on structures are involved, even
where thrust flanges on the piping are installed, shall be submitted,
with the calculations of the forces to be carried, to the Employers
Representative for approval.
PAGE 65 of 81
206 of 2461
MMRDA
The method of filling the pipeline with water shall be approved by the
Employers Representative. The length under test shall be filled making
certain that all air is displaced through an air valve installed at the top
of the blank flange situated at the high end of the line. The length shall
then remain under constant moderate pressure 10 to 20 m head of
water, for a period of several hours until the pressure can be
maintained without additional pumping. The pressure shall then by
slowly increased at a maximum rate of 1 bar per minute to the full test
pressure and pumping discontinued for 4 hours or until the pressure
has dropped by 10 m, whichever occurs earlier. Thereafter pumping
shall be resumed and continued until the test pressure has been
restored. The quantity of water pumped to restore the pressure shall be
the measure of leakage from discontinuation of pumping until its
resumption. In general, the welded MS pipe joints are not expected to
show any loss of water.
The pipe length shall pass the test if the leakage is not more than 0.1
liters per mm diameter per kilometer per 24 hours for each 30 m head
of pressure applied.
Notwithstanding the satisfactory completion of the hydraulic test, if
there is any discernible leakage of water from any pipe or joint the
Contractor shall, at his own cost, replace the pipe, repair the pipe or
remake the joint and repeat the hydraulic test. No pipeline shall be
accepted until the leakage on any length is not more than the rate of
leakage specified above and all sources of leakage have been
rectified.
7.10.1.3
Test Pressures
The field tests for both sectional testing and testing on completion shall
be carried out as per the provisions in the IS 5822 latest revisions.
Proposed test pressures shall be determined based on the actual Site
conditions, and shall be reviewed and approved by the Employers
Representative.
PAGE 66 of 81
207 of 2461
MMRDA
The field test pressure shall be as under:
For gravity main :1.5 times maximum static head on the pipeline
corresponding to the HGL @ BPT at C=120 + 5m residual head
For Pumping main: Working pressure + water hammer pressure

without water hammer control devices
Where the field test pressure is less than two-thirds the factory
test pressure, the period of test should be at least 24 hours. Test
pressures are to be measured at the center of the blank flange
situated at the lowest end of the pipeline under test
7.10.2
Tests on Completion of Pipeline Works
7.10.2.1
General
The tests on completion shall be carried out after all the pipeline
sections have been satisfactorily tested and the joints between each
section completed to provide a continuous test length between the
Contract interfaces. The entire length of the pipeline tunnel will be
subjected to hydraulic testing, in accordance with the preceding
procedures, after joining the intermediate portions which did not come
under testing of different sections during the sectional testing period.
The laid pipeline will be joined with respective manifold through valves.
Just before the commissioning the complete transmission main will be
checked for:
i.
All valves in the system will be inspected for proper lubrication,

manual / electrical operation as applicable
ii.
All air valves shall be inspected for proper fitting and operation
of isolating valves.
PAGE 67 of 81
208 of 2461
iii.
MMRDA
All flange joints/ expansion joints/ couplings will be checked for

tightness of all bolts, clamps, etc.
iv.
The entire transmission system shall be checked for proper soil

cover/ backfilling/ thrust and anchor blocking, etc.
v.
The structures will be checked for any constructional defects.
vi.
The valve chambers and their surroundings will be checked for

its cleanliness.
vii.
The all CP stations will be checked for their functioning along

with pipe to soil potentials (PSP) at every test lead point for
proper soil potential. All CP stations, test stations to be
monitored regularly during the commissioning and trial run
period and data related, individual anode current, energy
consumption, battery performance, etc., to be incorporated in
the log-book.
7.10.2.2
Pressure Test
The entire pipeline shall be subjected to a hydraulic test as follows, to
the required test pressure as per IS:5822and as specified in clause
7.10.1.3 the field test pressure shall be maintained for minimum 6(Six)
hours. If a drop in pressure occurs, the quantity of water added in order
to reestablish the test pressure should be carefully measured. This
should not exceed 0.1 liter/ mm of pipe diameter per kilometer of
pipeline per24 hours for each 30 m head of pressure applied. All the
joints, valves, fittings which are not tested during sectional testing shall
be physically checked for leakages and leakages repaired if found. The
Contractor
shall
provide
and
maintain
all
requisite
facilities,
instruments, for the field testing of the material. All pipes, specials,
valves and civil works shall be replaced by the Contractor free of cost if
damaged during testing.
PAGE 68 of 81
209 of 2461
7.10.3
MMRDA
Cathodic Protection System Test

The effectiveness of the cathodic protection system shall be checked
by monitoring the current requirements at all the Cathodic Protection
(CP) Stations. Corrective steps shall be taken if the direction of current
is not as per requirements.
7.11
Tests for Water-Retaining Structures
Water retaining structures for water supply purposes shall satisfy the
following tests for water tightness, before external finishes are applied
(if any). The water for testing shall fill the first 1.25 meters and may be
filled as quickly as supply permits. Between this and top water level,
the rate of filling shall not exceed a steady rate of 300 mm per 24 hours
unless otherwise directed. After filling to top water level no further
water shall be introduced for 7 days. After expiry of seven days and
after the filling, the level of the surface of the water shall be recorded.
The level of water shall be recorded again at subsequent intervals of
24hours over a period of seven days and the structure shall satisfy the
test if at the end of this week no leakage is apparent and or the water
level does not drop more than 40 mm over the period of 7 days. The
Employers Representative shall decide on the actual permissible
nature of this drop in surface level, taking into account whether the
tanks are open or closed and the corresponding effect it has on
evaporation losses. Foregoing visible leakages and sweating will not
be accepted. If the structure does not satisfy the condition of test and
the daily drop in water level is decreasing the period of test may be
extended for a further seven days and the if specified limit is then
reached the structure may be considered as satisfactory.
Following satisfactory completion of the tests the Contractor shall
empty the structures and dispose of satisfactorily the contents. He shall
clean and disinfect the structures and any equipment therein of all
deposits left by the testing.
PAGE 69 of 81
210 of 2461
7.12
7.12.1
General
MMRDA
Prior to the commencement of Tests on Completion the Contractor

shall submit for approval the following:
Site Acceptance Test Documents;
As-Built Drawings;
Operation and Maintenance Manuals.
Tests on Completion shall not be commenced until the aforementioned

documents are approved. The charges of oil, grease, electrolyte,
generator fuel, etc., necessary for Tests on Completion shall be
provided by the Contractor. Chemicals required for Tests on
Completion will be provided by the Contractor. Electricity shall be
provided by the Employer. The Contractor shall provide adequate raw
water to meet his requirements prior to commencement of the Tests on
Completion involving its use.
7.12.2
Dry Test Requirements

General
As a minimum requirement the following dry tests shall be carried out
as a general requirement:
A general inspection to check for correct assembly and quality of

workmanship;
A check on the presence of lubricant, cooling medium,

electrolyte, etc.:
PAGE 70 of 81
211 of 2461
MMRDA
A check on adequacy and security of plant fixing arrangements;
A general check to ensure that all covers, access ladders, water

proofing, guard railings, etc. are in place;
A check on damp-proofing, rust-proofing and vermin-proofing

and particularly the sealing of apertures between building
structures, chambers etc. and the outside;
7.12.3
Hydraulic Wet Test Requirements

Hydraulic wet tests shall be carried out on completion of dry tests. Raw
water or treated water (if available) shall be used for hydraulic wet
tests. The purpose of the tests is to prove as far as practical the
hydraulic performance of the Works. In order to demonstrate this, the
Contractor shall ensure that each part of the Works is hydraulically
loaded to its rated throughput for a period of at least four hours. In
order to ensure a sufficient supply of raw water to carry out these tests
the Contractor shall provide facilities for the disposal off-Site in an
approved manner not less one third of the Works rated output.
In order to remove doubt, the following tests, inter alia, shall be carried
out:
Pressure testing of all piped systems laid direct in ground in

accordance with the relevant standards;
Fill all structures and check for leaks;
Filling of all storage vessels to check for leaks and distortion;
Running of all pumped systems in order to check for:
Correct functionality;
PAGE 71 of 81
212 of 2461
MMRDA
Absence of leaks;
Correct running temperatures
Smoothness of running and the absence of undue vibration

or stress;
Check drive running currents;
Carry out calibration of instruments where appropriate;
Hydraulic testing of primary/ impulse tubing.
Carry out valving, diversions, etc., to full hydraulic load (or

where there is a requirement to withstand an over load to
overload) for each process element;
Demonstrate correct functionality of electrical, control and

instrumentation systems.
The Contractor shall simulate the conditions that will prevail

when operating as a process in order to demonstrate the correct
functionality of process control loops, etc.
During these tests a check on the performance of Plant shall be made,

as far as site facilities will allow, to compare its site performance with
the factory test data and to identify any constraints on performance due
to site conditions.
7.12.4
Filter Wet Tests

The Contractor shall carry out the following tests on each of the
completed filters:
PAGE 72 of 81
213 of 2461
7.12.4.1
MMRDA
Pressure Test
All the nozzle outlets shall be plugged and the filter under drainage
system shall then be filled with water leaving an air gap of between 25
mm and 50 mm between the water surface and the underside of the
filter floor. The top of the filter floor shall be covered with water to a
depth of 50 mm above the top of the nozzle plugs. The underside of
the filter floor shall then be pressurized to 0.5 bar, by either utilizing the
Plant air scour blowers or by providing and connecting up a temporary
air blower. The test shall be maintained for one hour and all leaks
identified. The pressure shall then be relieved, the water removed from
the filter and the detected leaks rectified. The filter shall then be
retested and the procedure repeated until all leaks are rectified to the
satisfaction of the Employers Representative. On rectification of all
leaks the filter's strength shall be tested by applying the above
mentioned test pressure for a period of 48 hours. Any leaks or minor
structural damage shall be rectified and the filter retested to the
satisfaction of the Employers Representative. If, in the opinion of the
Employers Representative, structural damage has occurred to the filter
floor, which cannot be satisfactorily repaired without affecting the
structural integrity or performance of the filter, the entire floor shall be
replaced.
During the above tests the Contractor shall set the pressure relief valve
on the air blower system to relieve pressure above the test pressure.
He shall also install a standpipe connected to the under drain to ensure
that over-pressurization cannot take place. The bottom end of the
standpipe shall be below the air/water interface under the filter floor
and the top end shall be at the level equivalent to the test pressure.
7.12.4.2
Flow Distribution Tests

a) Air Distribution Test
PAGE 73 of 81
214 of 2461
MMRDA
The empty filter shall be filled with water to a level of 25 mm above

the top of the nozzles. Air shall be introduced into the under drain
system at such a rate that the system can be seen to pass air
through the nozzles over the whole filter area. Any discrepancies in
distribution over the filter shall be rectified and the test repeated
until the Employers Representative is satisfied that the air
distribution is uniform over the entire filter with all nozzles blowing.
b) Combined Air Scour and Backwash Distribution Test
The filter shall be tested for combined air and water scour at the
design rates in the same manner as described above for the air
distribution test. Air shall be brought on first and allowed to fully
develop before the water is introduced. Any discrepancy in
distribution over the filter shall be rectified and the test repeated
until the Employers Representative is satisfied that the distribution
is uniform over the entire filter with all nozzles blowing.
If for any reason it is necessary to remove a nozzle dome after it
has been fully tightened, it shall not be re-used but replaced by a
new one. As soon as possible after satisfactory completion of the
above tests the filter shall be charged with filter media.
7.12.4.3
Safety Audit
After satisfactory completion of hydraulic wet tests and prior to
introduction of process fluid to the plant a safety audit shall be carried
out to ensure compliance with the necessary requirement for safety
and for operation of Plant. The safety audit shall be documented. The
safety audit document shall be approved by the Employers
Representative prior to commencement of Plant sterilization.
7.12.4.4
Plant Sterilization
PAGE 74 of 81
215 of 2461
MMRDA
On approval of the safety audit document the Contractor shall carry out
sterilization of the wetted parts of the Works. In order to remove doubt
this shall also include the wetted surfaces of water treatment chemical
storage and dosing systems.
The sterilization process shall be carried out by completely filling the
item or items concerned with water containing not less than 30 mg/l of
free chlorine and leaving it to stand for not less than 2 hours. On
draining down the Contractor shall demonstrate that the chlorine
residual has not fallen below 20 mg/l of free chlorine. If this is not true,
the sterilization process shall be repeated until this condition is met.
The Contractor shall be responsible for the disposal of the sterilization
solution. The Contractor shall take the necessary measures to ensure
that the free chlorine residual of the solution for disposal is not greater
than 1 mg/l before discharge to the environment.
Areas such as the roofs of tanks not easily wetted by filling the vessel
with sterilization solution shall be sterilized using a procedure approved
by the Employers Representative.
The Contractor shall give 2 weeks advance notice to the Employers
Representative and the Employer of the proposed date for carrying out
sterilization.
The Contractor shall advise the Employers Representative and the
Employer in writing when all wetted parts of Plant and civil structures
have been sterilized. If the Contractor carries out any new work that
invades a previously sterilized area the Contractor shall be required to
carry out re-sterilization of that area to the approval of the Employers
Representative.
7.12.5
Process Wet Tests
PAGE 75 of 81
216 of 2461
MMRDA
On approval of the sterilization process the Contractor shall carry out

process wet tests.
Raw water shall be used as the primary feed stock for process wet
tests. These tests shall be carried out to demonstrate the process
performance of the Works. In order to demonstrate this, the Contractor
shall ensure that each part of the Works is loaded to its rated
throughput (including a period of overload if required in order to
demonstrate compliance with the Employers Requirements) for a
continuous stable operating period of not less 48 hours.
The Contractor shall provide facilities for the disposal off Site in an
approved manner a quantity of treated water equal to not less than one
third of the Works rated output.
The following tests, inter alia, shall be carried out:
Check for leaks on vessels, structures, pumps and pipe work;
Running of all pumped systems in order to check for:
Correct functionality;
Absence of leaks;
Correct running temperatures
Smoothness of running and the absence of undue

vibration or stress;
Check drive running currents where the solution pumped is

different from that pumped during hydraulic wet tests;
Carry out calibration of water quality instruments;
PAGE 76 of 81
217 of 2461
MMRDA
Carry out valving, diversions, etc., to full hydraulic load (or

where there is a requirement to withstand an over load) for each
process element;
Demonstrate correct functionality of electrical, control and

instrumentation systems
On completion of the tests on the various parts of the works the

Contractor shall run the plant as a whole in order to demonstrate
the full functionality and performance of the Works at various
throughput rates fora continuous period of not less than 5 days
or as per directives from Employers representative.
During the various process tests the Contractor shall take samples
and carry out water quality analysis at not greater than one hourly
intervals in order to demonstrate to the Employers Representative
that the Works is functioning in accordance with the Employers
Requirements. Each sample shall comprise two 1liter (minimum)
quantities and shall be labeled to identify the contents, where taken
and time and date.
One sample shall be used by the Contractor for his analysis; the
other shall be handed over to the Employers Representative. The
Employers Representative reserves the right to take additional
samples and to carry out his own tests or to check the samples
taken by the Contractor. The Employers Representative shall be
given reasonable access to the premises where analysis is taking
place in order to check on working practices and the procedures
being adopted.
7.13
Trial Run of the entire System
After individual commissioning tests of components of the works the

Contractor shall make trial runs. A continuous operation for a period of
7 days to the satisfaction of the Employers Representative will be
PAGE 77 of 81
218 of 2461
MMRDA
deemed to demonstrate satisfactory completion of trial run for the

individual component. The cost of chemicals and other consumables
for operation and maintenance of the System during the period of this
trial run will be borne by the Contractor. The costs towards the
Contractors supervisors and other operating personnel along with cost
of tools and spare parts, which are required for operation and
maintenance of the plant and equipment during the trial run period shall
also be borne by the Contractor and shall be included in Contract
Price. In the event that the System or any of the facilities do not
satisfactorily achieve the required performance standards during this
period, the trial run period shall be extended until such time as the
Contractor has satisfactorily rectified any deficiencies as may be
necessary to satisfy the performance requirements, at the risk and cost
of the Contractor
7.14
Commissioning of the entire System
On completion of the Trial Run, commissioning of the System shall be

done by the Contractor. The total time allotted for commissioning of the
full system is 90 days. The commissioning of the system shall be
considered as fully achieved after the full system has run continuously
for a period of 15 days without any breakdown to the satisfaction of
Employers Representative. If continuous run is not achieved fully to
the satisfaction of Employers Representative, the Contractor has to do
the needful to achieve the same at his cost. All the costs thereof,
including the cost of staff, maintenance, and any other consumables
including chemicals used for operation and maintenance of the system
during the period of commissioning except electricity consumed during
the commissioning period shall be borne by the Contractor. The cost of
electricity will be borne by the Employer.
Last 30 days during the commissioning period of the entire system
shall be considered as test on completion as detailed below.
7.15
Tests after Completion
PAGE 78 of 81
219 of 2461
7.15.1
MMRDA
Employers Obligations
The Contractor shall provide the necessary labor, materials, electricity,
fuel and water, and shall carry out the Tests after Completion in
accordance with the manuals provided by the Contractor and such
guidance as the Contractor may be required to give during the course
of such Tests.
The Tests after Completion shall be carried out for last 30 days of
commissioning period.
The results of the Tests after Completion shall be compiled and
evaluated by the Employer and the Contractor. Any effect on the
results of the Tests after Completion which can reasonably be shown
to be due to the prior use of the Works by the Employer shall be taken
into account in assessing such results.
7.15.2
Retesting on Failure
If the Works, or a Section, fail to pass the Tests after Completion, the
Employer or the Contractor may require such failed Tests, and the
Tests after Completion on any related work, to be repeated under the
same terms and conditions. If such failure and retesting result from a
default of the Contractor and cause the Employer to incur additional
costs, such costs shall be recoverable from the Contractor by the
Employer, and may be deducted by the Employer from any monies
due, or to become due, to the Contractor.
7.15.3
Test during Monsoon

After successful completion of the Tests on Completion the Contractor
shall carry out, as soon as reasonably possible but over a period of
time not exceeding one year, 30 days operational tests during
monsoon. These tests shall be used to prove the operation of the
PAGE 79 of 81
220 of 2461
MMRDA
Works at varying flows and with varying raw water quality. During the
tests water produced by the Works will be entering the public supply
network. The tests after completion shall be undertaken in accordance
with as mentioned above Each part of the Works shall be considered
separately as far as the tests are concerned.
The timing of the tests shall be determined by the Employer who shall
give notice to the Contractor in accordance with Contract. The total
time for carrying out the tests shall not be less than 30 days
corresponding to period of high raw water turbidity.
On commencement of 30 days test the Contractor shall allocate a
continuous period to complete the test. If the part of the Works fails to
pass the test in the 30 days period, the test shall be deemed as a
failure and the Contractor shall carry out any necessary remedial work
to the satisfaction of the Employers Representative before the
Contractor restarts the test again. During the tests the Contractor shall
take samples to demonstrate that the part of the Works is performing in
accordance with the Employers Requirements. Samples shall be taken
at
locations
and
intervals
as
directed
by
the
Employers
Representative. The tests for performance of the system to meet the

tender requirements shall be completed in this period and the penalties
if any due on the Contractor as per the Contract shall be finalized. The
results of the Tests after Completion shall be compared and evaluated
by the Employer and Contractor. The Contractor will not be held
responsible for interruptions to the water treatment process as a result
of power failures (unless as a result of a Plant failure), interruptions in
the raw water supply, etc., which are out of his control. However, the
Contractor shall be required to demonstrate that the Works can cope
with these inevitable interruptions in an orderly fashion and recover to a
normal operational state with the minimum of manual intervention. All
staff and consumables needed for operation of the Works such as
fuels, lubricants etc. and transportation of sludge off site, except raw
water and power shall be provided by the Contractor under his
operation and maintenance responsibilities. The Contractor shall be
PAGE 80 of 81
221 of 2461
MMRDA
required reasonably to co-operate and co-ordinate his activities with

those of the Employer and other agencies. The Contractor shall
provide all facilities and equipment not supplied under the Contract and
which are deemed necessary to carry out and monitor the tests after
completion.
7.15.4
Treated Water Quality Criteria

The Works shall be considered to have passed the 30 Day Test for
treated water quality if all samples taken during the 30-day period
comply with the criteria set out below in Table.
The Works shall have fulfilled the treated water quantity criteria if the
Works have demonstrated that this can provide the quantity of treated
water detailed in the Contractors Functional Guarantee over a
sustained and continuous period during the tests after Completion. The
treated water quantity criteria are an absolute requirement; i.e. the
guaranteed treated water quantity must be achieved.
PAGE 81 of 81
222 of 2461
SUB-SECTION 6A.8
HEALTH, SAFETY, WELFARE AND
ENVIRONMENT
223 of 2461
MMRDA
Table of Contents
SUB-SECTION 6A.8: HEALTH, SAFETY, WELFARE AND ENVIRONMENT ......................................... 1
8.1
Applicable Regulations, Acts etc. .................................................................................................... 1
8.2
Health, Safety and Welfare ................................................................................................................. 1
8.2.1
Failure to Comply ............................................................................................................................... 1
8.2.2
Contractor's Health, Safety, Welfare and Security Implementation Plan ................................... 1
8.2.3
Contractor's Health, Safety, Welfare and Security (HSWS) Officer ............................................ 2
8.2.4
Contractor's Health, Safety, Welfare and Security Committee .................................................... 3
8.2.5
Site Health, Safety, Welfare and Security Coordinator ................................................................. 3
8.2.6
First Aid Facilities ............................................................................................................................... 4
8.2.7
Overhead Hazards ............................................................................................................................. 4
8.2.8
Excavations or Underground Hazards ............................................................................................ 4
8.2.9
Drowning Hazards .............................................................................................................................. 5
8.2.10
Slipping Hazards ............................................................................................................................ 5
8.2.11
Tripping Hazards ............................................................................................................................ 5
8.2.12
Access to workplace ...................................................................................................................... 5
8.2.13
Dust and Gases .............................................................................................................................. 6
8.2.14
Hazardous and Corrosive Substances ....................................................................................... 6
8.2.15
Eye and Ear Protection ................................................................................................................. 6
8.2.16
Respiratory and Resuscitation Equipment ................................................................................. 6
8.2.17
Work in Confined Spaces ............................................................................................................. 7
8.2.18
Personal Protective Equipment (PPE) ........................................................................................ 8
8.2.19
Electrical Hazards .......................................................................................................................... 8
8.2.20
Power Driven Saws, Abrasive Wheels and Grinders ............................................................... 9
8.2.21
Public vehicular traffic.................................................................................................................... 9
8.2.22
Site traffic ...................................................................................................................................... 10
8.2.23
Stability of structures ................................................................................................................... 10
8.2.24
Storage of materials and equipment ......................................................................................... 10
8.2.25
Disposal of debris......................................................................................................................... 10
8.2.26
Excavations ................................................................................................................................... 11
8.2.27
Ladders, step ladders and access platforms ........................................................................... 12
8.2.28
Working at height ......................................................................................................................... 12
8.2.29
Positioning of machinery ............................................................................................................. 12
8.2.30
Fixed and mobile cranes ............................................................................................................. 12
8.2.31
Attachment of loads ..................................................................................................................... 14
8.3
Environmental Protection................................................................................................................. 15
224 of 2461
MMRDA
SUB-SECTION 6A.8: HEALTH, SAFETY, WELFARE AND ENVIRONMENT
8.1
Applicable Regulations, Acts etc.
The Contractor shall comply with the relevant requirements of all local and
the national health, safety, welfare and environment acts and regulations
issued by the Ministry of Labour (MoL).
Compliance with the requirements of acts and regulations by the
Contractor shall not relieve the Contractor from responsibility for the
safety of his workers and employees and those of his subcontractors.
8.2
Health, Safety and Welfare
8.2.1
Failure to Comply
In the event that the Contractor fails to comply with the requirements of the
regulations or with the Specification in respect of safe working conditions
or practices on the Site, the Employers representative will have the
authority to instruct the Contractor to stop work in any particular location
until the unsafe conditions or practices have been rectified to the
satisfaction
of
the
Employers
representative.
The
Employers
representative will issue safety violation notices to the Contractor,

informing him that he is working unsafely and describing the nature of the
unsafe working practice, the time and date and the location. In this event,
the Contractor shall be responsible for all costs and delays resulting from
complying with such instruction by the Employers representative and for
the actual costs incurred on rectification of the unsafe conditions or
practices.
8.2.2
Contractor's Health, Safety, Welfare and Security Implementation Plan

The Contractor shall prepare and submit to the Employers representative
for review a Site implementation plan specific to health, safety, welfare and
SECTION 6A.8: HEALTH SAFETY WELFARE & ENVIRONMENT
225 of 2461
PAGE 1 of 17
MMRDA
security practices of the work to be carried out under the Contract. The
Contractor shall carry out all work on the Site in accordance with the
agreed Site implementation plan. The Contractors plan shall reflect the
requirement of the local and national requirements. It will include a
methodology for carrying out risk assessments by the Contractor where
these are deemed necessary. The plan will be updated from time to time
to reflect any significant changes to laws and regulations or site activities.
8.2.3
Contractor's Health, Safety, Welfare and Security (HSWS) Officer

The Contractor shall appoint a qualified and experienced HSWS officer for
the duration of the Contract. The full time duty of the officer will be to
implement the site implementation plan, to prevent accidents and enforce
the requirements of legislation in force. The name and qualifications of
the officer so designated shall be submitted to the Employers
representative by the Contractor for approval within two weeks of the
commencement of the Contract. The officer shall attend full time on site
during normal working hours and whenever work is in progress during out
of hours working, public and national holidays approved by the Employers
representative and available by phone and mobile during non-working
hours.
The Contractor shall engage senior site engineers and foremen that are
properly trained in the application of correct Health and Safety practices.
These individuals shall liaise closely with the HSWS to maintain safety on
site at all times. The Contractor shall submit the details of the Health and
Safety qualifications of all such site personnel.
The HSWS officer will be responsible for ensuring all relevant
information and posters are displayed at locations throughout the site in
accordance with the site implementation plan.
The HSWS officer will be responsible for keeping a site accident book to
record all site incidents or any major site rescue events. The book will be
available for inspection by the Employers representative or any MOL
226 of 2461
PAGE 2 of 17
MMRDA
authorized person. Record keeping must also be maintained to comply

with any other legal or regulatory requirements.
The HSWS officer will be responsible for ensuring that every site worker
and regular visitor is given site HSWS procedure training when they first
enter the site and refresher training at an appropriate frequency agreed by
the Employers representative. All occasional visitors will be trained on
arrival and be provided with the appropriate personal, protective
equipment. Records of the training will be kept and available for
inspection by the Employers representative.
8.2.4
Contractor's Health, Safety, Welfare and Security Committee

The Contractor shall set up a safety committee comprising the his
full-time HSWS officer, project manager, site engineers and foremen for
the Contract. The committee shall meet weekly and minutes shall be
recorded and a copy shall be submitted to the Employers representative.
The Employers representative shall be invited to be present at the
meetings.
The purpose of the meetings will be to discuss and resolve health, safety,
welfare and security aspects of various parts of the work, including
possible areas of conflict or difficulty. Where different contractors are
working in the same area or adjacent areas, or where the work of one may
impinge upon the work of another, the meetings will consider what action
needs to be taken to ensure that each contractor is aware of the safety
requirements of others.
8.2.5
Site Health, Safety, Welfare and Security Coordinator

The Employer may oversee the health, safety, welfare and security
arrangements of the various contractors working on the Site, to liaise with
the Employers representative and to draw his attention to any breaches
of Contract requirements or the approved safety plans of the Contractor.
227 of 2461
PAGE 3 of 17
8.2.6
MMRDA
First Aid Facilities

The Contractor shall provide a complete approved first aid kit in his site
office. The kit shall be in the charge of either the Contractor's HSWS
Officer or some other responsible person who will also be on the site
during all working hours to ensure that the first aid kit is available without
delay. The Contractor shall also provide a first aid kit in the office for the
Employers representative. Kits shall also be provided at all remote sites.
The HSWS Officer and adequate numbers of other senior members of
the Contractor's staff shall be trained in occupational site first aid duties
including resuscitation to take account of numbers of site workers
located on the permanent site and mobile site operations.
The Contractor will make arrangements with the emergency and rescue
services to provide adequate support where on site first aid assistance is
inadequate to meet the welfare requirements of all site workers.
The Contractor shall comply fully with all rules and regulations from time
to time issued and orders given by the Health Service of the Government
or the local medical or sanitary authorities.
8.2.7
Overhead Hazards
Overhead protection shall be provided at any location where there is a
hazard of falling objects. This shall particularly be observed around any
scaffolding and in excavations.
Goalposts shall be erected beneath all overhead lines to prevent the
arms or jibs of plant from approaching such lines. No plant shall be
trafficked beneath overhead lines until the Employers representative has
inspected and approved the erected goalposts.
8.2.8
Excavations or Underground Hazards

Every excavation or underground space into or through which a person
228 of 2461
PAGE 4 of 17
MMRDA
may fall shall be covered by a temporary cover fixed securely in position

or guarded by an effective barrier to prevent falls except where free
access is required by work actually in progress. In such a case where
work is in progress, the barrier shall be maintained in position to the extent
possible, and suitable warning signs shall be erected.
8.2.9
Drowning Hazards
Where the work involves filling tanks with water leaving an open surface,
the Contractor shall provide at all times and at suitable locations
equipment for promptly rescuing persons from the water and resuscitating
rescued persons. The Contractor shall take all necessary steps to
prevent any such accidents occurring by providing adequate guarding.
8.2.10
Slipping Hazards
The Contractor shall not suffer or permit an employee to use a
passageway, or a scaffold, platform or other elevated working surface
which is in a slippery condition. Oil, grease, water and other substances
causing slippery footing shall be removed, sanded or covered to provide
safe footing.
8.2.11
Tripping Hazards
All passageways, platforms and other places of work shall be kept free
from accumulations of dirt and debris and from other obstructions that
may cause tripping. Sharp projections shall be removed or covered.
8.2.12
Access to workplace
Temporary stairways, ramps or runways shall be provided as the means
of access to working levels above or below ground except where the
nature or progress of the work prevents their installation, in which case
ladders or other safe means shall be provided. The Contractor shall not
assume that access arrangements provided by the Employer will
229 of 2461
PAGE 5 of 17
MMRDA
necessarily remain in place after the time that the Contractor commences
work in a particular area.
8.2.13
Dust and Gases

Dust and gases shall be controlled by ventilation or otherwise so as to
prevent concentrations tending to injure health or obstruct vision or from
exceeding safe levels.
8.2.14
Hazardous and Corrosive Substances

All alkalis, acids, gases and other hazardous and corrosive substances
shall be so stored and used so as not to endanger employees in
accordance with national and state regulations. Suitable protective
equipment for the use of such substances shall be provided. Clean water
supply shall be readily available for washing off any spillage of any
corrosive substance on the employees.
8.2.15
Eye and Ear Protection

Suitable eye protection equipment shall be provided for and shall be used
by employees while engaged in welding or cutting operations or in
chipping, cutting or grinding any material from which particles may fly, or
while engaged in any other operation which may endanger the eyes. The
Contractor shall ensure that fully equipped eye washing facilities are
available on permanent and mobile site locations. Ear protectors shall be
made available for employees when operating noisy machinery.
8.2.16
Respiratory and Resuscitation Equipment

Where required the Contractor shall provide sufficient numbers of
respiratory equipment and the employee shall be trained to use
respiratory equipment suitable for the type of operation for which it is to be
used. The Contractor shall maintain such respiratory equipment in good
condition and shall furnish the means for its continued efficient working
230 of 2461
PAGE 6 of 17
MMRDA
condition. The Contractor shall provide regular inspection, cleansing and

sterilization of such equipment. Such equipment, when not in use, shall
be stored in an accessible, closed container.
The respiratory equipment shall be either of the escape set type, where it
is provided for possible emergency use, or working sets where work has
to be carried out in conditions where toxic gases are present or where
there may be a deficiency of oxygen identified by the HSWS officer or his
appointed staff when a risk assessment is undertaken prior to a site
operation commencing. Risk assessments will be available for inspection
by the Employers representative immediately on request.
All persons who may be required to use such equipment shall be
adequately trained and shall have certificates to that effect. Individual
certificates will be available for inspection from all authorized workers by
8.2.17
Work in Confined Spaces

Where work is required to take place in a confined space, defined as an
enclosed space or excavation with limited access and where there is no
natural ventilation, the Contractor shall provide equipment for monitoring
the quality of the atmosphere within the space. The equipment will be
calibrated to occupational standards to measure the range of gases and
atmospheres identified as part of the risk assessment undertake prior to
entry. The equipment shall be used to check the atmosphere before
personnel enter, and shall remain in place while work is in progress to
ensure that the confined space is free of harmful or noxious gases. The
Contractor shall not permit anyone to enter or work in a confined space,
including
personnel
from
other
contractors,
the
Employers
representative staff or the Employer's staff if harmful or noxious gases

are detected. Any personnel inside shall be evacuated immediately.
Prior to the commencement of the work, the Contractor will document a
safe system of work which will be available for inspection by the
231 of 2461
PAGE 7 of 17
MMRDA
All personnel working in such conditions shall be provided with escape
sets. The Contractor shall provide a "top-man" who shall be stationed
immediately outside the entrance to the confined space, and who shall
maintain communication with personnel working inside the confined
space. In the event of a transverse entry, this may require additional
personnel to be used to facilitate a reliable line of communication if
evacuation has to take place. The top man shall have the means to raise
the alarm in case of any emergency inside the confined space.
The Contractor shall provide adequate ventilation for workers carrying
out work inside a confined space, pipeline or chamber or other enclosed
areas by using blowers or other suitable means.
8.2.18
Personal Protective Equipment (PPE)

Every site worker and visitor shall be provided with a full set of personal
protective equipment for use at all times including a luminous vest,
helmet of a type tested and approved by the MOL, steel toe-capped
boots, gloves and other specific work related clothing offering ear and eye
protection. All site workers and visitors shall be required to wear PPE
while working on the Site, except in the Employers representatives and
Contractor's office. The Contractor shall display a notice on the access to
the site stating that entry is for authorized personnel only, and that PPE is
to be worn at all times.
Every employee required to work in water, wet concrete or other wet
footing shall be provided with suitable safety, waterproof boots.
Every employee required to use or handle alkaline, acid or other corrosive
substances shall be provided with appropriate PPE.
8.2.19
Electrical Hazards
232 of 2461
PAGE 8 of 17
MMRDA
Before work commences, the Contractor shall ascertain by inquiry or direct

observation, or by instruments, where any part of an electric power circuit
exposed or concealed is so located that the performance of the work may
bring any person, tool, or machine into physical or electrical contact
therewith. The Contractor shall post and maintain proper warning signs
to his employees of the location of such lines, the hazards involved and
the protective measures to be taken and shall, if practicable, de-energise
the electric power circuit.
The Contractor shall not suffer or permit an employee to work in such
proximity to any part of an electric power circuit that he may contact the
same in the course of his work unless the employee is protected against
electric shock by de-energising the circuit and earthing it or by guarding it,
by effective insulation or other means acceptable to the Employers
representative. The location of underground powerlines that encroach on
the Works shall be confirmed using cable detectors, the path of the cable
shall be clearly marked. If such cables are adjacent to excavations, the
cable location shall be confirmed by finding the cable using carefully
controlled hand-dig methods under the supervision of a senior member
of the Contractors staff. No live cables shall be retained within working
trenches or other excavations. Any such cables shall be diverted prior to
excavation commencing. The Contractor shall at all times liaise with the
local electricity supplier with regard to the locating and diverting of any
supplies.
8.2.20
Power Driven Saws, Abrasive Wheels and Grinders

All portable power-driven hand operated saws, abrasive wheels and
grinders shall be equipped with guards above the base plate which
completely protects the operator from contact with the saw blade when in
motion and with self-adjusting guards below the base plate which
completely covers the saw to the depth of the teeth when the saw is
removed from the cut.
8.2.21
Public vehicular traffic
233 of 2461
PAGE 9 of 17
MMRDA
Whenever any work is being performed over, on, or in proximity to a

highway or any other place where public vehicular traffic may cause
danger to men at work, the working area shall be so barricaded with
fluorescent signs as to direct traffic away from it or the traffic shall be
specially controlled by persons designated for that purpose.
8.2.22
Site traffic
All vehicles used at the worksite must be roadworthy and registered with
the appropriate authority. No person shall drive a vehicle at the worksite
unless they are a holder of the appropriate driving license or certificate.
A site internal access management system including all appropriate road
signs will be submitted by the Contractor to the Employers
representative for approval at the commencement of the Contract.
8.2.23
Stability of structures
No section of the plant or other structure or part of a structure shall be left
unguarded in such condition that it may fall, collapse or be weakened due
to wind pressure or vibration.
8.2.24
Storage of materials and equipment

All materials shall be stored or stacked in a safe and orderly manner so as
not to obstruct any passageway or place of work. Material piles shall be
stored or stacked in such a manner as to ensure stability. Hazardous
materials shall be stored in secure areas and the HSWS shall maintain
an up-to-date list of the persons with a key to those areas.
8.2.25
Disposal of debris
Debris shall be handled and disposed of by a method which will not
endanger persons. Debris shall not be allowed to accumulate so as to
234 of 2461
PAGE 10 of 17
MMRDA
constitute a hazard.
8.2.26
Excavations
No employee shall be permitted to enter any excavated area, including
areas excavated by other contractors on the Site, unless sheet piling,
shoring or other safeguard that may be necessary for his protection is
provided. In most cases, excavations will be considered to be confined
spaces and the appropriate procedures followed.
Where any employee in an excavation is exposed to the hazard of falling
or sliding material from any bank or side more than 1.5 m high above his
footing, adequate piling and bracing shall be provided against the bank
or side to eliminate such hazard. The excavation and its vicinity shall be
checked by a designated person after every rain, storm or other
hazard-increasing occurrence and the protection against slides and
cave-ins increased if necessary.
Shoring adequate to support the overhanging material shall be provided
where banks are undercut.
Excavated material and other superimposed loads shall be placed at
least 1 m back from the edge of open excavations and trenches and shall
be so shored or retained that no part thereof can fall into the excavation,
or cause the banks to slip or cause the upheaval of the excavation bed.
Banks shall be stripped of loose rock or other materials which may slide,
roll or fall upon persons below.
Open sides of excavations where a person may fall more than 1.5 m
shall be guarded by adequate barricades, and suitable warning signs
shall be put up at conspicuous positions.
No employee shall be allowed to work where he may be struck or
endangered by an excavating machine with which his activity is not
directly related.
235 of 2461
PAGE 11 of 17
8.2.27
MMRDA
Ladders, step ladders and access platforms

Every ladder, step-ladder and access platform shall be of good
construction, sound material and adequate strength for the purpose of
which it is used. Ladders, step-ladders and access platforms shall not
stand on loose bricks or other loose packing, but shall have a levelled and
firm footing. Ladders of over 2m in height shall be securely tied to the
structure it is propped against. Free-standing, portable ladders over 4m in
height shall not be used.
8.2.28
Working at height
All site workers who work at height shall be provided with appropriate
PPE to prevent an accident by slipping or falling.
8.2.29
Positioning of machinery
No person shall be permitted to position or operate machinery in a
manner likely to endanger himself or others.
8.2.30
Fixed and mobile cranes

Fixed and mobile cranes shall be so constructed, positioned and
operated as to be stable. No crane shall be loaded beyond the safe
working load except by an approved person or an inspector for the
purpose of testing such machine.
Every crane including all blocks, shackles, sheaves, wire ropes and the
various devices on the mast and jib shall be thoroughly inspected by an
approved person at intervals not exceeding 12 months. Cranes shall be
inspected before being first erected or operated on each job or after any
major repair. Inspection and repair of crane jib shall be made only when
the jib is lowered and adequately supported.
236 of 2461
PAGE 12 of 17
MMRDA
Outriggers and counter-weights shall be provided and used as specified

by the manufacturer of the crane or by an approved person.
Counter-weights shall be properly placed and secured. Levelling jacks or
other suitable means shall be provided and used with outriggers of
truck-mounted mobile cranes.
Firm and uniform footing shall be provided for cranes. When such a
footing is not otherwise supplied it shall be provided by substantial timber,
or other structural members sufficient to distribute the load so as not to
exceed the safe bearing capacity of the underlying material.
Every power-operated crane shall be provided with efficient brake or
brakes or other locking devices which will prevent the fall of the load when
suspended and by which the load can be effectively controlled whilst
being lowered. Hand or foot-operated bakes shall be provided with a
substantial locking device to lock the brake in engagement.
No load-bearing part of any crane shall be replaced by another part, and
no such machine shall be modified by the addition thereto or removal
therefrom of any load bearing part, unless the replacement or
modification shall be certified by either the manufacturer or the approved
person who tested the crane.
A capacity chart shall be provided for every crane. Such chart shall be
posted and maintained in a place clearly visible to the operator and shall
set forth the safe loads for various lengths of jib at various jib angles and
radial distances. Where outriggers are provided such loads shall be set
forth with and without the use of outriggers.
Unless furnished by the manufacturer or builder of the crane, a capacity
chart shall be prepared and certified by an approved person. Cranes shall
have audible overload warning alarms.
A crane shall not lift any load that exceed the corresponding safe working
load specified by its capacity chart.
237 of 2461
PAGE 13 of 17
MMRDA
Every crane having a jib shall be provided with an accurate indicator

which shows, clearly to the operator, the radius of the jib and the safe
working load corresponding to that radius at all times and gives warning
signal when the radius is unsafe.
Before hoisting any load at a new job site, the jib shall be operated to its
maximum height.
Crane cabs shall be locked when the operator is not present and no
unauthorized person shall enter the cab or remain immediately adjacent
to any crane in operation. If locking of a crane cab is impracticable, the
operating mechanism shall be locked as to prevent the crane from being
operated by an unauthorized person.
No crane shall be operated in such a location that any part of the crane
or of its load in any position of jib or swing may come within 3 meters of
live power line.
All the lifting equipment used at site shall be registered with the
appropriate GOI Ministry and shall have a valid certificate at the time of
usage.
All crane operatives should be authorized to operate the particular type
of fixed or mobile crane. Valid certificates will be available for inspection
by the Employers representative. All banksmen will be formally trained to
undertake their duties and refresher training will be given at an appropriate
frequency agreed by the Employers representative.
8.2.31
Attachment of loads
Where a sling is employed to hoist long-length material, a lifting beam
shall be used to space the sling legs for proper balance. When load is
suspended at two or more points with slings, the eyes of the lifting legs of
the slings shall be shackled together and this shackle or the eyes of the
238 of 2461
PAGE 14 of 17
MMRDA
lifting legs may be shackled directly on the hoisting block or balance

beam. The eyes may be placed on the lifting hook without shackles if the
hook is of the safety type.
Each container or receptacle used for raising or lowering filter media or
other loose material of any kind shall be so enclosed, constructed or
designed as to prevent the accidental fall of such material.
Crane loads shall be raised vertically so as to avoid swinging during
hoisting.
No crane shall travel with a suspended load except upon a safe runway.
During travel without loads, cranes falls shall be secured or placed so as
to prevent accident or damage by swinging.
8.3
Environmental Protection
The Contractor shall minimize, as far as is practically possible, the

effects of all his and his Subcontractors activities upon the environment
and shall implement and monitor measures to prevent:
(a)
Contamination of surfaces, ground, groundwater, surface water
and rivers,
(b)
Emissions to air, including smells, gases, smoke, and dust.
(c)
Unsanitary or unsafe storage or discharge to drain, sewer and

surface waters,
(d)
Unsanitary or unsafe storage or discharge of solid wastes,
(e)
Noise,
(f)
Visual intrusion, and
(g)
Excessive energy and water consumption.
These requirements shall be met through the constant and careful

attention of the Contractors management of all Site and off-site
activities, and by instruction to all staff and labour in these matters.
239 of 2461
PAGE 15 of 17
MMRDA
The Contractor shall appoint an Environmental Control Manager for the

Works, who shall be responsible for preparing an Environmental
Management Plan and ensuring its implementation by the Contractor
after obtaining approval of the Employers representative.
Implementation shall include for monitoring and reporting on the results
of the above measures. Monitoring reports shall be in writing and
submitted on a monthly basis as part of the monthly report referred to
above. The report shall include a listing and summary of daily monitoring
results on all aspects listed above.
All potentially affected areas of the Site, other areas used for or affected
by the works and all adjacent or affected waterways shall be monitored
and where instructed by the Employers representative tested.
The Environmental Management Plan (EMP) shall identify the potential
environmental impacts from the various construction and operations and
maintenance activities to be undertaken in the Contract and set out in
detail the approach he will adopt in mitigating these environmental
impacts to ensure that the residual impacts are minor and confined to a
short period.
The EMP shall consider but not be limited to the following:
-
The methods of materials delivery, storage, usage and disposal;

equipment usage; and site activities to ensure they have minimal
impact on the environment,
Only environmentally safe products and practices shall be adopted in

performing his works, and
The Contractor shall comply with all of the statutes regarding

environmental effects.
The EMP shall provide separate descriptions of its proposals for

240 of 2461
PAGE 16 of 17
MMRDA
minimizing any adverse environmental impacts/effects during the

construction phase and the subsequent operations and maintenance
phase.
The EMP shall be provided in draft form within 28 days from the Notice to
Commence, and shall be updated from time to time by the Contractor as
agreed or required by the Employers representative to ensure the
objectives of environmental protection are fully met.
241 of 2461
PAGE 17 of 17
SUB-SECTION 6A.9
OPERATION AND MAINTENANCE
MANAGEMENT REQUIREMENTS
242 of 2461
MMRDA
Table of Contents
SUB-SECTION 6A.9: OPERATION AND MAINTENANCE MANAGEMENT REQUIREMENTS ........ 1

9.1
General ........................................................................................................................... 1
9.2
O&M Strategy ................................................................................................................. 1
9.3
Customer Interface Management ................................................................................. 2
9.3.1
Systems and Procedures for Creating and Updating Customers Database ............ 3
9.3.2
Billing and Accounting History Meters and Meter Reading .................................... 3
9.3.3
Bill Queries ............................................................................................................... 4
9.3.4
Collection ................................................................................................................. 4
9.3.5
Customer Service ..................................................................................................... 5
9.3.6
Customer Complaints .............................................................................................. 5
9.4
Key issues and obstacles in regard to O&M .................................................................. 5
9.5
Contractors Responsibility ............................................................................................ 7
9.5.1
General Responsibilities .......................................................................................... 7
9.5.2
System Components ................................................................................................ 9
9.5.3
Security .................................................................................................................. 13
243 of 2461
MMRDA
SUB-SECTION 6A.9: OPERATION AND MAINTENANCE MANAGEMENT

REQUIREMENTS
9.1
General
The assessment regarding requirement & planning for long term O&M
sustainability of the Surya Regional Water Supply Project for the
Western Sub-region of the MMR has been presented in this subsection. It is envisaged that maintenance expenditure shall be met from
the revenue accruals from collection of water charges.
9.2
O&M Strategy
MMRDA shall constitute a Special Purpose Entity (SPE) with the

successful DBO bidder to take up the responsibility of the O&M of the
created infrastructure through integrated single contract along with
capital works for effective execution and operation of the water Supply
scheme.
A bulk water supply contract shall be executed for operating and
maintaining the project assets for an initial period of 8 years. Under this
arrangement, the operator shall be paid as per contract rate for O&M
activity. The performance benchmarks and supervision mechanism
shall also be coupled in the management contract. This shall be aimed
at enhancing the efficiency of project assets and reduction of water
losses.
In order to improve the service delivery further the bulk water supply
contract shall be extended to billing and collection of revenues from the
beneficiaries. The performance shall be linked to efficiency of operator
in enhancing the benchmarks in revenue collection.
The Contractor shall submit operation and maintenance management
plan before commencement of commissioning for review and approval
of the Employer. The plan shall include the followings.
SECTION 6A.9: O&M MANAGEMENT REQUIREMENTS
PAGE 1 of 13
244 of 2461
9.3
MMRDA
i)
Daily, weekly and monthly reporting formats and schedules
ii)
Contractors key staff
iii)
Supervisory staff
iv)
Skilled manpower with qualification and experience for
WTP
Pumping equipment
HT substation
Instrumentation, control and SCADA
Pipeline maintenance and repairs
v)
Operation and desludging philosophy
vi)
Equipment-wise periodical maintenance schedule
vii)
List of spares, oil and lubricants
viii)
List of tools, special tools and plant for maintenance and repairs
ix)
Methodology for repairs to pipeline during burst / failure
x)
Emergency and crisis management
xi)
Safety practices
xii)
Health and staff welfare
xiii)
Any other activity as per instructions of Employer
Customer Interface Management
PAGE 2 of 13
245 of 2461
MMRDA
Customer services encompass a broad range of activities

i)
The interface with the customers i.e. MBMC and VVCMC

premises to ensure required performances are met (e.g. water
pressure and flow) and proper responses are given to customer
enquiries.
ii)
Advance warning of planned supply shut off for repairs and

renewals
iii)
Advice customer during emergencies
iv)
Billing customers VVCMC & MBMC
v)
Dealing with billing queries
vi)
Recording and Responding to Customer Complaints
vii)
Consulting with customers and the Employer for future plans

regarding service standards and charges
9.3.1
Systems and Procedures for Creating and Updating Customers

Database
a)
During the early months of the operation period, a Customer

Information System (CIS) shall be introduced through which all
customer contacts with respect to billing and provision of
services can be controlled.
b)
Information held shall include customers name, reference

number, mailing address, telephone number and account history
information.
9.3.2
Billing and Accounting History Meters and Meter Reading
PAGE 3 of 13
246 of 2461
a)
MMRDA
For calculating water quantities, bulk water supply meters (at the
supply end at the respective MBRs shall be used. These meters
shall be with totalizers to indicate accurately the cumulative
water supplied and the rate of supply as well.
b)
Bulk Water Supply Meters: These shall be read on weekly basis

(at supply end) by the Operating organization personnel
responsible for system operation. Detailed records of these
readings shall be maintained to facilitate the computation of
volumes supplied and reconciliation through addition with the
WTPs/ Pumping Stations' outputs.
9.3.3
Bill Queries
a)
Enquiries shall be performed against charges for previous and

current billing periods
b)
Up-dating and amending of bills in accordance with user defined

parameters and rules
9.3.4
Collection
a)
The system shall support all currently used payment methods

and would be designed to incorporate additions
b)
Preparation and issue of a debtor statement
c)
Timetable for the issue of reminders and recovery notices shall

be established and issued to consumers at the regular intervals
based on the Employer's inputs.
d)
Notice to the Employer of continued debtor for the Employer's

action (like disconnection etc.)
e)
Additional charges such as disconnection/reconnection fees,
PAGE 4 of 13
247 of 2461
MMRDA
damage cost and late payment penalties shall be billed.

9.3.5
Customer Service
In order to maintain the efficiency and improve customer satisfaction, a
study shall be undertaken of the interfaces between the Operator and
customers. This shall be undertaken during the early months of
operation and thereafter similar test shall be made in order to monitor
the improvements in customer service and effectiveness of the steps
taken.
9.3.6
Customer Complaints
Complaints
received from
the
customer regarding
mal
attention
shall be investigated with special reference to the procedures invoked,

so as to establish and correct any weakness.
9.4
Key issues and obstacles in regard to O&M
The following issues have been considered for efficient management of

operation and maintenance of water supply scheme as, general and
personal administration, Inventory and financial control and public
relations. All these issues are important in view of safe water quality,
good services to consumers, and self-supporting operations with strong
financial management.
a) General and personal Administration
The general administration shall be achieved through supervisory
control and operational control. The supervisory control is expected
to control all the functions of management while the operational
level is to subordinate to supervisory level. The duties and
responsibilities of supervisory units cover development and
implementation of Annual operation and Maintenance program
(AOM), keeping accounts, material records, performance appraisal
PAGE 5 of 13
248 of 2461
MMRDA
system, purchasing tools and supplies and providing in-service

training. A well framed operation and maintenance manual is also a
key issue. In all supervisors should ensure that entire work of O&M
could be grouped into logical tasks or functions. For optimum output
of the operating staff modern business principles shall be
introduced. Personal administration is achieved by clear job
descriptions, setting goals with routine evaluation and in-service
training.
b) Inventory control
Many of the water works failure require spare parts or supplies
available instantly to put the system back in working condition.
Materials of stock would pertain to items which have frequent usage
and items of emergency repairs. Inventory control cards are vital
documents to serve the purpose of accountability and stock demand
by reflecting usage pattern for enabling stock control and recording
purchasing information
c) Accounting and Budgeting
Accounting system shall involve the following functions.
-
A basic chart of accounts for the organization
Accounting reports such as income and expenditure statements,

balance sheets, cash flows statements and debt servicing etc.
Annual O&M budget
Frequent review says quarterly, of income analysis from

customer class is desirable
d) In-service training
PAGE 6 of 13
249 of 2461
MMRDA
The objective of well-founded short term in-service training for

employees of the Surya Project shall be as under:
To improve group level of operational efficiency
To acquaint the group with the new developments
To develop amongst the members of the group a better

understanding of human relations and concept of their individual
responsibility to the community
To bring about and increase community awareness of water

works operation
9.5
Contractors Responsibility
9.5.1
General Responsibilities
i)
The Contractor shall be responsible for the operation and

maintenance of the project systems and system components
from the date of physical commissioning of the project after
successful trial runs duly certified by the Employer.
ii)
The Employer places the great importance on the successful

project delivery thereby implying continuous and uninterrupted
supply of 403 ML/day treated water to the VVCMC, MBMC and
seven groups of villages every day without fail. To achieve this
objective, the Contractor shall design and implement its
Operation and Maintenance Program and Guidelines which shall
be inviolable.
iii)
The maintenance of the intake works, jack well and pumping

station
refers
to
the
civil,
mechanical,
electrical
and
instrumentation components of the raw water collection and

pumping system so that it can operate at the designed output
PAGE 7 of 13
250 of 2461
MMRDA
through the project life. It is anticipated that routine repairs shall

be necessary to achieve this objective. The operation of the
system
components
shall
involve
routine
handling
and
inspections of the components.
Operation refers to the plants, equipment, valves, power
iv)
systems, machinery etc. which shall be handled and operated

by a trained operator. For the purpose of operation and
maintenance of the system the Contractor shall ensure the
following.
Eight sets of detailed As-Built drawings and maps of the system

and its components and the O & M Manual shall be kept
available with the operators at all times. These shall be renewed
and updated if any changes to structures and equipment are
necessitated during the O & M period
The schedule of daily operations shall be prepared and

distributed to the operators
A regular schedule for the inspection of the intake system

components shall be drawn and executed by the Contractor
Record of all inspections shall be maintained in soft files and

backups shall be available for inspections. All records shall be
authenticated by authorized and designated official of the
Contractor
Raw water quality shall be tested and recorded every day and
certified
Daily manning and deployment of operating staff and their

names shall be intimated to the Employer
Inventory of stores shall be maintained and updated every day
PAGE 8 of 13
251 of 2461
MMRDA
by the head of operations

9.5.2
System Components
a) Intake Works
i) Sanitary surveys shall be conducted every week in the

backwaters of the Kawadas Weir to ensure that there is no
indiscriminate discharge of pollution load in the catchment area
of the weir.
ii) Before every monsoon the intake structures shall be inspected
and repairs / rectifications shall be carried out if and when
required.
iii) Regulated desilting of the intake structures like intake wells, jack
well and inspection chambers shall also be carried out every six
months. Strainers and racks shall be cleaned and painted every
year
iv) All pumps and related equipment and machinery, valves and
connectors shall be checked and preventive maintenance shall
be carried out as per the maintenance manual of the
manufacturers and requirement in particular specifications.
b) Transmissions System
i) The entire raw water transmission line (pressure mains),

pumping mains to the BPT and treated water gravity main to the
MBRs including all en-route structures and air valves as well as
other
appurtenances
shall
be
maintained
as
per
the
maintenance plan of the Contractor and approved by the

Employer.
ii) All expansion joints shall be checked once every month.
PAGE 9 of 13
252 of 2461
MMRDA
iii) Sufficient stock of spare pipes of all relevant sizes shall be

maintained
for
replacement of damaged pipes. Regular leak detection surveys

shall be conducted along the entire length of the lines.
iv) All air and scour valves shall be inspected as per Contractors
inspection schedule approved by the Employer.
c) Water Treatment Plant
i)
The Plant Operation In-charge shall have thorough knowledge

and hands on experience in the operation and maintenance of
all the process units of the WTP. He shall be capable of trouble
shooting all design and operation faults and rectify them without
affecting the WTP performance and output.
ii) The plant in-charge shall be able to tackle issues arising out of
raw water quality and quantity fluctuations, malfunctioning of the
WTP units and all the electrical, mechanical, instrumentation
and SCADA equipment.
iii) Plant shall be maintained in a manner to prevent emergencies
and unscheduled breakdowns. The maintenance program shall
have the following components:
Sufficient number of as built drawings of the plant in hard

and soft copies, plans of daily operations and WTP
Operation & Maintenance Manual.
Routine
schedule
for
inspections
and
preventive
maintenance, record keeping, lubrication and cleaning

protocol.
Record of water quality at various points within the WTP to
PAGE 10 of 13
253 of 2461
MMRDA
establish the operating efficiency of process units and list of

safety measures for the plant operation
Record and schedule of sanitary survey of the Kawadas

Weir backwaters (source) and routine physical-chemical and
bacteriological examination of raw and treated water.
Initial and re-calibration of all flow measuring devices and its

record, servicing and checks.
Painting and maintenance of chemical preparation and

feeding tanks, jar tests for dose optimization, spares for
mixers and their motors and blades.
Annual overhaul and painting of clarifiers and cleaning of the

steel plates of the plate settlers, cleaning of sludge lines and
valves, removal of chokings, cleaning of components using
algaecides, prevention of short circuiting.
Rapid Sand Filters shall be checked for flow gauges and

head
loss
measuring
devices
frequently.
Alternative
arrangement for measuring head loss for every filter bed

shall be available and functioning at all times
Expansion of sand bed during backwash cycle shall be

regulated to ensure no loss of sand. Sufficient quantity of
stock sand shall be maintained at all times for recouping. Air
binding shall be prevented and avoided. Adequate water
depth above the sand bed shall be provided to avoid air
binding.
Cracking of sand beds, short circuiting, mud ball formation,

bumping of filter beds shall be prevented and corrective
measures shall be taken should such events arise. Wash
water and air scour flow shall be regulated to prevent sand
PAGE 11 of 13
254 of 2461
MMRDA
boils in the beds.
Slime growths shall be prevented using pre-chlorination.
backwashing shall be carried out as per the design schedule

of the beds.
However, the frequency / duration of back wash may vary
during monsoon when higher turbidity in raw water may be
encountered.
The vacuum type chlorinators shall be so adjusted that predetermined free residual Chlorine is always available in the
treated water. The chlorinator shall be maintained properly
and gas leakage shall be prevented at all times. Enough
numbers of gloves, gas masks and other safety equipment
shall be provided in serviceable condition. Low level
ventilation shall be provided in the gas storage and
chlorinator rooms. Gas piping and feeders shall be
completely cleaned periodically.
Clear Water Sump shall have proper and leak proof roof and
ventilation.
Birds and vectors entry shall be prevented. Regular cleaning
of the sump shall be done. The water level indicator shall be
serviceable at all times.
Treated Water quality shall be checked every day and during

special events requiring such checks as directed by the
Employer. The laboratory shall be staffed and provided for
such testing with adequately trained expert staff.
d) Master Balancing Reservoirs
PAGE 12 of 13
255 of 2461
MMRDA
i) Master Balancing Reservoirs shall be maintained at all times.

Inflows and outflows shall be measured and recorded as per the
Employers requirement. The structural safety, leak proofing,
painting and record keeping of all repairs shall be maintained.
Water level indicators shall be always working.
ii) Re-Chlorination arrangements at the MBRs shall be always
maintained in serviceable condition for rendering the required
doze of Chlorine to water before its entry into the distribution
system of VVCMC / MBMC. The record of chlorination shall be
maintained as directed by the Employer.
9.5.3
Security
Unauthorized entry and trespassing by persons and animals at any of
the system component locations shall be strictly prohibited. Adequate
safety and security staff shall be provided to prevent such incidents by
the Contractor as approved by the Employer.
PAGE 13 of 13
256 of 2461
SUB-SECTION 6A.10
TRAINING AND ADVISORY REQUIREMENTS
257 of 2461
MMRDA
Table of Contents
SUB-SECTION 6A.10: TRAINING AND ADVISORY REQUIREMENTS

10.1
Training Requirements
10.1.1
General
10.1.2
Off the Job Training
10.1.3
On the Job Training
10.1.4
Training Programme
10.1.5
Special Training to Employers Personnel
10.1.6
Training Personnel
10.2
Advisory Requirements
10.2.1
General
10.2.2
Advisory Personnel
258 of 2461
1
1
1
1
5
8
9
10
11
11
13
MMRDA
SUB-SECTION 6A.10: TRAINING AND ADVISORY REQUIREMENTS
10.1
Training Requirements
10.1.1
General
The Contractor shall provide comprehensive in-service training for the
different categories of his operation and maintenance staff as well as
the Employers O&M staff whenever deputed. The training shall be
conducted every year as refresher course for entire operation period.
Training shall fall into two main types which are off the job and on the
job. Off the job training shall take place in the class room, on the job
training shall be carried out on the running plant.
The entire cost of training shall be borne by the Contractor.
10.1.2
Off the Job Training

The Contractor shall prepare formal training documentation for
distribution to the trainees. Visual aids shall be used where possible to
illustrate the points being made and to make the training programme as
interesting and enjoyable as possible for the participants.
The off the job training shall comprise the following:
1. Off the Job Training Programme for all Trainees
To provide training:
a) on the simple chemistry and process principles involved in the
operation of the Works;
b) health and safety;
c) plant safety procedures;
SECTION 6A.10: TRAINING & ADVISORY REQUIREMENTS
PAGE 1 of 23
259 of 2461
MMRDA
d) on the use of the local and central HMIs

2. Off the Job Process Training Programme for Operators
a) on the operation of individual items of plant and sections of the
Works including automatic operation and manual operation in
the event of say automatic control failure;
b) on the day to day operation of the Works and procedures;
c) on a comprehensive list of what if scenarios dealing with the
actions to be taken in the event of potential process problems,
alarms, plant failures, overflows, power failures etc.;
d) on first line mechanical maintenance;
e) safe methods of work general;
f) on safety procedures to be followed in operating, maintaining
and cleaning the plant;
g) special precautions to be followed in the event of a chlorine leak.
3. Off the Job Training Programme for Electrical Maintenance Staff
a) on the configuration, construction and operation of the electrical
Plant;
b) on the electrical maintenance requirements of the Works;
PAGE 2 of 23
260 of 2461
MMRDA
c) on the switching and safety procedures to be followed;

d) safe methods of working;
e) on fault finding and repair procedures.
4. Off the Job Training Programme for Control and Instrumentation
Maintenance Staff
a) on the configuration, construction and operation of the Plant;
b) on the control and instrumentation maintenance requirements of
the Works;
c) on fault finding and repair procedures;
d) safe methods of working;
e) special training on the use of the PC and associated
programming software for fault finding on PLC based control
systems;
f) special training on the use and performance of the central HMI
SCADA hardware and software and other specialist hardware
and software systems used on the plant;
5. Off the Job Training Programme for Mechanical Maintenance Staff
a) on the routine mechanical maintenance requirements of the
Works;
PAGE 3 of 23
261 of 2461
MMRDA
b) on lubrication requirements of the Works;

c) on fault finding, repair and overhaul procedures;
d) safe methods of working.
6. Off the Job training for chlorination system
a) handling of hazardous chemicals and its statutory requirements;
b) types of chlorination system, layouts and its components
c) Fault finding and repairs
d) Scrubber and neutralization system
e) Safety equipments, use and mock drill
7. Off the Job Training Programme for Water Treatment Management
Staff
f) water treatment process management techniques;
g) water treatment plant cost management;
h) water treatment plant laboratory management;
i) safe methods of work general;
j) on safety procedures to be followed in operating, maintaining
and cleaning the plant.
PAGE 4 of 23
262 of 2461
10.1.3
MMRDA
On the Job Training

The Contractor shall utilise the Operations and Maintenance Manuals
as the primary training aid in carrying out the on the job training. Short
comings, omissions and errors identified in the O & M Manuals during
the training shall be rectified prior to final acceptance of the O & M
Manuals.
1. On the Job Training Programme for all Trainees
a) plant familiarisation tour;
b) on the use of the local and central HMIs;
c) health and safety;
d) identify areas where special safety precautions are necessary
2. On the Job Process Training Programme for Operators
a) under operational conditions on the operation of individual items
of plant and sections of the Works including automatic operation
and manual operation in the event of say automatic control
failure;
b) illustrate by example the day to day operation of the Works and
procedures;
c) illustrate by example the actions to be taken in the event of
potential process problems, alarms, plant failures overflows,
PAGE 5 of 23
263 of 2461
MMRDA
power failures etc. (as identified in the what if scenario off the
job training);
d) illustrate by example the first line mechanical maintenance;
e) illustrate by example safety procedures to be followed in
operation, maintenance and cleaning of the Works.
3. On the Job Training Programme for Electrical Maintenance Staff
a) carry out detail tour of the electrical plant;
b) illustrate by example the operation of the electrical Plant;
c) illustrate by example the electrical isolation and maintenance
procedures;
d) illustrate by example fault finding and repair procedures;
e) illustrate by example switching and safety procedures to be
followed;
f) illustrate by example safe systems of work
4. On the Job Training Programme for Control and Instrumentation
Maintenance Staff
a) illustrate by example the operation of the Works;
b) illustrate
by
example
the
control
and
instrumentation
maintenance requirements of the Works;

PAGE 6 of 23
264 of 2461
MMRDA
c) illustrate by example fault finding and repair procedures

d) illustrate by example fault finding on PLC based control
systems, the central HMI SCADA hardware and software and
other specialist hardware and software systems used on the
plant;
e) illustrate by example safe systems of work
5. On the Job Training Programme for Mechanical Maintenance Staff
a) illustrate by example the routine mechanical maintenance
requirements of the Works;
b) illustrate by example lubrication procedures;
c) illustrate by example fault finding, repair and overhaul
procedures.
f) illustrate by example safe systems of work
6. On the Job training for chlorination system
a) Illustrate by example handling of tonner, working of chlorinator;
b) Illustrate by example start and stop of chlorination system;
c) Illustrate by example of test residual chlorine;
d) Illustrate by example to use scrubber and neutralization system;
PAGE 7 of 23
265 of 2461
MMRDA
e) Illustrate by example to use safety equipments and arrest

chlorine leakage from the system
10.1.4
Training Programme
Off the job training shall be carried out prior to Taking Over of the
Works or any section of the Works.
This Operation & Maintenance manual shall be provided by the
contractor to establish guideline for plant operator to understand the
new Water Treatment Plant to operate this system efficiently and
successfully.
The guideline will be provided to the training personnel, on how to
operate the Plant so that they shall be able to manage to treat the
water to best quality; with less consumption of energy; with less cost of
maintenance expenses; providing a long life of equipment; protection
against accident, safe working methods and protecting systems from
damages.
The system operation and unit operation of each component will be
needed to be adjusted and modify depending on the raw water quality
and the required data are collected during the training program as well
as operation and maintenance period.
With the permission of the Employers representative and the Employer
on the job training shall be carried out prior to Taking Over. On the job
training shall be completed as a condition for acceptance of the Works
following completion of the Tests After Completion.
The Contractor shall provide a training plan for each category of staff.
The training plan shall detail the content and duration of each course.
The training plan shall be submitted for the approval of the Employers
representative
at least 90 days prior to the commencement of the
PAGE 8 of 23
266 of 2461
MMRDA
training program. The duration of training offered for each category of

staff shall not be less than that detailed in the following table.
Category of Staff
Off the Job
On the Job
(minimum days
(minimum weeks
duration for each
duration for each
course)
course)
All staff
Operator
Electrical
10
Chlorination operator
WTP management
(see note)
technician/electrician
Control/instrument
technician
Mechanical
technician/fitter
Note: It is assumed that WTP managers on the job training will be

available throughout the 12 month when the plant is operated by the
Contractor.
The training day shall be assumed to be not less than 6 hours split into
two sessions. The off the job training rooms shall be provided by the
Employer at the Site in the existing buildings. The Contractor shall
provide facilities for training which shall include inter alia tables and
chairs, projectors, white/black boards, training aids etc.
Where trainees of a given category can all be released from their
Works operational duties simultaneously they may be trained together.
Where this is not possible the Contractor shall repeat the complete
course for those who could not attend.
10.1.5
Special Training to Employers Personnel

The contractor shall organise special training to employers personnel
PAGE 9 of 23
267 of 2461
MMRDA
in year 8 of O&M period prior to handing over the WSS to the Employer
for further operation and maintenance.
Objectives of training shall be as under:
Capacity building of Employers personnel in Management and

O&M
In part all necessary knowledge and skill in day to day operation,

periodical maintenance and repairs
Familiarise with status of system components including any

predictive maintenance and replacement in near future
In depth training in contents and use of O&M manual for O&M

activities
Duration of training shall be two months. Suitable training module for

off-job and on-job training shall be prepared. Entire cost of the training
10.1.6
Training Personnel
The Contractor shall provide suitably qualified trainers to carry out the
off the job and on the job training.
The trainers are to be experienced in treatment plant management,
operation and maintenance in their relevant discipline and in the
training of skilled and unskilled staff.
The Contractor shall submit the curriculum vitae of the nominees to the
Employers Representative for approval 120 days. The training expert
shall be fluent in both English and Hindi or the Contractor shall provide
the services of an interpreter during the training periods.
PAGE 10 of 23
268 of 2461
10.2
Advisory Requirements
10.2.1
General
MMRDA
The Contractor shall provide personnel to advise in the operation of the

Works for a period of 1 year after Taking Over.
The personnel
provided shall have proven experience in their intended roles. Those

persons provided shall comprise:
Advisor to the process
duration 12 months;
Advisor mechanical operation and -
duration 12 months;
maintenance
Advisor HT electrical and Control -
duration 12 months;
Relay maintenance
Advisor
Instrumentation
and -
duration 12months
SCADA
Qualification - In the respective discipline /fields for above qualification
and experience as follows:
M.E. 5 years
B.E. - 10 years
Diploma- 15 years
The electrical/control, mechanical and process specialist visits are split,
the first visit to establish the procedures and implement, the second
visit to monitor and refine the procedures.
The Contractors personnel will be assisted by staff trained by the
Contractor and provided in sufficient numbers by the Employer.
PAGE 11 of 23
269 of 2461
MMRDA
The role of the Contractors advisory personnel shall be to:

-
to advise on day to day management of the water treatment plant;
to advise on the development procedures for the ordering and

reordering of consumables;
to propose and develop systems to monitor the consumption of

consumables and power and to advise actions to reduce their
usage to a minimum;
to establish analytical procedures within the laboratory and carry

out periodic checks to ensure that they are adhered to;
to establish routines for the analysis of water quality in all areas of

the plant and to establish procedures for corrective action in the
event of quality falling below that expected;
to establish systems for the recording of water quality appropriate to

a plant of this type;
ensure procedures for operation and planned maintenance of the

Works as detailed in the O & M Manuals are carried out;
advise on the optimisation of process settings, dosage rates,

operating regimes etc.;
provide continuing informal on the job training to the Employers

staff (this is in addition to formal training requirements detailed
elsewhere);
update the O & M Manuals in line with experience gained during the
years operation.
PAGE 12 of 23
270 of 2461
MMRDA
The Contractor shall be responsible for all costs associated with the
provision of his advisory personnel.
10.2.2
Advisory Personnel
The Contractor shall provide suitable personnel to provide advisory
services. The advisors shall be experienced in treatment plant
management, operation and maintenance in their relevant discipline.
The Contractor shall submit the curriculum vitae of the advisory
nominees to the Employers Representative for approval before 120
days. Prior to mobilisation, the advisors shall be fluent in both Hindi
and English or the Contractor shall provide the services of an
interpreter/s during the advisory period as necessary.
The Contractor shall train the Employers personnel about Plant
operation knowledge, abilities and skill as follows:
I.
Capacity Building
a) Knowledge;
System flow and unit operation, maintenance, pumps,
blowers, other plant equipment and machinery;
Basic Water Treatment Process;
Basic sludge handling principle and its characteristics;
Basic maintenance period and work sheet;
Basic laboratory techniques to make standardized tests;
Avoiding any chance of accident, and
PAGE 13 of 23
271 of 2461
MMRDA
Basic safety and health;

b) Abilities;
Make adjustments to water treatment system according
to Raw water characteristics and its flow fluctuation, and
control;
Make adjustments to control the chemical dosing system;
Adjust chlorination process, and to lift sacks of chemicals,
chlorine cylinders and to read and follow written and oral
instructions.
Make repairs and/or adjustments to water treatment
equipment and to keep records and prepare reports;
Make repairs and/or adjustments to each equipment and
to keep records and prepare reports;
Handling safely valves and its pipeline;
Read and interpret gauges and recording devices used in
the water treatment plant;
Usage of safety Equipment in case of Emergency.
II.
Tasks of Maintenance and Operation works shall include:

a. Operate water treatment plant under normal conditions such
as equipment, machinery and pipe line, including valves,
gate,
stop-logs,
pumps,
MBBRs,
Membrane
Filters,
thickeners, chlorine feeder, chemical tanks, dewatering

equipment, Chemical preparation and dosing system,
reading flow meter; regulate flow of water, disposing the
PAGE 14 of 23
272 of 2461
MMRDA
sludge;
b. Select the water treatment facility or equipment to meet
actual inflow pattern;
c. Take samples and make standardized laboratory test if
required, including tests for temperature, residual chlorine,
PH, turbidity and other required items;
d. Set the system/equipment to adjust timer or operation period
to meet the required specified amounts of feeding chorine
solution, chemical solution, air volume, sludge withdrawal,
recycling waste wash water, Dewatering unit;
e. Makes minor repairs and adjustments to machinery,
equipment, pipes and other materials pertinent to the
operation of the plant;
f. Work on troubleshooting including bulk flow control as well;
g. Maintain maintenance and operational records;
h. Cleaning of machinery, equipment and civil tanks, building,
loading and unloading of materials and storage of chemicals
properly;
i.
Does general maintenance of the plant, including, but not

limited to, painting, general custodial work, maintenance of
equipment, etc;
j.
Assists in repairing flow meters and pipe line including valves

in inactive time and/or operation time;
k. And assist in the inspection of all necessary equipment, of

water & wastewater sampling & of pipe line.
PAGE 15 of 23
273 of 2461
III.
MMRDA
Training in Operation and Maintenance Manual

a) Background of project;
b) Plan and design condition;
c) System operation indices and unit operation indices;
d) Water Quality & Quantity (Inlet / outlet)
Actual
Standard
e) Outline of system operation (Civil, Mechanical & Electrical);
Summary
Flow diagrams, plan view, hydraulic profile, Piping
isometrics
Operation flow diagram
Table of facilities
(Tag number, Type, Number, Nominal bore, capacity,
motor rating, weight)
f) Outline of component and its aim (Civil & Mechanical);
Normal operation
Emergency operation
Selection of facility
PAGE 16 of 23
274 of 2461
MMRDA
Selection of Auto/Manual mode

Notice of danger/peril/hazard
g) Verification items of system operation mode (Civil &
Mechanical);
Before start of system operation
Start of system operation
During regular operation
Set value of level sensors and safety pressure on safety
devices
Position of plant/equipment on the selected mode
Remove potential danger/peril/hazard
h) Details of facility/equipment component (Civil & Mechanical);
Summary
Specification
Outside dimension
Weight, quality of material
Outside drawing
Graph, charts, performance curve, table
PAGE 17 of 23
275 of 2461
MMRDA
Photo after installation

i) Verification
items
of
component
operation
(Civil
&
Mechanical);
Preparation before the operation
Starting operation flow
Normal operation
Set value of level sensors and safety valves
Emergency maintenance
Notice of danger, peril, hazard
j) Outline of component and its aim (Electrical);
Verify incoming power Hz, Kwh
Verify output from cogeneration Hz, Kwh
Ordinary line or Emergency line operation
Detail and full operation procedure
Select standby generator
Emergency operation
Selection of facility
PAGE 18 of 23
276 of 2461
MMRDA
k) Verification items of system operation mode (Electrical);
Set value of level sensors and protection
Select Auto/Manual mode on central control panel
l) Detail of facility component (Electrical);
Summary
Specification
Single line diagram
Panel dimension
Weight, quality of material
Outside drawing
Graph, charts, performance curve, table
Photo after installation
m) Facility verification items(Electrical);
PAGE 19 of 23
277 of 2461
MMRDA
Preparation before the operation

Select Normal operation or Emergency operation
Select equipment operation mode/switch by Auto /manual
Set value of level sensors and protection
n) Standard;
Water quality at inlet and outlet
Emission control
Noise and vibration
o) Fire/explosion protection
p) Dewatered cake sludge handling/disposal
q) Frequency of sampling, analysis and evaluation;
Inflow and outflow Quality /flow rate
Regulated pollutants
PAGE 20 of 23
278 of 2461
MMRDA
Operation index
Amount of sludge and its density
Water / sludge temperature
r) Maintenance schedule (Mechanical & Electrical);
Routine work
Regular work
Manufacturer recommendation
s) Maintenance schedule(Civil);
Routine work
Regular work
Manufacturer recommendation
t) Calculation sheets
Calculation of dosing amount(Alum/Chlorine/Poly/etc.)
Calculation of sludge amount
u) Troubleshooting guide (Phenomenon/action/comments);
Discharge quality and bulking
Process and system control
Mechanical equipment
PAGE 21 of 23
279 of 2461
MMRDA
Electrical equipment
Case
study
or/and
previous
experiences
(Normal
troubleshooting)
v) Operation / test data
Operation index
Mechanical site inspection data
Electrical site inspection data
Water quality and quantity(inlet/outlet)
Regulated pollutants
Amount of sludge and its density
Amount of cake and its density
Noise and vibration
Water / sludge temperature
Power /chemical consumption
Operation cost during training period
Performance test of flowmeter level meter
Consumables, spare parts and its list
Photo of inspection (evidence)
PAGE 22 of 23
280 of 2461
MMRDA
w) List
Equipment control
Operation record formats
Maintenance record formats
Material control
Inventory
Spare parts
Safety and Health
PAGE 23 of 23
281 of 2461
SUB-SECTION 6A.11
ENVIRONMENTAL MANAGEMENT PLAN
282 of 2461
MMRDA
Table of Contents
SUB-SECTION 6A.11: ENVIRONMENTAL MANAGEMENT PLAN
11.1
Introduction
11.2
Environmental Management and Implementation
11.3
Environmental Monitoring Plan
283 of 2461
1
1
1
18
MMRDA
SUB-SECTION 6A.11: ENVIRONMENTAL MANAGEMENT PLAN
11.1
Introduction
An Environmental Management Plan (EMP) takes into account all the

environmental issues and the corresponding mitigation measures to
minimize the impacts.
The EMP presented below includes:
Specific actions to be taken regarding site-specific issues;
Responsible agencies for its implementation & supervision;
Time frame for implementing Mitigation actions;
Reference to contract documents and specifications;
Project level environmental monitoring;
Environmental status reporting frequency; and
Institutional arrangement, Strengthening of their capability, and role
It also includes a monitoring plan to enable evaluation of the success or

failure of environmental management measures and reorientation of
the plan if required. Several of the protective and enhancement
measures can be implemented by adopting suitable planning and
design criteria during construction of the project. Further, it is necessary
that the resources required for the mitigation / protection, enhancement
measures and monitoring are provided for in the cost estimates of the
project, to ensure proper implementation.
11.2
Environmental Management and Implementation
SECTION 6A.11: ENVIRONMENTAL MANAGEMENT PLAN
PAGE 1 of 20
284 of 2461
MMRDA
The EMP has been delineated for all the three stages viz., Preconstruction, Construction and Operation stages of Surya project.
During construction phase, contractors as well as site-in-charge will be
responsible for implementing all the mitigation measures. Table-1,
Table-2 and Table-3 show the EMP for Pre construction, construction &
operational phase respectively.
PAGE 2 of 20
285 of 2461
MMRDA
Table 1: EMP for Pre-Construction Stage

S.
Environmental Issue
Mitigation Measures
Time Frame
Cross Reference to
No.
1
Documents
Resettlement and
The entitlement framework to the PAPs shall be Before
rehabilitation
in accordance to the RAP of the project. It shall construction
Start
of
-
be ensured that all R&R activities be reasonably

completed as per RAP, before the construction
activity starts in the relevant subsection.
Ecological impacts due to Trees falling within the alignment which are to
Before
tree cutting
construction of relevant
be
removed
before
commencement
of
construction shall be identified and approved
Start
of
-
subsection
by PIA. Prior permission from Forest dept. Tree

authorities shall be obtained. Compensatory
plantation shall be carried out.
Local traffic arrangement
Temporary
traffic
arrangement
during
construction within RoW shall be planned.
During site clearance
M/ORT&H: 112
and construction
This plan shall be periodically reviewed with

respect to site conditions.
During site clearance activity, the demolition
PAGE 3 of 20
286 of 2461
S.
MMRDA
Environmental Issue
Mitigation Measures
Time Frame
Cross Reference to
No.
Documents
debris shall be preferably removed during nonpeak hours and with deployment of more
vehicles for the purpose.
Providing labour camps
The Contractor shall abide by the Contract
During construction
M/ORT&H: 105.2
and facilities
conditions and directions of PMC/PIA with
The Contractor shall abide by the Contract During construction
M/ORT&H: 105.2
respect to siting of labour camps, providing

sanitation facilities and labour welfare issues
etc.
Siting
of
construction
site/casting yard
conditions and directions of PMC/PIA with

respect to siting of construction camps. The
construction camps should have located at
least
500
away
from
sensitive
receptors/residential area.
Traffic
Safety
Control
and
The
contractor
shall
take
all
necessary
measures for the safety of traffic during
During
construction
pre-
M/ORT&H: 112.4 and

112
PAGE 4 of 20
287 of 2461
S.
Environmental Issue
MMRDA
Mitigation Measures
Time Frame
Cross Reference to
No.
Documents
construction and provide, erect and maintain
such barricades, including signs, markings,
flags, lights and flagmen as may be required
by the PMC for the information and protection
of traffic.
Safety of pedestrians
Special consideration shall be given in the
Before
Construction
local traffic management to the safety of
and during construction
M/ORT&H: 112.2
pedestrians.
Impact
on
land
use
Construction activities shall be preferably
During site clearance
outside RoW
restricted within project road RoW.
and construction
Utility relocation including
All utilities, such as water supply lines,
Before
shifting of gas pipeline
electrical installations, telephone lines etc. to
construction of relevant
be shifted after prior approval of agencies.
subsection
Start
of
M/ORT&H: 201.2
M/ORT&H: 110
Utility relocation shall be carried out in shortest

possible time to reduce inconvenience to
public.
PAGE 5 of 20
288 of 2461
S.
Environmental Issue
MMRDA
Mitigation Measures
No.
Time Frame
Cross Reference to
Documents
PAGE 6 of 20
289 of 2461
MMRDA
Table 2: EMP for Construction Stage

S.
Environmental Issue
Mitigation Measures
Time Frame
Cross Reference to
No.
1.
Documents
Traffic Control and Safety
The
contractor
shall
take
all
necessary
During construction
measures for the safety of traffic during
M/ORT&H: 112.4 and

112
construction and provide, erect and maintain

such barricades, including signs, markings,
flags, lights and flagmen as may be required by
the PMC for the information and protection of
traffic.
2.
Air Pollution
All vehicles delivering material to the site shall
Entire
be covered by tarpaulin to avoid material
phase
construction M/ORT&H:
111.9,
111.11 and 11.12
spillage.
3.
Using existing hot mix/
If the contractor uses the existing Concrete, During entire
Concrete/ asphalt plants
Asphalt and Hot Mix Plants, he shall ensure that construction phase
M/ORT&H: 111.5
existing plants, which are sourced, are licensed

and authorised for operation by concerned
authorities and shall intimate the PMC/PIA prior
to procuring materials from them. PMC shall
PAGE 7 of 20
290 of 2461
S.
MMRDA
Environmental Issue
Mitigation Measures
Time Frame
No.
Cross Reference to
Documents
procure relevant documents from the plant

owners to ensure that they are adhering to
relevant emission norms as laid out by MoEF/
CPCB.
If the contractor wishes to establish a new plant,
he should obtain consent-to-establish and
consent-to-operate under Air and Water Act
from MPCB.
4.
Plying
vehicles
on
unpaved roads
The unpaved roads, if used by the contractor, Construction phase
M/ORT&H: 111.1
shall be sprinkled with water at least once in a

day to control the fugitive dust emissions. Dust
emission will be a critical issue near villages.
5.
Location of batching plant
Batching plant, if contractor wish to establish,
During
shall
phase
be
located
away
from
the
construction
-
residential/sensitive area and shall be licensed

and authorised for operation by concerned
authorities.
PAGE 8 of 20
291 of 2461
S.
MMRDA
Environmental Issue
Mitigation Measures
Time Frame
Cross Reference to
No.
6.
Documents
Watering to control dust
Construction site to be watered periodically to
During
at site
minimize
construction phase
fugitive
dust
generation
during
entire
M/ORT&H: 111.8
construction near urbanised area

7.
Roads used for transport
Contractor shall ensure that the transport
During
entire
vehicles used to ferry materials and dispose
construction phase
M/ORT&H: 111.9
debris does not create hazardous conditions

for general traffic using the roadway especially
the National Highway.
8.
Barricading site
The
construction
site
especially
near
During
habitation should be barricaded at all time in a
phase
construction M/ORT&H: 112
day with adequate marking, flags, reflectors

etc., for the safety of general traffic movement
and pedestrians.
9.
Earthwork
All earthwork and construction material should
During
be stored in such a manner to minimise
construction phase
entire
M/ORT&H: 201.4
PAGE 9 of 20
292 of 2461
S.
Environmental Issue
MMRDA
Mitigation Measures
Time Frame
No.
Cross Reference to
Documents
generation of dust and spillage on roads. The

stacks of earthwork shall be preferably located
away from habitation
10.
Inspection of site
Daily inspection at construction site should be
During
carried out to ensure removal of construction
phase
construction Contract Documents
debris. Debris removal frequency shall be

quicker to the extent possible.
Piling up of
debris generated near steep slope section

would create hazardous condition for traffic
movement and pedestrians.
11.
Earthwork debris disposal
The excavated material to the extent possible
During
would be reused for proposed construction and
phase
construction M/ORT&H: 201.4 and

301.3.11
the remaining material would be disposed at

authorised dumping grounds. In no case, loose
earth should be allowed to pile up along the
alignment.
PAGE 10 of 20
293 of 2461
S.
Environmental Issue
MMRDA
Mitigation Measures
Time Frame
No.
12.
Cross Reference to
Documents
Idling of vehicles
Idling of delivery trucks or other equipment
During
should not be permitted during periods of
phase
construction M/ORT&H: 201.2
unloading or when they are not in active use.
13.
Construction
equipment Exhaust and noise emissions of construction
emissions
During construction
Legal requirement
equipment shall adhere to emission norms as

laid out by MoEF/ CPCB.
14.
Noise
from
construction All construction equipment shall be fitted with During construction
equipment
M/ORT&H: 111.0
exhaust silencers. Damaged silencers to be

promptly replaced by contractor.
15.
Noise
impact
due
to
operation of DG sets
DG sets, if used, shall adhere to noise
During construction
M/ORT&H: 111
Construction activity induced noise levels shall
During construction of
M/ORT&H: 111
be mitigated.
relevant sub- sections
standards of MoEF.
Operation of DG sets
shall be preferably avoided near habitation and

sensitive receptors.
16.
Noise
residential
level
areas
near
and
The contractor can employ
PAGE 11 of 20
294 of 2461
S.
Environmental Issue
MMRDA
Mitigation Measures
Time Frame
Cross Reference to
No.
Documents
sensitive receptors
mitigation measures such as restricted and/or

intermittent activity or as directed by PMC.
17.
Exposure to loud noise
Workers exposed to loud noise
During construction
shall wear earplugs/earmuffs.
18.
Storage
of
105.2
construction Construction material containing fine particles
material
M/ORT&H: 111.6 and
During construction
M/ORT&H: 306
During construction
M/ORT&H: 306
shall be stored in an enclosure such that

sediment-laden water does not drain into
nearby storm water drains and underground
sewage pipes.
19.
Blockage and change in
Along steep slope section located along
drainage pattern
alignment, earth, stone, pipes or any other

construction material shall be properly stored, if
storage cannot be avoided, so as not to block
the flow of water.
If the channel/ drains gets blocked due to
negligence, contractor should ensure that they
are cleaned especially during monsoon season.
PAGE 12 of 20
295 of 2461
S.
Environmental Issue
MMRDA
Mitigation Measures
Time Frame
No.
Cross Reference to
Documents
Once the work is completed in all respects, the

contractor shall, as a mark of good gesture,
clean up the drains along the project road to
the extent possible.
20.
Soil erosion
On road embankment near steep hill section,
During construction
M/ORT&H: 306
slope shall be stabilized. The work shall consist

of construction of retaining wall.
21.
Areas
susceptible
erosion
to Along the steep hill section along the alignment, During construction
M/ORT&H:
earthwork should be preferably carried out
Project
before rainy season or temporary/permanent
requirement
306.2/
construction
erosion protection work as may be feasible

shall be provided.
22.
Debris disposal
Debris generated due to dismantling of

existing road/ pavement/structures shall be
During construction
M/ORT&H: 112.10 and

301.3.11
suitably reused in proposed construction.

Un-utilisable debris shall be suitably disposed
at sites authorised by competent authority
PAGE 13 of 20
296 of 2461
S.
Environmental Issue
MMRDA
Mitigation Measures
Time Frame
Cross Reference to
No.
Documents
with the approval of PMC.
23.
Soil
contamination
by Oil and fuel spills from construction equipment During construction
Project requirement
construction wastes, fuel shall be minimised by good O&M practice.

etc.
Soils contaminated by such spills shall be

disposed as per MoEF requirements.
24.
Sourcing quarry materials
Sand, aggregates and other quarry material
During construction
M/ORT&H: 111.30
shall be sourced from licensed quarries.

25.
Compensatory plantation
Compensatory plantation shall be done in line During construction
Preservation of Trees
with Tree authority / Forest Dept. regulations
Act
and guidelines. Also it is recommended to grow
1975
of
Maharashtra,
trees in lieu of loss of trees.
26.
Providing labour camps
The contractor shall abide by the contract During construction
and facilities
conditions and directions of PMC with respect
M/ORT&H: 105.2
to labour camps, providing sanitation facilities

and labour welfare issues.
PAGE 14 of 20
297 of 2461
S.
Environmental Issue
MMRDA
Mitigation Measures
Time Frame
No.
27.
Cross Reference to
Documents
Occupational Health and
The contractor is required to comply with all the
Safety
precautions as required for the safety of
During Construction
M/ORT&H: 105.2
During Construction
M/ORT&H: 105.2
workmen as per the International Labour

Organisation (ILO) Convention No. 62, as far
as those are applicable to the contract.
28.
Provision
of
Safety
The contractor shall supply all necessary safety
accessories/ appliances
appliances such as safety goggles, helmets,
to each worker
safety belts, ear plugs, masks etc. to the worker

and staff.
All laws related to safe scaffolding,
ladders, working platform, gangway, stairwells,

excavations, safety entry and exit etc. shall be
complied with.
29.
Safety precautions
Adequate precautions shall be taken to prevent

danger
from
electrical
equipment.
All
During Construction
-
machines/equipment used shall confirm to the

relevant Indian Standards (IS) codes and shall
be regularly inspected by the PMC.
PAGE 15 of 20
298 of 2461
S.
Environmental Issue
MMRDA
Mitigation Measures
Time Frame
No.
30.
Cross Reference to
Documents
Availability of first aid kit
A readily available first aid unit including an During Construction
at construction site
adequate supply of sterilized dressing material
M/ORT&H: 105.2
and appliances shall be provided.

31.
Workers
health
and
hygiene
All anti-malarial measures as prescribed by the During Construction
M/ORT&H: 105.2
PMC shall be complied with, including filling up

of burrow pits.
32.
Non-compliance of EMP
If during progress of work, breach in compliance During Construction

/ observance of mitigation measures observed,
competent authority/committee will have right to

levy any penalty as per the nature of default
summarily
without
assigning
any
reasons
thereof.
PAGE 16 of 20
299 of 2461
MMRDA
Table 3: EMP for Operation Phase

S.
Environmental Issue
Mitigation Measures
Time Frame
Cross Reference to
No.
1
Documents
Air quality impact
Ambient
Noise pollution
air
concentrations
of
various
Starting
immediately
pollutants shall be monitored as per the
after
completion
pollution monitoring plan.
construction
Monitoring of noise levels at locations as
Starting
per monitoring plan.
after
of
immediately
completion
Project requirement
Project requirement
of
construction
3
Survival rate of plantation
Adequate care of the compensatory plantation Up to 3 years after

should be taken up so as to comply the survival project
Project requirement
becomes
rates recommended in the relevant policies of operational

the Tree authority
4
Road
embankment
section stability
&
cut
Road embankment & cut section stability
Throughout
should be checked for erosion and rutting. The
stage
operation
Project requirement
high embankment section along the alignment

shall be periodically checked for soil erosion
and stability. Any sign of instability should
warrant adequate response immediately and
well before succeeding monsoon season
PAGE 17 of 20
300 of 2461
11.3
MMRDA
Environmental Monitoring Plan

Recommended Project level Environment monitoring plan is presented in Table 4
Table 4: Environmental Monitoring Plan
Project
Component
Parameters
Standard
Location
Frequency
Duration
Stage
Air Quality
Before
SPM,
PM10,
Construction
SO2, N0x
NAAQS of
Surya Nagar
CPCB
Once
every
season Winter,
24
hr/day
for
consecutive
working
days per week

Air Quality
Construction
SPM,
PM10,
SO2, N0x
Air Quality
Operation
SPM,
PM10,
SO2, N0x
Noise Level
Construction
NAAQS of
Surya Nagar
CPCB
NAAQS of
Surya Nagar
CPCB
Once every season
24
Summer, Winter,
consecutive
post monsoon
days per week
Once every season
Summer, Winter,
consecutive
post monsoon
days per week

of
for
working
hr/day
for
working
CPCB
Sensitive
At
night, L10, L50,
noise
and
construction
reading with a frequency
L90 dB(A)
standards
residential
activity, followed by
of 10 minutes for 2 non-
locations
every
consecutive
located near
(Summer,
construction
and post monsoon)
season
winter
Continuous
Leq Day, Leq
start
hr/day
24
days
week for 2 weeks
PAGE 18 of 20
301 of 2461
hr
per
MMRDA
Project
Component
Parameters
Standard
Location
Frequency
Duration
Stage
equipment
during construction
period
Noise Level
Soil Quality
Operation
Construction
Leq Day, Leq
CPCB
Once every season
Continuous
night, L10, L50,
noise
(excluding
reading with a frequency
L90 dB(A)
standards
monsoon)
Heavy
and
metals
Oil
and
grease
for
24
of 10 minutes for 2 non-
year after operation
consecutive
starts
week for 2 weeks
Contaminant Debris
At start and end of
One time sample
threshold
construction
disposal site
level
days
activity
given by
USEPA
Ecology
Pre-
Monitoring
construction
tree
of As laid out At locations of During tree felling
felling/ in
transplantation
project
--
Tree felling
detail
design.
Trees to be
adequately
marked
for
PAGE 19 of 20
302 of 2461
hr
per
MMRDA
Project
Component
Parameters
Standard
Location
Frequency
Duration
Stage
felling
Ecology
Operation
Survival
Survival
At locations of
rate of
rate to be at
compensatory
plantation
least
plantation
and other
70%.Belo w
compensatory
which
plantation
replantation
should
Annual
For
years
after
operation starts
be
done.
PAGE 20 of 20
303 of 2461
SUB-SECTION 6A.12
ACCEPTABLE MAKES
304 of 2461
MMRDA
Table of Contents
SUB-SECTION 6A.12: ACCEPTABLE MAKES ........................................................................... 1
1.0
Water Treatment Plant .......................................................................................................... 1
2.0
Mechanical ............................................................................................................................... 2
3.0
Civil ............................................................................................................................................ 3
4.0
Electrical ................................................................................................................................... 4
5.0
Instrumentation, Control and Automation (ICA) Equipment ...................................... 8
305 of 2461
MMRDA
SUB-SECTION 6A.12: ACCEPTABLE MAKES
Acceptable makes for Plant, pipe and material are specified in the table
below. The tenderer shall offer makes included in the list. Equivalent
makes unless specified in the list will not be accepted except where
prior approval by the Employer is granted before bidding.
1.0
S.
Equipment
Acceptable Makes
No.
1.
Centrifuge
HUMBOLTZ, HILLER, Pennwalt, Alfa

Laval
2.
Conveyor Belt
SHIV PAD, Voltas, Batliboi, Dynamic,

Indiana
3.
Gear Box
Premium,
ELCON,
Greaves
Cotton,
Allen Berry
4.
Clariflocculator
Geo-Miller,
Engineering,
EMCO
Va
KCP,
Tech
Triveni
Wabag,
Degremont Ltd. Voltas

5.
Sludge Thickener
Triveni Engineering, Degremont Ltd.,

Geo- Miller, Voltas
6.
Agitators
Filtech, MILTON ROY, FIBER & FIBER,

REMI, VOLTAS , SHIV PAD, Triveni
7.
Submersible Mixers
ABS, KSB, Grundfoss, KBL, Kishor

Pumps
8.
Weigh Bridge
Vishwa
Karma,
Avery
India
Ltd.,
Weightron, Rrockway Weigh Bridge

9.
Screw Pump
Tushaco, AVS, ROTO, ALPHA HELICAL
SECTION 6A.12: ACCEPTABLES MAKES
PAGE 1 of 11
306 of 2461
2.0
MMRDA
Mechanical
Equipment
S.
Acceptable Makes
No.
1.
V.T. Pump
WPIL, KBL, M&P (WILO), Grund Foss
2.
Centrifugal pump
M&P,
KB
L,
WPIL,
Grund
Foss,
Flowserve
3.
Submersible
Sewage
Sludge Pump
4.
Submersible
Kishor,
KSB,
Rotomac,
Tushaco,
kirloskar, Aqua
dewatering
Kishore, Sehara, Acqua
pumps
5.
Dose Metering pump
Positive, Mitton Roy, Toschon
6.
CI/ DI/ SG iron Double
KBL, IVC, Fouress, VAG R&D Multiple,
Flanged Sluice Valves/ CI
AMRI
Double Flanged Butterfly

valves/ Kinetic Double Air
Valves/ Dual plate check
valves as per API 598
7.
Non
Return
(Reflux)
KBL, FOURESS, IVC
Valves / Check Valves

8.
DI Resilient (Soft) seated

Butterfly
valve
Resilient(Soft)
Sluice
VAG, IVC, KBL, FOURESS, AMRI
DI
seated
valve/
DI
Resilient(Soft) seated Non

Return
valve/
Resilient(Soft)
DI
seated
Kinetic Air valve

9.
Knife edge Gate Valve
Jash,
KBL,VAG,
IVC,
Fouress,
keystone
10.
Air valves
ARI, R&D multiple, Amflow, Durga,

Mayur
11.
Thimble Mounted Sluice

Gate
&Open
JASH, Oriental Castings, IVC
Channel
PAGE 2 of 11
307 of 2461
MMRDA
Equipment
S.
Acceptable Makes
No.
Sluice Gate
12.
Coarse Bar screen
JASH, Oriental Castings, SHIVPAD,

Johnson
13.
Stop log gates
14.
EOT
15.
/HOT
Jash, Hydrogates, GMW

/
Crane
REWA,WH Brady Co, Hercules Hoists
Monorail
Ltd., INDEF, Morris
Chain pulley Blocks
REWA,WH Brady Co, Hercules Hoists

Ltd., INDEF, Morris
16.
Air Blower Root Type
SWAM, Usha, Everest,TMVT
17.
Chlorinators
Industrial Devices (I) Pvt. Ltd, METITO,

TUSCON JESCO, Pennwalt India Ltd.,
Siemens
18.
19.
Chlorine
Scrubbing
Industrial Devices (I) Pvt. Ltd, Pennwalt
system
India Ltd., SM Polymers
CI Double Flanged Pipes
CD
IRON
Industries,
TRUFORM,
ORIENTAL CASTINGS Kejariwal

20.
DI Pipes
Electrosteel,
Electro-
therm,
TATA-
Kubota, Jindal Saw

21.
CI/DI Specials
Electrosteel, KEJRIWAL, TRUFORM,

Jindal Saw
22.
3.0
UPVC
Pipes/
UPVC
Supereme,
Kisan
Irrigation,
Jain
Specials
Irrigation, Kisan Mouldings, FINOLEX
23.
MDPE Pipes
Jain Irrigation, Kisan irrigation
24.
GI Pipes
TATA, Jindal
25.
Air supply fan/Air Blower
Usha, RAICO, Turbomax
26.
MS Pipes
TATA, Jindal, SAIL, Well Spun
Civil
S.
Equipment
Acceptable Makes
No.
1.
Cement
ACC, Vikram, Ambuja, JK, Shri, Uttam
PAGE 3 of 11
308 of 2461
MMRDA
Equipment
S.
Acceptable Makes
No.
2.
Structural Steel
SAIL, TISCO, ISSCO
3.
RCC Pipes
ISI Marked
4.
SW Pipes
ISI Marked
5.
RCC Manhole Cover &
ISI Marked
Frame
6.
Epoxy Paint
Hindustan Ciba Giegy, Fosroc, Seiko

Roffec, Burger
7.
Bituminous Paint
Burger, Asian Paints, Shalimar, Tar

Products
8.
Synthetic Paints
Burger, Asian Paints, Nerolac, Delux,

Salimar
9.
Water proofing
Sika, Fosroc
Compounds
4.0
10.
Concrete Admixtures
Sika, Fosroc
11.
Bitumen
IOCL, HPCL, BPCL
Electrical
S.
Equipment
Acceptable Makes
No.
1.
HT Motors
KEC, CGL, GEC, Siemens, BHEL,

Bharat Bijlee
2.
LT Motors
KEC, Siemens, Bharat Bijlee, CGL,

GEC
3.
Protection Relay
Alstom, ABB, Siemens, Easun Reyrolle
4.
Potential Transformer
Gilbert & Maxwell, AE, Kappa, ABB
5.
HV Potential Transformers
ABB, KAPPA, or as per DISCOM

approved list
6.
Current Transformer
Gilbert & Maxwell, AE, Kappa, ABB,

Advance
7.
HV Current Transformer
ABB, KAPPA, or as per DISCOM

approved list
PAGE 4 of 11
309 of 2461
MMRDA
Equipment
S.
Acceptable Makes
No.
8.
Power Transformer
ABB,
CGL,
Alstom,
Bharat
Bijlee,
Kirloskar, VOLTAMP, Schneider Electric

9.
OEM Panel Manufacturers
ABB, Siemens, Schneider, Rittal, L&T
(In house / Franchise)

10.
Indicating Meters
AE, IMP,
Nippen
Rishab, SIMCO,
Electricals
MECO,
Instrument
Co,
Universal Electric, Conzerv

11.
Indicating Lamps
L&T(ESBEE), Teknik, Siemens, BCH,

CONCORD, C&S
12.
HT Cables
Gloster, RPG, Polycab, KEI, Unister,

Havells, CCI, Asian, Incab, Nicco
13.
LT Cables
ICI, CCL, Glostor, RPG,
Polycab,
Unistar, KEI, Finolex

14.
PVC Lighting Wires
Finolex, Incab, Asian, Fort, Gloster,

RPG, L&T, Polycab
15.
High
Voltage
Brake
Isolator
Double Star Industries, electrolytes, Pactil

with
or
without Earth Breaker

16.
HT
Vacuum
Circuit
ABB, Schneider, Crompton, Siemens, ,
Circuit
Merlingerin, ABB, L&T, Siemens, GE,
Breaker
17.
Moulded
Case
Breaker
C&S, Schneider, MDS
18.
HT Switch gear Panel
Siemens, ABB, Areva, Schneider, L&T
19.
LT
L&T,
Switch
MCCB,
gear
MCB,
(ACB,
SFU,
Siemens,
Schneider
Electric,
Control& Switchgear, ABB
Contactor)
20.
Protective Relays
Siemens, Schneider Electric, Control&

Switchgear,
ABB,
AREVA,
Easun
Reyrolle
21.
Battery
22.
Battery Chargers
Exide, Standard, AMCO,HBL Knife

Amara Raja, CDC Kerela state elect.
Corp., Mass Tech Controls, Automatic
PAGE 5 of 11
310 of 2461
MMRDA
Equipment
S.
Acceptable Makes
No.
Electric, HBL, Chhabi Electricals
23.
Air Conditioner
Hitachi,
Voltas,
Blue
Star,
Daikin,
Carriers, O-General
24.
Exhaust Fans
CG, Almonard, Usha, Bajaj
25.
Electrical Actuators
Beacon,
Rotork,
Auma,
Marsh
Automation, Limitorque - Flowserve

Corporation
26.
Outdoor Lightning Arrestor
OBLUM,
ALPRO,
Pactil,
OBO
Betterman
27.
HRC Fuses
L&T, GEC, SIEMENS, C&S
28.
Push Button
Siemens, C&S, GE, BCH, ABB,L&T,
VAISHNO, TECHNIC
29.
Control Fuses
L&T, SIEMENS, EE, C&S, BCH, CG,

SCHNEIDER
30.
Contactors
L&T,
SIEMENS,
EE,
C&S,
ABB,
SCHNEIDER
31.
DG Set
Cummins, Sterling, Caterpillar, Ashok

Leyland,
KOEL
Kirloskar
Green,
Cooper
32.
Cable Trays and Glands
OBO Bettermen, COMET, HENSEL
33.
Capacitors
L&T, Khatau Junker, Madhav, Voltas,

Unistar, CGL
34.
APFC Relays
EPCOS,
ENERCON,
GE,
ABB,
Crompton, L&T, Standard

35.
Lighting Fixtures & Fittings
PHILIPS, CG, BAJAJ, WIPRO, GE

Lighting, Havells
36.
Cable Termination kits
Raychem, Densons, Mseal
37.
Soft
DEN
Starters
motors)
38. VFD for LT Motors
(MV/HV
ENTERHUB,
Innovative,
Jayshree, LECON
L&T,
Siemens,
ABB,
Schneider
Danfoss, HITACHI
PAGE 6 of 11
311 of 2461
MMRDA
Equipment
S.
Acceptable Makes
No.
39.
LT Air Circuit Breaker
ABB, Siemens, GE, L&T, Merlin Gerin,

Moeller, Schneider
40.
Switch Fuse Unit Switch
ABB, Siemens, GE, L&T, Merlin Gerin,

Moeller, Schneider
41.
Terminals Connector
Connectwell, Elmex, Wago, Phoenix
42.
Ceiling Fans
GEC, CG, BAJAJ, USHA, Khetan,
43.
Hot
dipped
galvanized
swaged
Philips, Bajaj, PE
Tubular/
octagonal poles
44.
High
Mast
Lighting
Philips, BPP, PE, ASTER, , CG, Bajaj
System
45.
On
load
change
over
HPL, GE, L&T, C&S, ABB
change
over
Standard, Havells, HPL, IndoAsian
switch
46.
Off
load
switch
47.
MCB, Isolator, RCCB, DB,
Merlingerin, ABB, L&T, Siemens, GE,
enclosures
Lagrand, C&S, BCH, Schneider, CGL
48.
PVC conduit/ steel conduit
AKG, BEC, NEC, Kalinga, SAIL
49.
Volt meter
AE, IMP, KCE, L&T, Conzerv
50.
Ammeter
AE, IMP, KCE, L&T, Conzerv
51.
Selector Switch
GE, Siemens, C&S, HPL, L&T, ABB,

Moeller, Kaycee
52.
Capacitor duty contactors
Siemens, ABB, GE, Schneider, C&S,

L&T, Moeller
53.
Cam
Operated
rotary
GE, Siemens, C&S, HPL, L&T, Kaycee
switches
54.
Earthing
&
Lighting
OBO
Bettermen,
Kapitrode,
Sterlite
Equipments accessories
Engg. Ltd
55.
Air Insulated Bus duct
C&S, Godrej & Boyce, Zenith Engg.
56.
Timers
EAPL, Minilec, Siemens, Schneider, L &

T
57.
Time Switch
GEC, L & T, EAPL
PAGE 7 of 11
312 of 2461
5.0
MMRDA
Instrumentation, Control and Automation (ICA) Equipment
Equipment
S.
Acceptable Makes
No.
1.
Open
channel
type
Ultrasonic Flow Meter
ABB,
Siemens,
M/s
Yokogawa,
Endress+Hauser, M/s Krohne Marshall,

M/s Millitronics
2.
Portable Noise Meter
CYGNET, HTC, Sigma, IRD
3.
Portable Vibration Meter
CYGNET, HTC, Sigma, IRD
4.
Level Indicators
M/s Masibus, M/s Alan, M/s Omron
5.
Level Sensors (Ultrasonic
M/s
Type)
Siemens,M/s
Level Sensors
Yokogawa
6.
EMERSON,
M/s
ABB,
M/s
Endress+Hauser,
M/s
(Capacitance Type)
7.
Level Switch
M/s EMERSON , M/s ABB , M/s SBEM

M/s
Endress+Hauser,
M/s
Pune
Techtrol
8.
Annunciator
M/s Masibus, M/s Minilec, M/s Peacon
9.
Pressure Transmitter
M/s EMERSON, M/s ABB, M/s Siemens

M/s Endress+Hauser, M/s Wika
10.
Control
System
PLC
SCADA
Schneider Electric (Quantum Series),

Siemens
Rockwell
PLC(S7-400H
(Control
Logic
series),
series),
Mitsubishi
11.
Chlorine
Analyzer
including sensor
12.
Turbidity
M/s EMERSON, M/s WTW

Analyzer
including Sensor
13.
PH
Analyzer
M/s Hach Company, M/s Yokogawa
M/s Hach Company, M/s EMERSON

M/s WTW
including
M/s Hach Company, M/s EMERSON
Sensor
M/s WTW
14.
Annubar
M/s EMERSON
15.
RPM Meter
M/s Jayshree Electric, M/s Proton, M/s

Kana Electric
PAGE 8 of 11
313 of 2461
MMRDA
Equipment
S.
Acceptable Makes
No.
16.
Pressure Gauge
M/S Warree, M/S ABB, M/s Wika, M/s

Gen
Inst
Co.,
M/s
Switzer,
M/s
Dandfoss
17.
Solenoid Valves
Avcon, ASCO, Tyco, SMC, Rotex
18.
DP Transmitter
M/s EMERSON, M/s ABB, M/s Siemens

M/s Endress+Hauser, M/s Wika
19.
Digital
Panel
Temperature
Flow
Meters,
Scanners,
Indicator
Totalizer,
M/s Masibus, M/s Alan, M/s Omron,

M/s NISHKO
and
Alarm
Annunciators
20.
Pressure Switch
M/S Warree, M/S ABB, M/s Wika, M/s

Gen
Inst
Co.,
M/s
Switzer,
M/s
Dandfoss
21.
Multifunction Meter
Schneider-MG,
RISHAB,
AE,
SIEMENS, Conzerv, L&T

22.
Switch / Fuses
GE, L&T, Siemens, GE Power
23.
Push Button (Non Flame
Siemens, Baliga, FCG, L&T, Teknik
Proof / Flame Proof)

24.
Electromagnetic
Flow
Meters
M/s ABB, M/s Siemens, M/s Yokogawa

M/s
Endress+Hauser,
M/s
Krohne
Marshall
25.
SCADA Workstation
Dell, HP, Lenovo
26.
Optic Fiber Cables
M/s Finolex , M/s Polycab ,M/s Ericson

,M/s Molex, M/s Optel ,M/s Sterlite
27.
Instrument & Meters
Secure Meters, Automatic Elect Ltd,

Meco Industries, Yokogawa, Rishabh,
Magnetrol, Emerson
28.
Instrument / Control Panel
Rittal, Pyrotech, Hoffmann
29.
Magnetic
Magnetrol, General Instruments, Pune
30.
type
level
Indicator / Gauge
Techtrol, SBEM
Instrument cable
M/s Polycab , M/s Universal ,M/s
PAGE 9 of 11
314 of 2461
MMRDA
Equipment
S.
Acceptable Makes
No.
Havells
M/s Finolex , M/s KEI Wires and Cables
31.
PLC Enclosure
Rittal, Pyrotech, Hoffman
32.
Control Desk Enclosure
Pyrotech, Hoffman, Godrej
33.
Printer
HP, EPSON, Canon
34.
V-SAT
i-Direct
35.
Radio Modem
ELPRO/MTL, Prosoft Technology-USA,

Calamp-USA
36.
Wireless Gateways
ELPRO/Calamp/Teletronics
37.
SPDs & LPUs
M/s
Hensel,
Crompton
M/s
Phoenix,
M/s
M/s
MTL
Greaves,
Instruments, M/s Pepper & Fuchs, M/s

Cirprotec ,M/s MH Instruments
38.
UPS
Nelco,
APC,
APLAB,
Hi-Rel,
DB
Electronics, Emerson
39.
CCTV
Siemens, Honeywell, NELCO LIMITED
40.
CCTV CAMERA
BOSCH, PELCO, SANYO, SHARP,

SONY, SAMSUNG
41.
CCTV MONITOR
SHARP,
HITACHI,
PHILIPS,
LG,
SONY, SAMSUNG, SANYO

42.
CCTV CABLES
POLYCAB, FINOLEX, THERMOCABLE
43.
Fire & Alarm Systems
Siemens, Honeywell, Xtrails, Edwards,

Simplex
44.
Intelligent
(Photo
Detectors
electric,
thermal-
Siemplex, Notifier, Edwards, Siemens
heat,
UL/FM/ULC
approved)
45.
Intelligent
Fire
Alarm
Same as above
Addressable manual call
Same as above
Control Panels
46.
points including handsets

47.
Monitor
modules,
fault
Same as above
PAGE 10 of 11
315 of 2461
S.
MMRDA
Equipment
Acceptable Makes
No.
isolation modules, control
modules
48.
UV flame detector
Same as above
49.
Beam Detectors
Same as above
Note: For Equivalent makes other than those mentioned in the above
table, prior approval shall be obtained before bidding.
PAGE 11 of 11
316 of 2461
MMRDA
SUB-SECTION 6A.13
BUILDING INFORMATION MODEL
SPECIFICATION(BIM)
317 of 2461
MMRDA
BUILDING INFORMATION MODEL (BIM) SPECIFICATIONS

Implementation of and Support for Enterprise Resource Planning
(ERP) &
5-Dimension Building Information Modeling (5D-BIM) Solutions
MMRDA for effective implementation of Surya project intends to
deploy a proven integrated ERP (Enterprise Resource Planning)
and 5D-BIM (5 Dimensional Building Information Modeling)
solution to automate its operations and integrate its processes. An
employers Support Office shall be created which will depend on
the mentioned solutions for strategic and operational design,
delivery, execution and subsequent support. This document
defines the Design-Builder (Contractor) scope of work and
deliverables for using Building Information Modeling on project.
As built drawings shall be compiled by the contractor and
submitted to the employer using hand held Laser scanner of
Trimble or equivalent make for piping, tall structures and digitized
photographs shall be used for compilation of such as Built
drawings.
BIM
Building Information Model (BIM) or Model is a

parametric, computable representation of the
project design developed by the Contractor, its
consultants, and any design/build subcontractors,
and includes construction details developed by
the Contractor and its respective consultants and
subcontractors that are integrated into the model.
As used in this BIM Specification, references to
Building Information Model, BIM, or the Model,
include the primary design model or models and
all linked, related, affiliated or subsidiary models
developed
for
design,
analysis,
SECTION 6A.13: BUILDING INFORMATION MODEL SPECIFICATION
318 of 2461
estimating,
PAGE 1 of 24
MMRDA
detailing, fabrication, construction, operation or

maintenance of the project, or any portion or
element of the project, whether the model is
prepared
by
Contractor
or
prepared
by
Contractors subcontractors or consultants.
5D BIM
An
acronym
for
5D
Building
Information
Modeling, is a term used in the CAD and

construction
intelligent
industries,
linking
of
and
refers
individual
3D
to
the
CAD
components or assemblies with schedule (time 4D BIM) constraints and then with cost-related
information (5D BIM)
ERP
Enterprise
business
suite
Resource
software,
is
management
softwaretypically
integrated
applicationsthat
of
Planning
company can use to collect, store, manage and

interpret data from many business activities,
including: Product planning, cost, Manufacturing
or
service
delivery,
Marketing
and
sales,
Inventory, etc.
Ass
Is the management of the assets including Pickup
ets
weir, rising mains, Water treatment plants, break
Managem
pressure tanks, tunnels Pipelines and Master
ent
balancing reservoirs using the space in or around

these structures or facilities and land on which
the scheme is being developed.
Operations Comprises of solutions to manage the water

Manageme transmission and treatment scheme including
nt
Supply
and
demand
management
319 of 2461
energy
PAGE 2 of 24
MMRDA
monitoring and management, scheduling, billing,

and related activities
ESO
Employers Support Office includes development

and
implementation
of
governance,
organizations, processes, systems, standards

and
methodologies
execution.
It
for
involves
successful
project
Strategic
project
management as a support to the client office. It

includes
proactive
risk
identification
and
management, monitoring and reporting on project

and supporting the project until successful
completion.
The key outcome of OSO, ERP& 5D-BIM implementation is linked to

service
delivery,
operational
excellence,
transparency
and
compliance
1. Service delivery to employers

a.
Multi-channel service delivery for optimum and

efficient processes to end points via the best
suited technology and user interface that may
include
thick/thin
client,
portals
and
mobile
devices.
b.
Secure and convenient access to internal and

external clients to avail the services including but
not limited to features for direct upload of
directives, monitoring KPIs, and process execution
as empowered by MMRDA
c.
Facilitate and enable employees of Employers

management
in
administration,
support
and
service delivery
320 of 2461
PAGE 3 of 24
MMRDA
2. Operational excellence
a.
Integration of processes for all functions like

Finance,
Procurement,
Materials,
Project
Management, HR, etc.

b.
Estimation and optimum utilization of resources:

Assets,
Financial
resources
and
Intellectual
resources for delivering the services

c.
Quick turnaround time for financial transactions,

reporting, analysis and feedback
d.
Excellence in the Deployment of facilities and

resources, project planning, and exploiting internal
expertise
3. Transparency and compliance

a.
Proactive and tight adherence to regulation in

financial transactions and operations of MMRDA
b.
Adherence to standard government norms in

financial transactions, reconciliation and reporting
as required by regulatory authorities, dashboards,
reports and analytics needs of stakeholders.
c.
Compliance
to
best
practices
in
project
management, customer management, and service

delivery
4. Strategy of the Project
There are many dimensions to the strategy of OSO, ERP

and 5D-BIM deployment at MMRDA, and they are
formulated around the possibilities offered by these
solutions.
a.
Standardization standardization of processes,

records,
terminology,
321 of 2461
information
exchange
PAGE 4 of 24
MMRDA
mechanisms
b.
Proven solutions - With the scale and criticality of

its activities in mind, MMRDA has clearly identified
that a strong foundation of technology is essential
towards creating the best possible outcomes.
Thus it is envisaged that all activities will be
carried out with help of the best of technology
solutions.
5D-BIM which has the become the best practice
for the creation of large infrastructure projects
globally, with techniques that have been extended
beyond conventional 2D &3D modeling, the added
dimensions of time and cost have been beneficial
and have resulted in on-time and within budget
execution. The Contractor will provide a BIM of
the
following
systems
during
design
and
construction. For as-built model requirements

refer to clause 4 of this building information
modeling scope of services and requirements for
design/build document. The contractor(s) shall
properly use available intelligent objects to
embody information about the building component
requirements
and
properties
(e.g.,
material
properties, functional information, dimensions,

uniform
following
at
assembly
sections
information,
describe
more
etc).
The
specific
information that shall be included in, but not

limited to, the following models:
Architectural:
The Contractor will provide a 5D BIM created with
architectural components that embody proper
322 of 2461
PAGE 5 of 24
MMRDA
object information and parametric relationships in

accordance
with
good architectural practice.
These components include, but not limited, to Pick

up weirs Water treatment plants, administrative
buildings, slabs/floors, exterior and interior walls,
roofs, doors, windows, stairs, railings, elevators,
finishes, ceilings, millwork break pressure tanks,
Tunnels, Pipelines, Reservoirs and case goods.
Structural: The Contractor will provide a 5D BIM created with
structural components that embody proper object
information
and
parametric
relationships
in
accordance with good structural engineering

practice. These components include, but are not
limited to, all substructure and superstructure
components. The object information will include
member profile and dimension information.
Mechanical: The Contractor will provide a 5D BIM created with
mechanical components that embody proper
object information and parametric relationships in
accordance with good mechanical engineering
limited to, all major mechanical equipment and
items are to be modeled for coordination with
other trades.
Electrical: The Contractor will provide a 5D BIM created with
electrical components that embody proper object
information
and
parametric
accordance
with
good
323 of 2461
relationships
electrical
in
engineering
PAGE 6 of 24
MMRDA

limited
to,
all
transformers,
major
electrical
switchgear,
equipment,
generators,
panel
boards, lights, conduit, hangers, cable trays,

raceways and other electrical equipment. Conduit
bends are to be modeled for coordination with
other trades.
Telecommunications
Information
Technology: The Contractor will provide a 5D BIM created with

telecommunications and information technology
components
information
that
and
embody
parametric
proper
object
relationships
in
accordance with good engineering practice. These

components include, but are not limited to, all
major equipment, MDFs, IDFs, panel boards,
conduits, hangers, cable trays, raceways and
other equipment. Conduit bends are to be
modeled for coordination with other trades.
Life Safety and Fire Protection: The Contractor will provide 5D BIMs created with
life safety and fire protection components that
embody proper object information and parametric
relationships in accordance with good mechanical
and
electrical
engineering
practice.
These
components include, but are not limited to, fire

detection devices, fire alarm devices, fire alarm
panels, the main sprinkler piping risers and related
devices piping sprinkler heads, control valves, fire
suppression equipment, pumps, hangers, and
other equipment. Pipe bends are to be modeled
for coordination with other trades.
324 of 2461
PAGE 7 of 24
MMRDA
Underground Utilities (Civil): The Contractor will provide a 5D BIM for

underground utilities created with civil components
that embody proper object information and
parametric relationships in accordance with good
civil engineering practice. These components
include all underground utilities, piping, duct
banks, vaults, manholes, hand holes, location of
soil borings with associated data and other civil
features.
Site / Campus (Civil and Landscape): The Contractor will provide 5D BIMs for site and
campus design with both civil and landscape
components
information
that
and
embody
proper
parametric
object
relationships
in
accordance with good civil engineering and

landscape
architecture
components
include,
topographic
grading,
practice.
but
not
landscape
These
limited
to,
including
hardscape, trees, planting stock (including roof),

storm water drainage features (such as catch
basins and drain inlets), exterior lighting, and
other site and campus features.
The 5D-BIM solution would address the following
in near real-time where technically feasible:
a.
Focus on design beyond 2D drafting and 3D

modeling
Early visualization by MMRDA faster

approval cycles.
Ease of coordination between construction
325 of 2461
PAGE 8 of 24
MMRDA
documents.
b.
Spatial Coordination between disciplines
Clash detection and conflict resolution

limiting
issues
on-site
and
during
construction.
Extraction of intelligent data and automated

schedules.
Ability to take-off materials and quantities.
Models
Projects
Schedules
and
Construction Sequencing.
Projecting
future
construction
sequence
conflicts.
c.
Tracking and identifying location of material

and
pieces
on-site
in
simulated
environment.
d.
Transparent and realistic picture of the

actual activities in the Project.
e.
Visualization
of
construction-sites
for
contractors, subs and clients on- site.

f.
Integration of BIM with mobile-devices for

managing construction and commissioning
/ hand-over.
g.
View the current cost and compare it to the

estimated total target cost of their project
as well as interim costs against design
during design phases.
h.
Effective strategic and operational setup

right from the beginning of the Project
Implementation of an effective Operational
Excellence in Initialization & Execution True
and fair view on financials, reliable forecast
and what-if-scenarios.
326 of 2461
PAGE 9 of 24
i.
Cost
MMRDA
and
Time
optimized
Program
Management with early warning system in

place for on-time management action
j.
A platform to address the evolving needs

The operational characteristics of MMRDA
would evolve over a period of time, as the
project moves from construction stage to
operations of Metro. Keeping in line with
this change the requirements of MMRDA
from the IT system would also change. The
ERP solution is expected to act as a
platform
with
requirements
effectively.
which
could
The
the
be
ERP
multiple
addressed
solution
would
address the following:

i.
Integration of business processes across

departments onto a single enterprise-wide
information system
ii.
Automation and integration of the core

business operations
iii.
Requirements of asset management and

maintenance management
k.
iv.
Increased operating efficiency
v.
Reduced operating and inventory costs
vi.
Better day-to-day management
vii.
Support for strategic management

Global best practices and processes in
functions
like
project
management,
financial
management,
procurement,
materials management, Government file

management and documentation, etc.
327 of 2461
PAGE 10 of 24
l.
MMRDA
The objective of MMRDA in investing in 5DBIM &ERP based applications is to:

I.
Achieve world class quality of service,

achieve efficiency and practice better
control over the financial transactions
and project activities
II.
Establish
uniform
standards
for
excellence in operations, project

III.
management,
human
resource
management, financial management

and performance reporting
IV.
Create
and
empower
Employers
Support Office with technology to

achieve the most optimum results
possible.
V.
Adopt the global best practices in

different spheres of, procurement,
materials
management,
human
resource
management,
quality
management,
financial
accounting,
customer
service,
management
and
and
performance
management.
5.
Phased implementation
a.
Employers Support Office should be able to work

out a well-defined set of project requirements and a
sound
basis
for
successful
execution.
OSO
organizational and functional framework should

enable MMRDA to identify the necessary control
tools and procedures to effectively manage project
risks. This shall run as an independent project in
parallel to ERP and 5D BIM.
b.
With the evolving nature of operations of MMRDA,
328 of 2461
PAGE 11 of 24
MMRDA
it has been decided to implement the ERP solution

in two phases, with the first phase focusing on the
basic requirements of the Project construction
stage and the second phase of the project focusing
on the operational aspects of Water supply
scheme.
c.
The 5D-BIM project will be run in parallel to the

OSO and ERP projects with defined dependencies
and Master Data exchange planned between the
systems.
d.
Upon go-live all the systems need to interface with

each other by design for MMRDA to get the best
possible outcomes of the project.
6.
Expected outcomes of the project

a.
Adopting best practices offered by ERP solutions in

the key processes like finance and accounts,
control,
audit,
asset
management,
materials
management, human resources management, as

applicable to the operations of a Regional water
supply project, will lead to efficiency, transparency
and informed decision making
b.
The ERP Solution will facilitate embedding best

business practices and processes into all its
operations,
doing
away
with
non-value
adding/redundant processes in various functions of

the corporation to make them efficient, transparent
and compliant to regulations.
c.
The 5D-BIM solution is expected to ensure that

project execution stays within the defined timelines
and budgets with the best of quality resulting from
world-class practices on scheduling, estimation and
engineering.
d.
For Employers Support Office ability to apply
329 of 2461
PAGE 12 of 24
MMRDA
proven best practices to create robust insight into

overall project performance across the entire
project lifecycle
7.
The Project overview

a.
The Project will be executed by a competent sub

contracted agency approved by employer, on a
turnkey basis, with responsibility for all the
aspects of the project listed in this specification.
b.
The Contractor shall assess the requirements of

MMRDA as listed in the RFP and propose a
proven 5DBIM &ERP solution, to meet the
requirements of MMRDA
c.
The
Contractor
will
provide
installation,
implementation and post implementation Support

services, for the proposed combined 5D BIM &
ERP solution.
d.
Hardware sizing based on the concurrent load,

transaction volume, growth plan and response
time expectations of MMRDA. MMRDA will
procure and provision the necessary hardware as
mutually agreed based on technical justifications
provided.
e.
Hosting options for the solutions will be separately

evaluated and decided. The Contractor may
suggest
and
recommend
based
on
their
understanding of the solution.

f.
MMRDA will institutionalize the use of the 5D BIM

and ERP solutions and expects the solutions to
become the backbone of the project during the
build phase and subsequently for operations upon
go-live of the project. No change in platforms is
envisaged unless the technology solution is
declared obsolete and out of support.
330 of 2461
PAGE 13 of 24
g.
MMRDA
The 5D BIM solutions will be the master repository of BIM

data received from various construction and engineering
contractor BIM solutions. At the same time the 5D BIM
will be required to integrate with the MMRDA ERP
solution to provide material quantities, costs, and
schedule compliance amongst other functionality as
defined in the RFP for implementation.
h.
Post the implementation, the Contractor shall provide

operational support for the 5D.
i.
BIM & ERP solutions. Service Level Agreement for

support will be defined along with the terms of reference
for the implementation. The support contract shall be for
a period of 8 years.
j.
It is expected that the Contractor will assist MMRDA with

knowledge transfer; and
k.
Creation of a functional Center of Excellence (COE) for

5D BIM and the ERP.
8.
IMPLEMENTATION PHASES
Contractor shall procure the licenses for 5D BIM & ERP

solutions best suited for its requirements and implement
in phases. The architects, engineers, designers and
technicians involved with providing services under
Contractors
Agreement,
must
be
trained
and
experienced in using BIM technology and processes.

Contractor must have, or must obtain at its own cost,
sufficient software licenses and computer hardware to
adequately perform the services required.
Contractor will provide MMRDA with a detailed written
description of the BIM experience of its key project team
members. At a minimum, the key project team members
include the principal project designer, the design
discipline lead designers, the construction project
331 of 2461
PAGE 14 of 24
MMRDA
manager, the construction cost estimator, scheduling

engineer, construction project engineer and construction
superintendent. In addition, Contractor will designate a
BIM Manager to oversee the technical aspects of
developing, managing and maintaining the BIM model.
Contractors proposal will describe the BIM experience
and responsibilities of these key personnel on at least
three prior projects that are similar to the current project
in size and complexity. The proposal will also describe
how their prior BIM experience relates to specific BIM
deliverables and tasks within the Contractors scope of
work or proposal.
MMRDA will be provided access to the BIM and
associated servers for exporting information. MMRDA
reserves the right to utilize information exported from the
BIM at any time during the contract.
A. Phase I of the 5D BIM solution will be implemented to cover
the following functionality:
I.
2D drawing and 3D Visualization
II.
Addition the dimensions for Scheduling and time estimation
III.
Material and quantity estimation and associated costs
IV.
Clash and detection, and Layout
V.
Construction Management reporting
VI.
Collaboration between stakeholders
VII.
Integration with ERP and contractor BIM solutions
VIII.
Digital Project Delivery Services and the OSO
IX.
The Agency shall assess, design and implement a

Digital Project Strategy and Project Execution Plan
as well as the Project Organization.
X.
Develop long-term strategy around information needs

of stakeholders
XI.
Develop the Digital Strategy in line with project
332 of 2461
PAGE 15 of 24
MMRDA
execution strategy, including contracting strategy and

capital plan
XII.
Align and integrate project management processes

and tools
XIII.
Assess and design data flow between systems to

improve integration and efficiency
XIV.
Identify interfaces with corporate functions
XV.
Develop execution plan, setup and run a Digital

Project
XVI.
Define strategic project delivery options and develop

strategic framework
XVII.
Define
and
design
the
project
governance,
organization and process aligned to digital project

delivery
XVIII.
Define
decision
policies, roles
and
responsibilities,
making, escalation, standards, contracts
and procurement strategy

XIX.
Setting
up
performance
measurement
and
monitoring model fully integrated into the project

delivery environment
XX.
Designing the contract and sourcing strategies, and

contract management in line with digital project
delivery
XXI.
Aligning the procurement and supply chain strategy,

so that it will satisfy the requirements of digital project
delivery
XXII.
Undertake Information Management and Digital

Ecosystem Management
XXIII.
Define and design an integrated system to manage

all project functions such as:
Supplier & Contractor Management
Building and Design Information Management
Document Management including Engineering

Design Authorization
333 of 2461
PAGE 16 of 24
MMRDA
Contract Management and Construction Planning
Procurement Management
Estimation & Schedule of Rates,
Cost Control & Cash Flow,
Reporting
Scheduling
Quality Control and Site Management
Human Resources
Non-fare box revenue optimization
Accounting and Financial Management
Any other function required to successfully deliver

this project
B. Concurrent with Phase I of the implementation of 5D BIM

solution, the ERP solution will cover the following functions
I.
Procurement and Contract Management
II.
Materials management
III.
Finance and accounts
IV.
Project Management
V.
Human Resources, and optionally payroll management and

administration
VI.
Business analytics
VII.
Integration module to integrate other applications
VIII.
Asset management
IX.
Government file management
C. The Agency will undertake oversight during the project

implementation and undertake for Employers Support Office
services
I.
The following:
a. Communication and Stakeholder
Management
b. Advise on Investment Safeguarding Options
334 of 2461
PAGE 17 of 24
MMRDA
c. Design and Monitor Project Execution

Strategy
II.
Define, Design and Monitor Reporting System and Metrics
III.
Design and Monitor Project Gateway Approval Process
IV.
Undertake Independent Project Review
V.
Design Project Governance Model
D. The Agency will define, design and monitor overall Project

Management Tools and Systems such as:
I.
Document Management
II.
Project Management Tool
III.
Scheduling
IV.
Data Management
V.
Workflow Management
VI.
Building Information Management
E. Design and develop procurement and supply chain strategy

which meets the need of the project and reflects timescales
involved.
F. Phase II of the implementation will cover the following
functions and separate RFP may be released for the same.
i.
Assets Management
ii.
operations management
iii.
Maintenance management
G. BIM operations and maintenance
9.
Software and Operating Systems
The BEP must list the BIM software and computer

operating system or systems to be used by Contractor
and its consultants for this project. The software and
operating systems should be identified by vendor,
product name, version identifier, build identifier, patch
number, and data architecture (32bit/64bit). Listed
software, and listed operating systems, cannot be
335 of 2461
PAGE 18 of 24
changed
or
MMRDA
upgraded
without
MMRDA's
written
approval, which will not be granted unless Contractor

demonstrates that the change or upgrade will not affect
the ability to use existing BIM information or to reliably
and accurately exchange BIM information with other
listed software.
BIM softwares for the Project must support intelligent
objects and parametric relationships. The software must
comply with current industry interoperability standards
and be usable in a collaborative environment. All
software platforms used for MMRDA projects will be
compliant with:
Provision of Project Execution and O & M Related Software
The Contractor shall arrange to license, subscription, buy,
install, operationalize and provide computing software listed in
the table below as per the numbers and the duration indicated
against each. The availability of the installed software shall be
for the entire duration of the project. The software availability
shall commence with effect from a date within four to six weeks
of the date of the Letter of Award of the contract. The contractor
shall provide adequate back up for interrupted power supply in
all offices on 24 x 7 basis.
S.
Software
Brief Specifications
Number
of Users
No.
1
Bentley BIM
Suite (Micro
3D Architectural, Structural,
Station,
Mechanical, Electrical, and
Bentley
Generative
Architecture,
Modeling
Components
Structural,
336 of 2461
PAGE 19 of 24
S.
Software
MMRDA
Number
of Users
No.
Mechanical,
Electrical,
Generative
Design)
or
equivalent.
2
MS Project,
4D Scheduling
Bentley
Navigator/
primavera
3
5D Cost Estimating
Energy Analysis
Power Civil
Site Development
Coordination
(clash
detection)
7
for The software shall be capable of
STAAD.pro
Structural
Analysis analyzing structure exposed to static

loading, dynamic loading, soil- structure
& design
interaction, wind, earthquake, and

moving loads.
8
STAAD.
Foundation The software shall be capable of
Advanced
Design
for designing isolated, combined,

of Octagonal, Pile Cap and Mat foundation
substructures
in a single file. It should have
(foundations)
capabilities to design foundations for

Vibrating Machines, Pressure vessels,
Heat exchangers, API 650 tanks and
should have capabilities to design
laterally loaded piles
Bentley Geo Web
Provides functionality for data
Publisher
integration, web site creation and
337 of 2461
PAGE 20 of 24
S.
Software
MMRDA
Number
of Users
No.
Or equivalent
layout, web site administration and

maintenance, as well as end-user tools
providing for map navigation, querying,
analysis and reporting
10
Bentley Water GEMS:
Graphical and Geo-Referenced
Water Supply Design &
representation of your distribution &
Modelling Solution or
transmission system,
equivalent
Work within Multi-Platform
environments of AutoCAD, ArcGIS &
Microstation without customization
11
Bentley Hammer: Surge
Graphical and Geo-Referenced
Analysis & Design of
representation of your distribution &
Water Transmission /
transmission system
Distribution Systems or
equivalent
Work within Multi-Platform
environments of AutoCAD, ArcGIS &
Microstation without customization
12
Bentley Road: MxROAD
Work with any type of field-data survey,
or equivalent
ASCII, GPS, LiDAR, contour maps,
photogrammetric, and many other forms

of data. Use immersive corridor
modelling tools to streamline the
complex development of every aspect
of the roadway in a single, parametric
presentation
13
AECOSIM - Multi-
Design, analyze, document, and
Discipline Building
visualize buildings of any size, form,
Design Software or
and complexity. Effectively
338 of 2461
PAGE 21 of 24
S.
Software
MMRDA
Number
of Users
No.
equivalent
communicate design intent and bridge

barriers between building disciplines
and geographically distributed teams,
deliver high-performance buildings.
14
Bentley Substation
capability of creating the Intelligent 3D
Design, 3D substation
Physical Design (which is including
Civil Design, 3D
Transformers, Structural systems) of the
Substation Building
substation & also should have the
Design, Substation
capability of generating produce single-
structural design or their
line drawings, protection and control
equivalents
schematics, panel layouts and wiring
diagrams in a unified environment,

capability to acquire and incorporate
surveys, Work with any type of fielddata survey, ASCII, GPS, LiDAR,
contour maps, photogrammetric, and
many other forms of data, capable of
uniquely provides a comprehensive set
of capabilities to effectively design,
construct, document, analyze, and
visualize buildings of any size and
complexity. With federated approach,
distributed teams of any size can work
on models simultaneously, regardless of
geographic location, to enable
integrated project delivery, capable to
Detail and schedule concrete rebar.
Produce rebar placing drawings,
including sections, plans, details, bar
bending schedules, material take-offs
and beam/column/footing schedules, all
339 of 2461
PAGE 22 of 24
S.
Software
MMRDA
Number
of Users
No.
based on the 3D model.
15
Bentley Project wise
Project Information Management and
Collaboration Cloud Services

16
CONTEXT CAPTURE - quickly produce even the most

Reality
Modelling challenging 3D models of existing
Software
or conditions for infrastructure projects of
equivalent
all types, derived from simple

photographs, develop precise reality
meshes, affordably, with less
investment of time and resources in
specialized acquisition devices and
associated training
17
EADOC - Cloud-based Improve collaboration and gain real-time 6

visibility into your capital project risks
Construction
Software and costs
Management
or equivalent
18
AMULET-
Predictive Gain operational intelligence across the

whole organization with real-time
Operational
Analytics
Software predictive and operational analytics.
or equivalent
Optimize the organizations operational

performance with improved production,
reduced operational costs, and smarter
decision making by predicting
performance, threats, and business
opportunities. Asset Wise Amulet is a
user-driven platform employing
industrial analytics to provide predictive
solutions using operational and IT data
in real time
19
ARC GIS
20
AutoCAD
GIS mapping etc
8
8
340 of 2461
PAGE 23 of 24
S.
Software
MMRDA
Number
of Users
No.
21
CIVIL 3D
22
Microsoft OFFICE and

Adobe acrobat
4
Word-processing documents, Spread
25
sheet documents
professional
23
Microsoft Access
Databases
341 of 2461
PAGE 24 of 24



dEDDZt^ZD
/^Zt^^
t^ZDDZDDZ
DKdDKd

OCTOBER 2016

UB-SECTION 6B.1
CIVIL WORKS
343 of 2461
MMRDA
Table of Contents
SUB-SECTION 6B.1: CIVIL WORKS ................................................................................. 1
1.1
General.......................................................................................................................... 1
1.1.1
Specification in Bid Document ............................................................................ 1
1.1.2
Specification Drawings ......................................................................................... 1
1.2
Specific Civil Engineering Requirements............................................................ 2
1.2.1
Design Submissions ............................................................................................. 2
1.2.2
Design Standards ................................................................................................. 2
1.2.3
Design Loadings ................................................................................................... 2
1.2.4
Joints ....................................................................................................................... 4
1.2.5 Design Conditions for Underground or Partly Underground Liquid

Retaining Structures ........................................................................................................... 4
1.2.6
Foundations ........................................................................................................... 6
1.2.7
Design Requirements ........................................ Error! Bookmark not defined.
1.2.8
Minimum Cover to Main Reinforcement ............................................................ 7
1.2.9
Minimum Bar Diameter ........................................................................................ 8
1.2.10
Bar Spacing ........................................................................................................ 8
1.2.11
Materials ............................................................................................................. 8
1.2.12
Samples and Tests of Materials ................................................................... 10
1.2.13
Orientation ........................................................................................................ 11
1.2.14
Roadways, Pathways and Hardstandings ................................................... 11
1.2.15
Site Drainage ................................................................................................... 12
1.2.16
Cables and Pipework Trenches .................................................................... 12
1.2.17
Pipe and Ducts ................................................................................................ 13
1.2.18
Soil Data and Ground Water Table .............................................................. 13
1.2.19
Buildings and Structures ................................................................................ 13
1.2.20
Anticorrosive Treatment ................................................................................. 18
1.2.21
Pressure Grouting ........................................................................................... 18
1.3
Earthwork and Excavation .................................................................................... 21
1.3.1
Relevant IS Codes .............................................................................................. 22
1.3.2
Excavation ............................................................................................................ 22
1.3.3
Dewatering ........................................................................................................... 39
1.3.4
Timber Shoring .................................................................................................... 40
1.3.5
Rain Water Discharge ........................................................................................ 42
1.4
Anti Termite Treatment ........................................................................................... 43
1.4.1
Delivery, Storage and Handling ........................................................................ 43
1.4.2
Safety Requirements .......................................................................................... 43
344 of 2461
MMRDA
1.4.3
Warranty ............................................................................................................... 44
1.4.4
Quality Assurance ............................................................................................... 44
1.4.5
Products ............................................................................................................... 44
1.5
Concrete and Allied Works.................................................................................... 46
1.5.1
General ................................................................................................................. 46
1.5.2
Applicable Codes ................................................................................................ 47
1.5.3
Materials for Standard Concrete ...................................................................... 53
1.5.4
Fine Aggregate .................................................................................................... 57
1.5.5
Coarse Aggregate ............................................................................................... 59
1.5.6
Water..................................................................................................................... 61
1.5.7
Steel and Aluminium Members encased in Concrete ................................... 63
1.5.8
Controlled Concrete ............................................................................................ 64
1.5.9
Mix Design ........................................................................................................... 65
1.5.10
Proportioning, Consistency, Batching and Mixing of Concrete .......... 69
1.5.11
Sampling and Testing of Concrete in the Field .......................................... 77
1.5.12
Concrete Tests ................................................................................................ 79
1.5.13
Admixtures........................................................................................................ 82
1.5.14
Preparation Prior to Concrete Placement, Final Inspection and Approval

83
1.5.15
Transportation .................................................................................................. 85
1.5.16
Application of Araldite for Bonding of New and Old Concrete ........ 94
1.5.17
Handling Precautions ..................................................................................... 97
1.5.18
Construction Joints.......................................................................................... 98
1.5.19
Movement Joints ............................................................................................. 99
1.5.20
Water Stops and Joint Fillers ...................................................................... 100
1.5.21
Sealing Compounds ..................................................................................... 102
1.5.22
Tolerances in Concrete Surfaces ............................................................... 102
1.5.23
Curing, Protecting, Repairing and Finishing ............................................. 103
1.5.24
Hot Weather Requirement ........................................................................... 112
1.5.25
Placing Concrete Underwater ..................................................................... 113
1.5.26
Precast Concrete........................................................................................... 114
1.5.27
Slots, Openings, etc...................................................................................... 115
1.5.28
Inspection ....................................................................................................... 118
1.5.29
Clean-Up......................................................................................................... 119
1.5.30
Records of Concreting .................................................................................. 119
1.5.31
Supply of Cement .......................................................................................... 119
1.5.32
Foundation Bedding, Bonding and Jointing .............................................. 120
1.5.33
Preparation of Rock Strata of Foundations ............................................... 120
1.6
Formwork ................................................................................................................. 121
345 of 2461
MMRDA
1.6.1
Formwork, Fixing and General ....................................................................... 121
1.6.2
Removal of Formwork ...................................................................................... 123
1.6.3
Formed Surfaces - Classes OF Finish .......................................................... 125
1.6.4
Defects in Formed Surfaces ............................................................................ 126
1.6.5
Holes to be Filled .............................................................................................. 127
1.6.6
Tolerances ......................................................................................................... 128
1.6.7
Bracing, Struts and Props ................................................................................ 132
1.7
Reinforcement......................................................................................................... 132
1.7.1
Relevant IS Codes ............................................................................................ 132
1.7.2
General ............................................................................................................... 133
1.7.3
Storage ............................................................................................................... 133
1.7.4
Quality ................................................................................................................. 134
1.7.5
Laps..................................................................................................................... 134
1.7.6
Bending............................................................................................................... 134
1.7.7
Fixing................................................................................................................... 135
1.7.8
Cover................................................................................................................... 136
1.7.9
Inspection ........................................................................................................... 137
1.7.10
Welding of Reinforcement ........................................................................... 137
1.7.11
Supply of Reinforcing Bars .......................................................................... 138
1.8
Structural Steel Work ............................................................................................ 138
1.8.1
1.8.2
General ............................................................................................................... 139
1.8.3
Materials ............................................................................................................. 139
1.8.4
Fabrication and Erection .................................................................................. 140
1.8.5
Painting ............................................................................................................... 144
1.9
Brick Work and Stone Masonry ......................................................................... 147
1.9.1
1.9.2
Materials ............................................................................................................. 148
1.9.3
Construction ....................................................................................................... 149
1.9.4
Curing ................................................................................................................. 151
1.9.5
Scaffolding ......................................................................................................... 151
1.9.6
Stone Masonry for Retaining Walls................................................................ 151
1.9.7
Uncoursed Stone Masonry .............................................................................. 152
1.9.8
Stone Pitching ................................................................................................... 154
1.9.9
Rubble Packing ................................................................................................. 155
1.9.10
Concrete Block Masonry .............................................................................. 155
1.9.11
Damp-Proof Course ...................................................................................... 160
1.10
Plastering ............................................................................................................. 161
346 of 2461
MMRDA
1.10.1
Relevant IS Codes ........................................................................................ 161
1.10.2
Plastering ........................................................................................................ 161
1.10.3
Putti.................................................................................................................. 163
1.11
Flooring ................................................................................................................. 164
1.11.1
1.11.2
General ........................................................................................................... 164
1.11.3
Cement Concrete Flooring ........................................................................... 165
1.11.4
Granolithic (IPS) Flooring ............................................................................. 169
1.11.5
Terrazzo (Mosaic) Tile .................................................................................. 170
1.11.6
Terrazzo (Mosaic) in-situ Flooring .............................................................. 174
1.11.7
Glazed Tile Flooring ...................................................................................... 176
1.11.8
Kota Stone Flooring ...................................................................................... 179
1.11.9
Mosaic Finished Dado or Skirting ............................................................... 181
1.11.10
Hardonite Flooring......................................................................................... 182
1.12
Distempering and Painting .............................................................................. 183
1.12.1
General ........................................................................................................... 184
1.12.2
Concrete, Brickwork And Plaster ................................................................ 184
1.12.3
Ironwork and Ungalvanised Steelwork ...................................................... 185
1.12.4
Galvanised Steelwork ................................................................................... 186
1.12.5
Bituminous Surfaces ..................................................................................... 187
1.12.6
Aluminium Surfaces ...................................................................................... 187
1.12.7
Woodwork....................................................................................................... 188
1.12.8
Waterproof Cement Paint ............................................................................ 188
1.12.9
Silicon Paint.................................................................................................... 190
1.12.10
1.12.11
Distempering .................................................................................................. 192
1.12.12
Decorative Finish Cement Paint ................................................................. 193
1.12.13
Painting ........................................................................................................... 194
1.12.14
Painting With Synthetic Enamel/Enamel Paint ......................................... 196
1.12.15
Plastic Emulsion Paint .................................................................................. 197
1.13
Expansion Joints and Construction Joints ................................................. 198
1.13.1
General ........................................................................................................... 198
1.13.2
Material ........................................................................................................... 198
1.13.3
Joints in Floor................................................................................................. 198
1.13.4
Joints in Walls ................................................................................................ 199
1.14
Epoxy Coating, Bituminous, Polymer Painting .......................................... 203
1.14.1
Epoxy Coating................................................................................................ 203
1.14.2
Bituminous Painting ...................................................................................... 205
347 of 2461
1.14.3
1.15
MMRDA
Polymer Painting ........................................................................................... 206
Door, Windows, Grills, Shutters etc. ............................................................. 206
1.15.1
1.15.2
General ........................................................................................................... 207
1.15.3
Woodwork in Doors, Windows, Partitions, Louvers, Railings etc. .. 208
1.15.4
Steel Doors, Windows and Fittings (Aluminium Windows) ..................... 210
1.15.5
Rolling Shutters ............................................................................................. 211
1.16
Hand Railing ........................................................................................................ 212
1.17
Rungs .................................................................................................................... 213
1.18
Piping Work.......................................................................................................... 213
1.18.1
Reinforced Cement Concrete Pipes (Class NP 3) ................................... 213
1.18.2
Centrifugally Cast (Spun) Ductile Iron Pipe .............................................. 222
1.18.3
General Specifications for CI Piping Work ................................................ 230
1.18.4
Specification For Laying, Jointing & Testing of CI Pipe ........... 232
1.19
Valves .................................................................................................................... 236
1.19.1
Butterfly Valve ................................................................................................ 236
1.19.2
Sluice Valve.................................................................................................... 236
1.19.3
Dual Plate Check Valve ............................................................................... 236
1.19.4
Knife Gate Valves ......................................................................................... 237
1.19.5
Reflux Valves ................................................................................................. 239
1.20
Single Faced Sluice Gates ............................................................................... 240
1.21
Water Supply and Sanitary Works ................................................................. 240
1.21.1
Applicable Codes .......................................................................................... 240
1.21.2
Sanitary Installation....................................................................................... 243
1.21.3
Indian Type Water Closet ............................................................................ 244
1.21.4
Urinals ............................................................................................................. 244
1.21.5
Wash Basin .................................................................................................... 244
1.21.6
Sinks ................................................................................................................ 244
1.21.7
Cast Iron Soil Waste And Vent Pipes and Fittings ................................... 245
1.21.8
Galvanised Mild Steel (GI) Pipes ................................................................ 246
1.21.9
Not Used ......................................................................................................... 249
1.21.10
Stoneware Pipe and Fittings ....................................................................... 250
1.21.11
Stop Cock And Bib Cock .............................................................................. 254
1.21.12
Not Used ......................................................................................................... 254
1.21.13
Manholes / Inspection Chambers ............................................................... 254
1.21.14
Vent Shafts ..................................................................................................... 263
1.21.15
Septic Tank .................................................................................................... 264
1.21.16
Miscellaneous ................................................................................................ 264
348 of 2461
1.22
MMRDA
Road Side Drains ................................................................................................ 265
1.22.1
Applicable Codes and Specifications ......................................................... 265
1.22.2
Slab Culvert .................................................................................................... 265
1.22.3
Pipe Drains ..................................................................................................... 266
1.23
Bored Cast in Situ Piles for Foundations .................................................... 270
1.23.1
Scope of Work ............................................................................................... 270
1.23.2
Related Specifications and Codes ............................................................. 270
1.23.3
Diameter of the Piles .................................................................................... 271
1.23.4
Materials ......................................................................................................... 272
1.23.5
Drilling Mud (Bentonite) ................................................................................ 274
1.23.6
Boring Operations ......................................................................................... 275
1.23.7
Inspection of Bored Piles: ............................................................................ 276
1.23.8
Concreting ...................................................................................................... 276
1.23.9
Testing of Piles .............................................................................................. 278
1.23.10
Replacement of Rejected Piles ................................................................... 279
1.23.11
General ........................................................................................................... 279
349 of 2461
MMRDA
SUB-SECTION 6B.1: CIVIL WORKS
1.1
General
1.1.1 Specification in Bid Document
These specifications shall be read in conjunction with the other

specifications mentioned against the specific items of work mentioned in
the Schedules and drawings wherever applicable and the better / higher
of the two shall be accepted.
The Contractor may improve on these specifications in order to fulfill the

project objectives and may make such amendments to these
specifications through an amendment sheet duly approved by the
Employer.
These specifications including their amendments / revisions / addenda /

corrigenda shall form the part of the contract agreement between the
Employer and the Contractor.
1.1.2 Specification Drawings
The site plan, of the proposed work(s) which comprise the entire project
is a part of the tender documents. The Contractor will have to submit
detailed design as well as the civil guide drawings with his bid. The
Contractor shall also submit his civil General Arrangement drawings as
well as structural drawings to the Employers representative and obtain
prior approval to start the construction, erection and commissioning of
civil, electrical and mechanical components of the project.
Work shall be carried out by Contractor exactly in accordance with the

Drawings marked as RELEASED FOR CONSTRUCTION and approved
by Employer / Employers representative and as per the instructions of
SECTION 6B.1: CIVIL WORKS
PAGE 1 OF 281
350 of 2461
1.2
MMRDA
Specific Civil Engineering Requirements
1.2.1 Design Submissions
The Contractor shall submit complete detailed design calculations of

foundations and superstructure together with general arrangement
drawings and explanatory sketches to the Employer. Separate
calculations for foundations or superstructures submitted independent of
each other should be deemed to be incomplete and will not be accepted
by the Employer.
The design considerations described herewith establish the minimum

basic requirements of plain and reinforcement concrete structures,
masonry structures and structural steel works. However, any particular
structure
shall
be
designed
for
the
satisfactory performance of
the functions for which the same is being constructed. The Contractor
shall also take care to check the stability of structure partly constructed
to comply with design loads.
1.2.2 Design Standards
All designs shall be based on the latest International and / or

Bureau of Indian
as applicable.
Standards (BIS) Specifications or Codes of Practice

The design standards adopted shall follow the best
modern engineering practice in the field based on any other international

standard or specialist literature subject to such standard reference or
extract of such literature in the English language being supplied to and
approved by the Employer.
In case of any variation or contradiction
between the provision of the IS Standards or Code and the

specifications given with the submitted tender document, the provision
given in the Specification shall be followed.
1.2.3 Design Loadings
All building and structures shall be designed to resist the worst

PAGE 2 OF 281
351 of 2461
MMRDA
combination of the following loads/stresses under test and working

conditions these include dead load, live load, wind load, seismic load,
stresses due to temperature changes, shrinkage and creep in materials,
dynamic loads and uplift pressure.
1.2.3.1
Dead Load
This shall comprise all permanent construction including

walls, floors, roofs, partitions, stairways, fixed service
equipment and other items of machinery. In estimating the
loads of process equipment all fixtures and attached piping
shall be included, but excluding contents shall be
considered.
1.2.3.2
Live Load
Live loads shall be in general as per IS 875.
In the absence of any suitable provisions for live loads in IS

Codes for any particular type of floor or structure,
assumptions made must receive the approval of the
Employers representative prior to starting the design work.
Apart from the specified live loads or any other loads due
to material stored any other equipment load or possible
overloading during maintenance or erection/construction
shall be considered and shall be partial or full whichever
causes the most critical condition.
1.2.3.3
Wind Load
Wind loads shall be as per IS:875
1.2.3.4
Earthquake Load
This shall be computed as per IS:1893 in Appropriate Zone.

PAGE 3 OF 281
352 of 2461
1.2.3.5
MMRDA
Dynamic Load
Dynamic loads due to working of plant items such as

pumps, blowers, compressors, switch gears, traveling
cranes, etc. shall be considered in the design of structures.
1.2.3.6
Other Loads
In addition to earth pressure and water pressure etc., the

surcharge of 1 Ton/sq. shall be taken into account in the
design for channels, tanks, pit, sludge settler, etc.
1.2.4 Joints
Movement joints such as expansion joints, complete
contraction joints,
partial contraction joints and sliding joints shall be designed to suit the
structure as per relevant IS code provisions. Expansion joints of suitable
gap at intervals not more than 30 m shall be provided in walls, floors and
roof slabs of Liquid Retaining Structures.
Construction joints shall be provided at right angles to the general

direction of the member.
The locations of construction joints shall be
decided on convenience of construction.
To avoid segregation of
concrete in walls, horizontal construction joints are normally to be

provided at every 2 m height, PVC water stops of suitable type and
approved make, minimum 230 mm width, 6 m thick shall be used for
walls and base slabs.
1.2.5 Design Conditions for Underground or Partly Underground Liquid Retaining

Structures
All underground or partly underground liquid containing structures shall

be designed for the following conditions:
PAGE 4 OF 281
353 of 2461
1.
MMRDA
Liquid depth up to full height of wall: no relief due to soil pressure

from outside to be considered.
2.
Structure empty (i.e. empty of liquid, any material, etc.) full earth
pressures including saturated condition and surcharge pressure
wherever applicable to be considered.
3.
Partition wall between dry sump and wet sump to be designed for
full liquid depth up to full height of wall.
4.
Partition wall between two compartments to be designed as one

compartment empty and other compartment full.
5.
Structures shall be designed for uplift in empty conditions with the

water table indicated in the geotechnical report or high flood level,
whichever is maximum. No reduction factor for the uplift force
shall be considered.
6.
The dead weight of the empty structures should provide a safety

factor of not less than 1.2 against uplift pressures during
construction and in service.
7.
Wall shall be designed under operating conditions to resist

earthquake forces from earth pressure mobilization and dynamic
water loads.
8.
Underground or partially underground structures shall be checked

against stresses developed due to any combination of full and
empty compartments with appropriate ground/uplift pressures
from below to base slab.
9.
The walls and base slabs shall be designed for saturated

earth/water pressure corresponding to high flood level or finished
plot level whichever is higher.
PAGE 5 OF 281
354 of 2461
MMRDA
1.2.6 Foundations
1.
The minimum depth of foundations for all structures, equipments

buildings and frame foundations and load bearing walls shall be
as per IS:1094.
2.
The earth fill above virgin ground level till formation level shall be
taken as a surcharge load and shall be added in the loads coming
on foundations appropriately.
3.
Maximum
safe bearing
capacity of
soil
strata
shall be
taken as indicated in geotechnical reports.
4.
Care shall be taken to avoid the foundations of adjacent buildings

or structure foundations, either existing or not within the scope of
this Contract. Suitable adjustments in depth, location and sizes
may have to be made depending on site conditions. No extra
claims for such adjustments shall be accepted by the Employer.
5.
Special attention is drawn to danger of uplift being caused by the

ground water table.
6.
Plinth level of all structures/top of tanks shall be at least 500 mm

above high flood level.
1.2.7 Design Requirements
The following are the design requirements for all reinforced or plain
concrete structures:
1.
All blinding and leveling concrete shall be minimum 100 mm thick

in concrete grade M20 for Building & minimum 150 mm thick for
Water Retaining Structure.
2.
All structural reinforced concrete shall be with a maximum 40 mm
PAGE 6 OF 281
355 of 2461
MMRDA
aggregate size for footings and base slabs and with a maximum
20 mm aggregate size for all the Water Retaining Structures &
other structural members.
3.
All liquid retaining structures shall be designed as per IS:3370.

The minimum grade of concrete shall be.M35.
4.
All new liquid retaining structures shall be form finished.
5.
For all old liquid retaining structures inside finish shall be provided
in CM 1:3 smooth cement plaster 20 mm thick and outside finish
shall be 20 mm thick sand face plaster CM 1:3. Snowcem shall
also be applied for finishing the outer surfaces.
6.
Minimum Cement Content shall be 450 kg/cu.m for.M35.
7.
The maximum free water cement ratio shall not exceed 0.40 for
all liquid retaining structures.
8.
The amount of reinforcement in each of the two directions at right

angles within each surface zone should not be less than the
minimum specified as IS:3370 or IS:456 whichever is applicable
for the type of structure.
9.
Use of pressure relief valves to reduce uplift pressure due to

ground water table shall not be allowed.
10.
All pipes and ducts laid below the structural plinth and road works
shall be surrounded with concrete of grade M20.
The following minimum thickness shall be used for different reinforced

concrete members irrespective of design thickness.
1.2.8 Minimum Cover to Main Reinforcement

PAGE 7 OF 281
356 of 2461
MMRDA
Minimum cover shall be as per relevant IS code requirements

considering severe condition of exposure.
1.2.9 Minimum Bar Diameter
Minimum bar diameter shall be as per relevant IS code.
1.2.10 Bar Spacing

The bar spacing shall be as per design and conform to IS: 456 2000.
* Bar spacing shall be provided in multiples of 25 cm.
1.2.11 Materials
1.2.11.1
General
The term materials shall mean all materials, goods and
articles
of
every kind
whether raw,
processed
or
manufactured and equipment and plant of every kind to be

supplied by the Contractor for incorporation in the Works.
Expect as may be otherwise specified for particular parts of

the works the provision of clauses in Materials and
Workmanship shall apply to materials and workmanship
for any part of the works.
All materials shall be new and of the kinds and qualities

described in the Contract and shall be at least equal to
approved samples.
As soon as practicable after receiving the order to

commence the works, the Contractor shall inform the
Employers representative of the names of the suppliers
PAGE 8 OF 281
357 of 2461
MMRDA
from whom he proposes to obtain any materials but he

shall not place any order without the approval which may
be withheld until samples have been submitted and
satisfactorily tested. The Contractor shall thereafter keep
the Employer informed of orders for and delivery dates of
all materials.
Materials shall be transported handled and stored in such a

manner
as
to
prevent
deterioration
damage
or
contamination failing which such damaged materials will be

rejected and shall not be used on any part of the Works
under this contract.
1.2.11.2
Cement
The Cement shall be Ordinary Portland Cement grade-43 /

53, conforming to the relevant BIS codes and approved by
Manufacturers Test
Certificate shall have to be furnished.
1.2.11.3
Reinforcement Steel
Reinforcement Steel shall confirm to BIS Specification 4321966 (with up to date revision) and B.I.S. Specification
1786-1985 (with up to date revision). Only Corrosion
Resistant steel shall be used. If there is none availability
of C.R. steel, then fusion bonded epoxy paint for anticorrosion on Tor Steel / TMT shall be done. Epoxy coating
shall be done in stages i.e. pre-treatment, primer coating
and final coating.
The
Contractor
shall
be
required
to produce the test certificate of the manufacturers

to the department before use of Steel for the work. No
untested steel shall be allowed under any circumstances.
The Employer, however, reserves the right to get to steel
tested at the cost of Contractor. The Epoxy coating of
PAGE 9 OF 281
358 of 2461
MMRDA
standard manufacturers i.e. Dr. Beck & Co., Ciba Atal and
Fosroc (I) ltd. shall only use as per specifications with prior
approval of the Employer.
1.2.11.4
Minimum cement Content
The minimum cement content for each grade of concrete

shall be as per table below.
S.
Grade of Concrete
Minimum Cement Content in Concrete
No.
(kg/cum of finished Concrete)
(ii)
(iii)
(iv)
M 20
M 25
M 35
330
360
450
1.2.12 Samples and Tests of Materials
The Contractor shall submit samples of such materials as may be

required by the Employer and shall carry out the specified tests directed
by the Employer at the site at the Site at the suppliers premises or at the
laboratory approved by the Employers representative. All testing
charges shall be borne by the Contractor.
Samples shall be submitted and tests carried out sufficiently early to

enable further samples to be submitted and tested if required by the
Employer.
The Contractor shall give the Employers representative seven days
notice in writing of the date on which any of the materials will be ready
for testing or inspection at the suppliers premises or at a laboratory
approved
by
the
Employers
representative.
The
Employers
representative shall attend the test at the appointed place within seven
days of the said date on which the materials are expected to be ready for
testing or inspection according to the Contractor, failing which the test
may proceed in his absence unless instructed by the Employers
representative to carry out such a test on a mutually agreed date in his
PAGE 10 OF 281
359 of 2461
MMRDA
presence. The Contractor shall in any case submit to Employer within

seven days of every test such number of certified copies (not exceeding
six) of the test results as the Employers representative may require.
Approval by the Employers representative as to the placing of orders for
materials or as to samples or tests shall not prejudice any of the
Employer powers under the Contract.
The provisions of this clause shall also apply to materials supplied under
any nominated sub-contract.
1.2.13 Orientation
The works shall be laid out within the confines of the site in order to be
compatible with the existing infrastructure facilities, inlet and outlet pipe
work /channels and nearby water bodies.
Underground services
requiring being relocated in order to accommodate the proposed site

layout shall be relocated by the Contractor to alignments approved by
the Employers Representative.
1.2.14 Roadways, Pathways and Hard standings
A comprehensive network of roadways shall be provided around the

treatment plant to link in with the existing approach road and permit
access to the plant for necessary maintenance, delivery of consumables
and personnel access.
All roads shall be of cement Concrete with
reinforcement and constructed as per the standards of the MORTH.

Vehicular access shall be provided for all Plant structures and buildings.
All roads shall be provided with drainage and shall be constructed to
prevent standing water.
Paved pedestrian access ways with minimum width of 1.8 m shall be

constructed with interlocking pavement tiles to provide a network of
logical routes inter-linking plant areas.
PAGE 11 OF 281
360 of 2461
MMRDA
Hard standing areas with concrete top shall be provided to permit the
parking of vehicles involved in the delivery of consumables from blocking
site roadways during unloading or loading.
The road system shall be
designed such that vehicles involved in the delivery of consumables can

follow a continuous route through the works and out again.
1.2.15 Site Drainage
The Contractor shall provide a site drainage system.
The system shall
comprise of the following:
Storm Water Drainage
Foul Drainage
1.2.15.1
Storm Water Drainage
Storm water drains adjacent to the existing and proposed

roads (under this Contract) shall be sized for a rainfall
intensity of 50 mm/hr., allowing for 100% runoff.
Drains
adjacent to roads shall be in stone/brick masonry (1:5) of

appropriate thickness topped with 75 mm thick M15
concrete and internally flush pointed plastered in cement
mortar (1:4) mm thick. The storm water drainage system
shall be designed to cater for the run-off from the existing
plot areas and structures, if necessary.
1.2.15.2
Foul Drainage
The foul drainage system shall accept discharge from

toilets, washrooms, offices and the laboratory. The foul
drainage system shall be conveyed to the nearby sewer
manhole or septic tank.
1.2.16 Cables and Pipework Trenches

PAGE 12 OF 281
361 of 2461
MMRDA
Cables and pipe work trenches shall generally be constructed in

reinforced concrete. However, 500mm x 500mm size or small trenches,
not on fill may be constructed in 350 mm thick brick masonry (1:4). The
trenches will be plastered internally with cement mortar (1:4) and
externally in cement mortar (1:3).
Trenches within the buildings or Plant areas shall be covered with GI

cheered plates, suitably
painted
and
that
outside
the
buildings
shall be covered with M25 remolded /branded precast RCC covers.

The trenches shall be suitably sloped to drain rainwater.
Layout of trenches outside the buildings shall allow space for

construction of future trenches where necessary with due consideration
for planning for future developments. This aspect shall be brought to the
notice of the Employer while planning the works.
1.2.17 Pipe and Ducts
RCC ducts for drainage shall have adequate cover while laid under
roads. Access shafts, where required shall not be of size less than not
less than 600 mm x 1000 mm.
All drains (except storm water drains adjacent to roads) shall be covered
and designed structurally for appropriate loads.
1.2.18 Soil Data and Ground Water Table
The Contractor shall visit the site and should carry soil investigation and
confirm the data at his own cost.
1.2.19 Buildings and Structures
All
the
building
and
structure
works
shall
generally
comply
with the following Employers Requirements unless otherwise specified

PAGE 13 OF 281
362 of 2461
MMRDA
elsewhere:
1.
All the buildings and structures are signature structures

showcasing the Employer ethos. These shall be designed,
constructed and finished internally and externally accordingly.
Wherever needed form liners and patterns shall be used for
effect. These shall be sourced from M/s. Reckli or other
equivalent brands. All building works shall be reinforced concrete
framework with concrete floors and roofs.
2.
All internal partition walls except for toilet shall be in 230 mm thick
brick masonry built in cement mortar 1:5 with transomes and
mullions.
Toilet partition walls shall be in 115 mm thick brick
masonry built in cement mortar 1:4 and shall have transomes and
mullions and shall form panels not exceeding 1200 mm x 1200
mm in size.
3.
Toilet floor slab shall be filled with brick bat cobas (broken bricks
in lime) and provided with waterproofing as per the specifications
of an approved specialist waterproofing company.
4.
The finished floor level in toilet areas shall be 25 mm below

general finished floor level elsewhere in the building.
5.
The toilet facilities shall be provided in Administration-cumLaboratory building separately for men and women which include
at least:
i)
2 Nos. Toilet (1 no. for men and 1 no. for women) with
white porcelain Orissa pan minimum 580 mm long with
flushing cistern of 10 litres capacity.
ii)
2 Nos. wash basins (1 no. for men and 1 no. for women) of
size 510 mm x 400 mm in white porcelain with inlet, outlet
and overflow arrangements.
PAGE 14 OF 281
363 of 2461
iii)
MMRDA
2 Nos. mirrors (1 no. for men and 1 no. for women) of size
400 mm x 600 mm wall mounted type fitted over wash
basins.
iv)
2 Nos. plastic liquid soap bottles (1 no. for men and 1 no.
for women)
v)
2 Nos. chromium plated brass towel rails (1 no. for men

and 1 no. for women) minimum 750 mm long.
vi)
All stopcocks, valves and pillar cocks shall be heavy-duty

chromium plated brass.
vii)
All fittings such as P or S traps, floor traps, pipes,

downtake pipes etc.
viii)
The sewage from toilet blocks shall be led to the nearest

sewerage network sewer line or septic tank.
6.
All staircases shall have 25 mm thick granite slabs for treads and
for risers set in cement mortar or lime mortar to give an overall
thickness of 50 mm.
7.
All floor cut-outs and cable ducts, etc. shall be covered with
precast concrete covers in outdoors areas and mild steel
chequered plates of adequate thickness in indoor areas.
All
uncovered openings shall be protected with galvanised MS hand

railing. (S.S, railings)
8.
All staircases shall be provided with MS galvanised and MS hand

railing for protection. . (S.S, railings)
9.
For the entire finished roof surface shall have adequate slope to
drain quickly the rainwater to rainwater down take inlet points.
PAGE 15 OF 281
364 of 2461
10.
MMRDA
For roofing drainage, CI rainwater down takes with CI bell mouth

and MS grating at top shall be provided. For roof areas up to 40
sq. minimum two nos. 100 mm diameter down take pipes shall
be provided. For every additional area of 40 sq.m. or part thereof,
at least one no. 100 mm diameter downtake pipe shall be
provided.
11.
Top surfaces of chajjas and canopies shall be made waterproof

by providing a screed layer of adequate slope or application of an
approved roof membrane and sloped to drain the rainwater.
12.
All doors, windows, rolling shutters shall have lintels above.

Chaija protection to lintels on external walls shall be such as to
prevent the rainwater splashing into the building. The minimum
width of chajja for doors, windows, and rolling shutter shall be 750
mm, 600 mm, and 900 mm respectively.
13.
All windows and ventilators shall have 25 mm thick Tandoor/Kota

stone stills bedded in cement mortar (1:3) (Granite)
14.
All concrete channels and ducts use for conveying liquid shall
have inside width not be less than 500 mm. All open channels
shall be provided with hand railings.
Also all such channels,
which are more than 1000 mm above finished plot level, shall be
provided with walkways for access.
15.
Kerbs
to
be
provided
below
the
hand
railing
on
the
catwalks/pathways should be as per relevant sections of Factory

Act.
16.
Wherever equipment and machinery are to be moved for

inspection, servicing, replacement etc., suitable movable gantry of
minimum capacity of 2 tons or more as required shall be provided
with monorail and operating equipment.
PAGE 16 OF 281
365 of 2461
17.
MMRDA
The design of buildings shall reflect the climatic conditions

existing on site. Process buildings shall be as far as is possible
permit the entry of natural light.
18.
The Laboratory, Chlorine House and office building shall be

provided with a sink with two drinking water taps of 20 mm
size with adequate inlet and outlet connections.
19.
The sidewalls of buildings shall, except those used for storage

and handling of Chlorine gas comprise at least 15% ventilation
areas. Ventilated brickwork or louvers shall not be used where the
ingress of driven rain could affect plant or stored materials.
20.
All walkways, staircase, platforms etc., shall be minimum 1200

mm wide and will be provided with hand railing on one or both
sides as required.
21.
The floor shall generally be made of 150mm thick concrete slab

on grade with 230 mm thick rubble soling and polyethylene sheet.
The grade slab shall be provided with TOR 8 mm reinforcement
Bars at 200 mm c/c both ways.
22.
All hardware fittings and fixtures for doors, windows and louvers
(e.g. Hinges, bolts, locks, latches, stay doorstops, door closers,
floor springs) shall be heavy type matching to the size and weight
of the door/window/ventilator shutters. These shall operate easily
without hindrance secure properly without jamming, require
nominal maintenance durable under prevailing site/weather
conditions.
23.
Suitable steps and/or ramp with overhead RCC Canopy shall be

provided as per requirement, at the entrances of the buildings.
24.
1,000 mm wide Plinth Protection (Apron) shall be provided
PAGE 17 OF 281
366 of 2461
MMRDA
all around the Building/Sheds.
1.2.20 Anticorrosive Treatment
All the water retaining RCC structures shall be given anticorrosive

treatment. The wall from inside shall be coated with polymer
anticorrosive paint.
It shall be elastomeric (450% elongation),
thermoplastic, fire retardant. The coating skin shall have tensile strength
of 18 to 21 kg/cm2. It shall be antifungal and antibacterial. The polymer
paint shall be of Meta-chem or equivalent make as approved by
1.2.21 Pressure Grouting
1.2.21.1
Products
All components used for grouting repair system are to be

from one of the approved makes of polymers.
All
components are to be of the same make. No components

of different makes can be used in conjunction with each
other.
MC Bauchemie or equivalent product shall be
used. The product shall only be from the approved list of

companies. Proper care is to be taken when using the
material to maintain the required consistency and purity.
Only polymer latexes based on Styrene butadiene (SBR),

acrylics, polyvinyl acetate or epoxies can be used. The
latex should have solid to a maximum of 50% and
minimum of 40%.
The physical chemical and structural
properties of the material used are to be submitted and

specific approval to be seek for the material/system, to be
used.
1.2.21.2
Surface Inspection and Preparation
PAGE 18 OF 281
367 of 2461
MMRDA
All surfaces to be treated are to be exposed to the base

level with removal of all claddings, plasters, facades,
waterproof layers etc.
The surface is to be examined for
surface cracks, crevices and spalls and honey combing.
Concrete surface to which treatment is to be applied shall

be freshly exposed parent concrete free of loose and
unsound materials.
Prepare surfaces by mechanical
abrasion unless prohibited by environmental limitations in

which case acid etching may be used.
Mechanical abrasion Use sandblasting or scarifying or
water blasting or other approved means.
ACID ETCHING - Etch surface with a commercial

grade (22
deg.
Baume) of hydrochloric acid diluted at a
ratio of 10:90 to 20:80.
After this application, scrub
surface with a stiff bristled broom, or similar implement.

Immediately after foaming action of acid has subsided,
flush surface with water jets until all residue is removed.
Repeat procedure until laitance is completely removed.
Wash such areas with water at least three times and allow
to air dry prior to further treatment. This method of cleaning
is to be used only in exceptional cases and under normal
cases permission will not be given for use of this method.
Inspection of concrete surfaces prior to mortar application.
Inspect all concrete surfaces prior to application of mortar

to ensure that requirements of this Article are met.
Surfaces shall be free of any deleterious materials such as
laitance, curing compounds, dust, dirt and oil. Materials
resulting, from surface preparation specified shall be
removed.
PAGE 19 OF 281
368 of 2461
MMRDA
All concrete surfaces shall be dry
unless a water
insensitive coating is used. Surface temperature shall be

at least 40F to permit wetting of concrete surface by
polymer coating.
Valuate moisture content for concrete by determining if

moisture will collect at surfaces. This may be accomplished
by taping a 4 x 4ft polyethylene sheet of concrete surface.
If moisture collects on underside of polyethylene sheet
before polymer would cure, then all concrete to dry
sufficiently.
Drying of the surfaces can be accomplished
by either heating the surfaces by blow lamps or by use of

sawdust, sand or any other means so that the surface is
bone-dry.
1.2.21.3
Identification of Methods of Grouting
1.2.21.3.1
For All Surfaces having Cracks / Crevices:
Locate
the
cracks
by
either
surface
inspection or by scrubbing the surface.
In
case the cracks are not visible to naked eye

use compressed air to clear marks. Having
identified the cracks use light chisel or
mechanical/electrical saw to clear the crack
up to the depth of the crack.
In case
widening of the crack is necessary to reach

the depth of the crack it is advisable to do so
at this juncture.
After
cleaning/widening
the
crack
use
compressed air/water jet to clean the opened

crack surface.
Ensure that the surface is
dried in case water jet is used.
PAGE 20 OF 281
369 of 2461
MMRDA
A method of grouting thorough rows of grout

nipple is to be adopted for all such cases.
1.2.21.4
Grouting for Honey Combed Surfaces
For surface, which exhibits honeycombed concrete, the

surface has to maintained in its dry state and a method of
grouting through triangular grout nipples is to be adopted.
The opposite side to the grouting surface has to be sealed

for flowing grout by either impervious cement plaster or by
use of proper sealant as specified in the material to be
used for grouting.
1.2.21.5
Size and Spacing of Nipples
To determine the size of nipples, use a standard caliper or

a metric scale and measure the width of the opened crack.
The size of the nipple to be fixed within the crack has got to
be minimum half the surface width of the crack measured
above, but should not exceed s15 mm in dia.
The nipples to be used should be of metal with one end

tapered and thickness should be sufficient to withstand 5 m
head of water.
The spacing for the crack depends
inversely to the width of the crack and will not exceed more
than 300 mm c/c and will not be less than 125 mm c/c.
The member of nipples along the crack will always be a
less than two rows of nipples that needs to be fixed parallel
to the crack at the same distance as the nipples spacing in
the crack so as to form equilateral triangle with the apexes
in the crack.
1.3
Earthwork and Excavation
PAGE 21 OF 281
370 of 2461
MMRDA
1.3.1 Relevant IS Codes
IS: 1200
: Method of Measurement for Building Works
IS: 3764
: Safety code for Excavation Work
IS: 3385
: Code of practice for measurement of civil engineering

works
IS: 2720
: Part II - Determination of Moisture Content
: Part VII - Determination of Moisture content dry density

relation using light compaction
: Part VIII - Determination of Moisture Content Dry

Density using heavy compaction
:
place,
Part XXVIII - Determination of Dry Density of soils, in

by the sand replacement method
Part XXIX - Determination of Dry Density of soils, in

place, by the core cutter method.
1.3.2 Excavation
1.3.2.1
Definitions
The following terms shall have the meanings hereby assigned

to them:
Top Soil means any surface material, including turf,

suitable for use in soiling areas to be grassed or
cultivated
Excavation means excavation in open cut (excluding
PAGE 22 OF 281
371 of 2461
MMRDA
trench excavation) down to levels required as per

approved Drawings or otherwise as being the
general levels after completion of excavation
1.3.2.2
Site Clearance
All area of the Site, marked in the Specification Drawings

shall be cleared to the extent required by the Employers
representative of all buildings, walls, gates, fence and other
structure and obstructions of all bushes, hedges, trees,
stumps, roots and other vegetation except for trees marked
for preservation. Material so cleared shall so far as suitable
be preserved and stacked will be the property of Employer
for further use but shall otherwise be burnt to ash or
disposed of the Site as directed by the Employers
representative.
Before starting the work, the site shall be cleared of:
1.
All shrubs, grass, and other vegetation including

large and small bushes, all stumps, removal of
roots, cutting and disposal of small trees up to 300
mm girth etc.
2.
All the tress having girth above 300 mm. (the girth
shall be measured at a height of 1.5 m above the
ground level) by felling, logging, fashioning of timber
and billeting of all branches, trunks etc.
including removal of all roots etc.
are
complete as
directed.
3.
All serviceable reclaimed material shall be stacked

separately at the site shown by the Employers
representative near the site of excavation and/or
transported as directed.
PAGE 23 OF 281
372 of 2461
4.
MMRDA
After the tree is cut and roots taken out the potholes
formed shall be filled with good earth in 250mm
layers and consolidated unless directed by the
Employers representative otherwise.
The trees
shall be cut in suitable piece as instructed by the

1.3.2.3
General Excavation
1.
General excavation means excavation in all types of

solid like dry soil, wet soil, murum, boulders, hard
strata, rock of any type at different depth and lift
required for structures and from borrow areas, and
shall
not
include
trench
excavation.
General
excavation may also include miscellaneous isolated

lengths of trenches beneath or adjacent to other
structures, trial pits along the structural layout or
otherwise.
2.
The ground shall be excavated by such methods

and to such dimensions and
Depths as shall allow
for the proper construction of the works and safety

of personnel and equipment used on excavation.
Slopes required for stable formation of sides shall
be provided.
3.
The excavation in earth, murum, boulders, soft and

hard rock shall be carried out to the correct levels
required and specified and no tolerance, plus or
minus,
shall
be
permitted.
However,
if
any
depressions/Loose pockets are formed due to

removal of boulders, they shall be made good by
filling with 1:5:10 concrete up to the bottom layer of
the footing/raft.
PAGE 24 OF 281
373 of 2461
4.
MMRDA
Payment for
all types of excavation shall be made
by detailed Measurement supported by ground

levels recorded prior to and after completion of
excavation, subject to the limit for payment indicated
by the slopes of excavation indicated in the
specification drawing.
Any
additional
excavation will be at the Contractors expense,

unless specifically approved by the Employers
representative.
Measurement for excavation shall
be done all as per dimensions of P.C.C. given in

design drawings & specifications.
For concrete
foundations same shall be paid on least dimensions

at bottom and Contractor shall cover any extra
excavation required for workspace, supports etc.
while quoting.
5.
As far as possible excavation should be done by

means of mechanical equipment.
6.
It will be the responsibility of the Contractor to obtain

prior permissions from
The competent authority to
use blasting device, if at all to be resorted to and the

license are to be obtained for the same.
7.
The charge of blasting required shall be well

decided with the expert, to avoid any damage
the
surrounding
such
damage
public
or
property.
to
additional
However, for
to
any
the surrounding property or

excavation
shall
be
the
Contractors responsibility and the risks what so

ever arising from the same will have to be borne by
the Contractor.
1.3.2.4
Lift and Lead
PAGE 25 OF 281
374 of 2461
MMRDA
Lead for deposition of the excavated materials should be

5000 m. For the purpose of measurement of lead, the area
to be excavated or filled or area in which excavated
material is to be deposited /disposed of shall be divided
into suitable blocks and for each of the blocks, the distance
between centerlines shall be taken as the lead which shall
be measured by the shortest straight line route on plan and
not the actual route taken by Contractor. No extra
compensation is admissible on the grounds that the lead
including that for borrowed material had to be transported
over marshy or kuccha land route.
1.3.2.5
Excavation in Hard Rock
Excavation in hard rock may be done either by blasting or

chiseling or by mechanical means depending upon the site
conditions. When excavation has reached within 300 mm
of the required formation level, further excavation shall be
carried out carefully either by blasting (if as directed by the
Employers representative) or chiseling. Where blasting is
resorted to, small charges shall be used to minimize
occurrence of heavy over-cuts. The Contractor shall make
every effort to carry out the excavation to correct formation
level as far as practicable. In order to minimize the over
break and loosening of materials at the finished surfaces,
final cutting for the last 450 mm to 600 mm in rock shall be
carried out by controlled blasting and trimming with the
help of pneumatic or other power tools. Unless otherwise
specified, the over break shall not exceed 75 mm. Stacks
shall not be of width greater than 1.5 m wide or of height
less than one meter.
1.
Blasting shall be carried out by the licensed person

only if permitted by the Employers representative
PAGE 26 OF 281
375 of 2461
MMRDA
for which Contractor shall obtain the required

permission from the Employers representative.
2.
The Contractor shall provide a method statement

and shall comply fully with the requirements of this
clause, or any direction, order, requirement or
instruction given by the police department or any
other relevant authorities as required by the law.
3.
Contractor shall submit Blasting plan to the

Employers representative and take approval for the
same on daily basis
4.
Contractor shall plan the blasting activities in well

advance and convey same to the Project In-charge
so as to co-ordinate with all the work groups at site.
5.
If blasting is not permitted then Contractor shall

excavate the rock by manual methods or by
mechanical mean like needle breaker, proclaim,
rock splitter etc. without any extra cost.
This includes rock, which is easily excavated by blasting,

but due to close proximity of structures or any other reason
that the Employers representative may consider, will have
to be excavated by chiseling.
Hard rock excavation means excavation in all types of rock

at any depth or lead required as per design and drawings.
The Contractor shall ascertain the level and type of rock by
inspecting site, trial pits or trial bore at his cost.
It should be noted that this clause does not override the

Contractor's obligation to satisfy the requirement of the
relevant authorities but sets out the extent to which the
PAGE 27 OF 281
376 of 2461
MMRDA
Employers representative will exercise his control in

approving the Contractor's use of explosive to ensure that
explosive is always used in a safe manner. It is the
Contractor's sole responsibility to ensure that his method of
blasting is safe, that all statutory and imposed limitation are
adhered to, and to obtain a permit to use explosive from
the relevant authorities and to comply with the condition of
issue of the permit.
The Contractor shall be solely responsible for obtaining the

necessary licenses for the procurement, possession,
transport, storage and handling of explosive and for
ensuring the validity of such licenses at all times. Before
starting work, the Contractor shall satisfy the Employers
representative that all the requirement permits are in order
and that this category of work is adequately covered in the
policies of insurance.
Explosives
shall
be used in the quantities and manner
recommended by
the manufacturers. All necessary
precautions shall be taken to preserve the materials below

in the soundest possible condition and also beyond the
lines of all excavations.
Blasting by means of drill holes, tunnels or any other

similar method shall be the responsibility of the Contractor.
The Contractor shall take all necessary precautions during

blasting operations to ensure that no injury is caused to
persons or damage to property or to the finished works.
Shots shall be properly loaded and capped and only
appropriate charges shall be used in each hole.
a)
Storage and Transport
PAGE 28 OF 281
377 of 2461
Proper
MMRDA
building
or
magazine,
with
separate
compartment for detonators in suitable positions for

the storage of explosive in the manner and
quantities to be approved, shall be provided.
Separate vehicles or vessels for detonators shall
also be used for the transportation of explosives.
The prevention of any unauthorized issue or
improper use of any explosive brought on to the site
shall be the responsibility of the Contractor and only
experienced licensed short firers shall be employed
to handle the explosive for the purpose of the work
the relevant security regulations dealing with the
storage, handling and transport of explosives shall
be complied with.
b)
Safety
The Contractor shall provide an approved system of

warning and preparing the general public and all site
personnel of an impending blast by both audible &
visual means and shall ensure that the blasting area
is cleared of all personnel immediately prior to
blasting. This system shall comply with all statutory
requirements. The Contractors attention Is drawn
to the need to devise adequate system for warning
and clearing the public from specified areas during
blasting operations and to prevent persons entering
the blasting area.
When blasting is near to the proximity of existing

public and private thoroughfares, traffic is to be
stopped just prior to firing. The operation is to be
carried out in close cooperation with the police
department and in such a way as to cause minimum
traffic delay.
PAGE 29 OF 281
378 of 2461
All
MMRDA
operations
involving
suspended on the approach
explosives shall be
of
a thunderstorm
and shall not be resumed until the storm has clearly

passed.
Blasting screens shall be erected to conform with

the permit conditions. Public roads, private roads
and property adjacent to the site and services within
the site area shall be protected by rock fall fences
which will be subjected to approval of Employers
representative.
The Contractor shall take all necessary precautions

to avoid damage to permanent and temporary works
already completed.
In all cases, delay blasting
techniques will be mandatory with the quantity of

explosives restricted to ensure that the peak particle
velocity generated does not exceed the peak
particle velocity of each component of the safe limits
of the nearest structure subject to vibration damage.
All operations shall stop when these limits are
exceeded until reports are made available to the
Employers representative that no damage has
occurred and will not occur or corrective action has
been taken to lower the vibration. The sound level
limit in areas where site personnel or public can
access during blasting operation must not exceed
110 dB.
The Contractor may not be permitted to use

explosives in areas of the site immediately adjacent
to
pylon
positions
and
highways.
Particular
limitations may apply in such areas depending on

the Contractors proposed method of working and a
PAGE 30 OF 281
379 of 2461
MMRDA
detailed
method
statement
will
therefore
be
required. The method statement shall cover the

methods of excavation and protection systems
proposed, all of which shall be subjected to the
approval of the relevant
authorities and
the
In all such cases particular attention should be paid

to the requirements stated above and effects on
these structures and installations shall be closely
monitored and the quantities of explosives limited
accordingly.
Drilling rigs for shot hole shall be of the hydraulic

type fitted with efficient silencers and with means of
dust separation.
The Contractor may report to any of the following

methods to excavate rock by chiseling:
Wedging by means of crowbars, pick axes or

pneumatic drills
Heating and quenching
Controlled blasting with a small charge just

sufficient to make a crack in rock which will
be subsequently removed by wedging
No extra payment shall be made for removal

of rock by chiseling and controlled blasting
1.3.2.6
Excess excavation to be made good
The Contractor, at his own expense, shall, if directed,

PAGE 31 OF 281
380 of 2461
MMRDA
remove from the Site all excess material resulting from

excess excavation and shall make good the same with
such kind of fill material or in such class of concrete as
may
be
reasonably
required
by
Employers
the
representative having regard to the circumstances.
1.3.2.7
Stripping Top Soil

Where ordered by the Employers representative, top soil
shall be stripped to such depths and over such areas as he
may direct, as a separate operation prior to any further
excavation, which may be required.
1.3.2.8
Supporting Excavations
1.
The Contractor shall properly support the sides and

ends of all excavations to prevent any fall or run
from any portion of the ground outside the
excavation and to prevent settlement
or
damage
to structures adjacent to the excavation. Any

excavation necessary to provide space for such
support or other working space shall be carried out.
If, for any reason, any portion of the bottoms, sides
or ends of any excavations shall give way, the
Contractor shall at his own expense take all
necessary remedial measures including the extra
necessary excavation and removal of excess
material.
2.
Where the Contractor proposes and is permitted by

the
Employers
representative
to
perform
excavations with sloping faces (other than sloping

excavations shown on the Drawings or required as
permanent features of the Works) and without
shoring, the excavated faces shall be to stable
PAGE 32 OF 281
381 of 2461
MMRDA
slopes and heights.
1.3.2.9
Trimming Excavations
1.
When excavating to specified or required levels for

the foundation of any structure or to specified or
required limits for the face of any structure required
to abut undisturbed
ground, the Contractor
shall
not excavate the last 150 mm until immediately

before
commencing
the
constructional
work,
except where the Employers representative shall

permit otherwise. After getting the permission for
the commencement of the construction, if the
Contractor delays on any account & the formation
level gets damaged he will have to do further
excavation up to 150 mm or as per Employers
representative instructions at his own account.
2.
Before commencement of any constructional work

all shattered and loose materials shall be removed
from the excavations by hand so as to ensure that
the work rests on a solid and perfectly clean
foundation or abuts against solid ground.
1.3.2.10
Inspection by the Employers representative
1.
When the specified levels or limits of excavation are

reached the Employers representative will inspect
the ground exposed, and if he considers that any
part of the ground is by its nature unsuitable he may
direct the Contractor to excavate further.
Such
further excavation shall be refilled to the specified

levels or limits with concrete, selected excavated
material or selected imported material as directed
by the Employers representative.
PAGE 33 OF 281
382 of 2461
2.
MMRDA
Should the material forming the bottom of any

excavation, while acceptable to the Employers
representative at the time of his inspection,
subsequently become unacceptable to him due to
exposure to weather conditions or due to flooding or
have puddles, soft or loss during the progress of the
works, the Contractor shall remove such damaged,
softened or loosened material and excavate without
any extra cost.
1.3.2.11
Disposing Excavated Material
All excavated material shall remain the property of the

Employer. The Contractor shall ensure that no excavated
material which is suitable for and is required for re-use in
the Works is transported unless so ordered by the
1.3.2.12
Back-Filling General Site Grading and Sand Filling
a)
Fill Material
1.
All fill material whether such material is

brought
from
outside
borrow
areas
or
excavation within the site, will be subject to

Employers
carrying
representative
required
laboratory.
tests
approval
at
Soil
after
testing
Notwithstanding any approval
given to the fill material or borrow areas from

which fill material is proposed to be brought,
the Employers representative reserves the
right to reject such material which does not
meet
the
specification
requirements
or
unsuitable for the purpose for which it is

PAGE 34 OF 281
383 of 2461
MMRDA
intended.
2.
Roads, of a temporary nature, required to be

constructed
for
access
and
for
movement of men, materials, equipment,

transport
vehicles,
vehicles
carrying
fill
material, etc. to or over borrow areas and or

to or over areas on which fill has to be
deposited
shall
Contractor.
be
constructed
by
the
Such access roads shall be
maintained in good condition during all

seasons to ensure completion of the work
according to the time schedule. No separate
payment shall be made for such items of
work.
b)
Backfilling
1.
Excavated material used as back filling to

excavations or completed structures shall be
free from rubbish, vegetation, clods and
lumps
and
shall
be
approved
by
the
The approved
materials shall be placed in layers, not

exceeding 150
mm in
depth
before
compaction and shall be compacted with

watering, consolidating and ramming.
The
maximum boulder size shall be of 150 mm for

filling material.
2.
Soft material shall not be used as back filling

around structures in
rock. The Contractor
shall backfill such excess excavation with

concrete; rubble, stone or rock fills as
directed by the Employers representative.
PAGE 35 OF 281
384 of 2461
MMRDA
Filling other than concrete shall be placed in

layers not exceeding 150 mm in thickness,
shall be thoroughly compacted and have
adequate fined content to fill the voids.
3.
Should the material being placed as back

filling, while acceptable at time of selection,
become unacceptable to the Employers
representative
due
to
exposure
to
weather conditions or due to flooding or have

become puddles, soft or segregated during
the progress of the works, the Contractor
shall remove such damaged, softened or
segregated material and replace it with fresh
approved material at his expense.
4.
The Contractor shall while placing the back

filling make due allowance for
any
settlement that may occur, remove any

excess material or make up any deficiency by
back filling to the specified levels. As a rule,
material to be back filled shall be stacked
temporarily at a suitable place.
5.
General Site Grading: Site grading shall be

carried out as directed by the Employers
representative.
Excavation shall be carried
out as specified in the specification.
Filling
and compaction shall be carried out as

specified under (6) of this Clause unless
otherwise indicated below.
6.
The approved material shall be placed in

layers not exceeding 150 mm in depth before
compaction and shall be compacted to 90%
PAGE 36 OF 281
385 of 2461
MMRDA
of Proctor Density with water contain at OMC.
7.
The Contractor shall protect the earth fill from

being washed away by rain or damaged in
any other way.
Contractor
Should any slip occur, the
shall
remove
the
affected
materials and make good the slip without any

extra cost.
8.
The
fill shall be carried
out
to
such
dimensions and levels as directed by the

Employers
representative,
after
the
compaction.
9.
Sand filling below Plinth and other places.
Back filling shall be carried out with sand at places

as directed by the Employers representative.
The
sand used shall be clean, medium grained and free

from impurities.
The filled-in-sand shall be kept
flooded with water for 24 hours to ensure maximum

consolidation.
Any temporary work required to
contain sand under flooded conditions shall be to

the Contractors account.
The surface of the
consolidated sand shall be dressed to the required

level or slope.
Construction of floors or other
structures on sand fill shall not be started until the

Employers
representative
has
inspected
and
approved the fill.
Where
specified
in
the
schedule
of
works,
compaction of the plinth fill shall be carried out by

means of 12 tons rollers smooth wheeled, sheep
foot or wobbly wheeled rollers.
PAGE 37 OF 281
386 of 2461
MMRDA
A smaller weight roller may be used only if permitted

by Employers representative. As rolling proceeds
water
sprinkling
shall
be
done
to
assist
consolidation. Water shall not be sprinkled in case

of sandy fill.
The thickness of each unconsolidated fill layer can

in
this
case
up
to
300
Employers
mm.
representative will determine the thickness

layers
in
which
fill
has
to
be
of
consolidated
depending on the fill material and equipment used.
Rolling shall commence from outer edge and

progress towards the centre and continue until
compaction is to the satisfaction of the Employers
representative, but in no case less than10 passes of
the roller will be accepted for each layer.
The compacted surface shall be properly shaped,

trimmed and consolidated to an even and uniform
gradient. All soft spots shall be excavated and filled
and consolidated.
At
some
possible
locations
to
use
areas
rollers
it
may
because
not
of
be
space
restrictions etc. Contractor shall then be permitted

to use pneumatic tampers, rammers etc. and he
shall ensure proper compaction.
1.3.2.13
Fill Density
The compaction, only where so called for, in the

schedule of quantities /items shall comply
specified
moisture
(proctor/modified
proctor)
with
the
density
at
content differing not more than 4 percent
PAGE 38 OF 281
387 of 2461
from
MMRDA
optimum
moisture
content.
Contractor
shall
demonstrate adequately at his cost, by field and laboratory

tests that the specified density had been obtained.
1.3.2.14
Local Rules and Regulations
1.
The
the
Contractor
local
rules
shall
and
familiarize
himself
with
regulations governing the
excavation, quarrying operations, etc. and the work

shall be carried out strictly in accordance with rules
and regulations, if any.
Whenever a quarry is
required to be opened in connection with the

execution of work covered under this Contract, the
Contractor shall investigate that it shall yield stones
and other materials such as sand, murum, soil etc.
of approved quality and shall satisfy him as to
the availability in desired quantity. He shall supply
necessary quantity of sand, stone, metal aggregate
etc.
for carrying out tests as desired by the
Employers representative and well in advance of its

use so as to carry out tests and to get approval. The
cost of opening and operating the quarry & royalties
and ant other charges shall be borne entirely by the
Contractor.
2.
The Contractor shall obtain necessary permission

from the concerned authorities before opening
the quarry. In case of quarries in private land
on payment of whatever charges as may be due to
the Employer.
1.3.3 Dewatering
a.
All excavations shall be kept free of water.
Grading in
the
vicinity of excavations shall be controlled to prevent surface

PAGE 39 OF 281
388 of 2461
water
running
MMRDA
into
excavated
areas. The Contractor
shall
remove by pumping or other means approved by Employers

representative
any
sub-soil water
excavations
water
inclusive
accumulated
de-watered
of
in excavation
until
the
rain
water
and
and
keep
all
foundation
work
is
completed and back filled. Sumps made for dewatering must

be kept clear of the excavations/trenches required
for further
work. Method of pumping shall be approved by Employers

representative; but in any case, the pumping arrangement shall
be such that there shall be no movement of sub-soil or blowing
in due to differential head of water during pumping.
Pumping
arrangements shall be adequate to ensure no delays in

construction.
b.
When there is a continuous inflow of water and quantum of water

to be handled is considered in the opinion of Employers
representative, as large, well point system: Single- stage
or
Multi-stage shall be adopted. Contractor shall submit to the

Employers representative his scheme of well pointing system
including stages, the spacing, number and diameter of well
points, headers etc. and the number, capacity and location of
pumps for approval.
c.
The quoted prices are inclusive of dewatering by any means

and no extra payment is allowed for excavation in wet condition.
1.3.4 Timber Shoring
The Timber Shoring shall be as per 3764-1966 safety code for

excavation work.
a.
Close timbering shall be done by completely covering the sides of

the trenches and pits generally with short, upright members called
polling boards. The boards shall generally be placed in position
vertically side by side without any gap on each side of
the
PAGE 40 OF 281
389 of 2461
MMRDA
Excavation and shall be secured by horizontal walings of

strong wood at maximum 1.2 m spacing and suitably strutted. If
the soil is very soft and loose, the boards shall be placed
horizontally against each side of the excavation and supported by
vertical walings, which in turn shall be suitably strutted.
The lowest boards supporting the sides shall be taken into the
ground and no portion of the vertical side of the trench or pit shall
remain exposed, so as to render the earth liable to slip out.
b.
The shoring material shall not be sizes less than those specified
below unless steel sheet piling is used or unless otherwise
approved by the Employers representative in writing:
c.
Planks
5 cm x 25 cm
Waling pieces
Struts
10 cm x 20 cm
15 cm x 20 cm
Timber shoring shall be close or open type, depending on the

nature of soil and the depth of pit or trench.
The type of
timbering shall be as approved by Employers representative. It

shall be the responsibility of the Contractor to take all necessary
steps to prevent the sides of excavations, trenches, pits, etc.,
from collapsing.
d.
Timber shoring may be required to keep the sides of excavations

vertical to ensure safety of adjoining structures or to limit the
slope of excavations, or due to space restrictions or for
other reasons. Such shoring shall be carried out, except in
an emergency, only under instructions from the Employers
representative.
e.
The withdrawal of the timber shall be done very carefully to

prevent the collapse of the pit or trench. It shall be started at one
end and proceeded systematically to the other end. Concrete or
masonry shall not be damaged during the removal of the
PAGE 41 OF 281
390 of 2461
MMRDA
timber. No claim shall be entertained for any timber, which can

not be retrieved.
f.
In the case of open timbering, the entire surface of the side

of trench or pit is not required to be covered. The vertical
boards of minimum 25 cm X 5 cm sections shall be spaced
sufficiently apart to leave unsupported strips of maximum 50
cm average width. The detailed arrangement, sizes of the timber
and the spacing shall be
subject
In
to
the
approval
all
other
of
the
respects,
the
specification for close timbering shall apply to open timbering.
g.
In case of large pits and open excavations, where shoring

is required for securing safety of adjoining structures or for any
other reasons and where the planking across sides of
excavations/pits cannot be strutted against, suitable inclined
struts supported on the excavated bed shall be provided.
Load from such struts shall be suitably distributed on the bed
to ensure no yielding of the strut.
1.3.5 Rain Water Discharge
1.3.5.1
Scope
The scope covers the drainage of the rainwater in excavated

areas.
Grading in the vicinity of excavation shall be such as

to
exclude
rain/surface
water draining into excavated
areas. Excavation shall be kept clean of rain and such

water as the Contractor may be using for his work by
suitably pumping out the same at no extra cost to the
Employer. The scheme for pumping and discharge of
such
water
shall
be approved by the Employers
representative.
PAGE 42 OF 281
391 of 2461
1.4
MMRDA
Anti Termite Treatment
Applicable IS
IS: 6313 1981
: Code of Practice for Anti Termite Measure in

Buildings
IS: 6313 (Part I) 1981
: Construction Measures
IS: 6313 (Part II) 1981
: Pre-Construction Chemical Treatment

Measures
IS: 6313 (Part III) 1981
: Treatment for existing Buildings
1.4.1 Delivery, Storage and Handling
Deliver pesticides to the project site in sealed and labeled containers in

good condition as supplied
by the
Store,
use
handle,
and
manufacturer
pesticides
or
formulator.
in accordance with
manufacturers labels. Labels shall bear evidence of registration as per

the IS or appropriate regulations.
1.4.2 Safety Requirements
Formulate, treat, and dispose of termiticides and their containers in

accordance with label directions.
Draw water for formulating only
from sites designated by the Employers representative, and fit the

filling hose with a backflow preventer meeting local plumbing codes or
standards. The filling operation shall be under the direct and continuous
observation of a Contractors representative to prevent overflow.
Secure pesticides and related materials under lock and key when
unattended. Ensure that proper protective clothing and equipment are
worn and used during all phases of termiticide application.
Dispose of
used pesticide containers off Government property

PAGE 43 OF 281
392 of 2461
MMRDA
1.4.3 Warranty
Furnish
an
three-year
written
warranty
against
infestations
or
reinfestations by subterranean termites of the buildings or building

additions
inspections
constructed
of
the
under
this contract.
building(s) or
building
Perform
addition(s).
annual
If
live
subterranean termite infestation of subterranean termite damage is

discovered during the warranty period, and the soil and building
conditions have not been altered in the interim, the Contractor shall:
1.
Retreat the soil and perform other treatment as may be necessary

for elimination of subterranean termite infestation;
2.
Repair damage caused by termite infestation; and
3.
Re-inspect the building approximately 180 days after the

pretreatment.
1.4.4 Quality Assurance
1.4.4.1
Application Report
Upon completion of this work, submit Pest Management

Report, Identifying target pest, type of operation, brand
name
and
manufacturer
of
pesticide,
formulation,
concentration or rate of application used. Maintain daily

records using Pest Management Maintenance Record, and
submit copies of records to the Employers representative.
1.4.5 Products
1.4.5.1
Pesticides
Termiticides bearing current registration or approved

PAGE 44 OF 281
393 of 2461
MMRDA
for such use by the appropriate agency of the host

country.
The
Contractor
shall
comply
with
the
requirements on Contractors licensing, certification, and

record keeping.
1.4.5.2
Execution
a)
Verification of Conditions
At the time of application, the soil shall have

sufficiently low moisture content to allow uniform
distribution of the treatment solution throughout
the soil.
Do not make applications during or
immediately
conditions
following
may cause
heavy
runoff
rains
and
or
when
create
an
environmental hazard.
1.4.5.3
Application
a)
Treatment Area
Apply termiticide to soil material which will be

covered by or lie immediately adjacent to the
buildings and structures so as to provide a
protective barrier against subterranean termites.
b)
Treatment Application
Apply termiticide as a coarse spray and in such

matter as to provide uniform distribution onto the
soil surface. Apply treatment prior to placement
of a vapor barrier or waterproof membrane and
prior to concrete pouring. Where treated soil or fill
material is not
barrier
or
to
be
waterproof
covered
with
membrane,
vapor
exercise
PAGE 45 OF 281
394 of 2461
MMRDA
adequate precautions to prevent its disturbance.

If soil or fill material has been disturbed after
treatment,
retreat
as
specified
above
before
placement of slabs or other covering structures.

Coordinate treatment of the soil on the exterior
sides
of
foundation
walls, grade beams, and
similar structures with
final grading and planting
operations so as
to avoid
disturbance
treated barriers by such operations.
of
the
Observe
manufacturers warnings and precautions in the

handling and use of such materials.
Exercise
precaution that these chemicals do not enter

water supply systems or potable water supplies
or aquifers,
and
that
they do
not
endanger
plants and animals as well. Notify the Employers

representative at
least
48
hours
prior
to
beginning of treatment and perform formulating,

mixing, and application in the presence of the
Employer.
1.4.5.4
Rates and Methods of Application
Apply in accordance with the pesticide label. Provide

maximum application or dosage rates.
Resolve conflict
between this specification and label direction in favor

of the label.
1.5
Concrete and Allied Works
1.5.1 General
a.
The quality of materials and method and control of manufacture

and transportation of all concrete work irrespective of mix,
whether reinforced or otherwise shall conform to the applicable
portions of this specification.
PAGE 46 OF 281
395 of 2461
MMRDA
The Employers representative shall have the right to inspect the
b.
source/s of material/s, the layout and operation of procurement

and storage of materials, the concrete batching and mixing
equipment, and the quality control system.
shall be arranged
and
Such an inspection
Employers representatives
approval
obtained, prior to starting of concrete work. However, this shall

not relieve the Contractor with any of his responsibilities and all
the materials, which do not conform to the specifications, will be
rejected.
c.
The minimum wall thickness for all RCC wall shall be 200 mm thick.
d.
The liquid retaining structures will be in minimum M35 grade.
e.
The Contractor will maintain all registers and formats for quantity
qualitative and quantitative measures of all concrete works on daily
basis of steel consumed and concreting done updated on daily basis.
f.
As per site conditions, if required, Contractor may use ready mix

concrete of approved mix design from approved ready mix plant without
any extra cost.
1.5.2 Applicable Codes
The following specifications, standards and codes, including all official

amendments / revisions and other specifications & codes referred to
therein to therein, should be
considered a part of this specification. In
all cases the latest issue/edition/revision shall apply. In case of

discrepancy between this specification and those referred to herein this
bid document, this specification shall govern.
Materials
IS:455
Specification for Portland slag cement.
PAGE 47 OF 281
396 of 2461
MMRDA
IS:1489
Specification for Portland-pozzolana cement.
IS:8112
Specification for 43-grade ordinary Portland

cement.
IS:12330
Specification for sulphate resisting Portland

cement.
IS:383
Specification for coarse and fine aggregates

from natural sources for concrete.
IS: IS: 432
Specification for mild steel and medium tensile

steel (Parts-I & II) bars and hard-drawn steel
wires for concrete reinforcement.
IS:1786
Specification
steel
for
bars
high
and
strength
wires
deformed
for concrete
reinforcement.
IS:1566
Specification for hard-drawn steel wire fabric

for (Part-I) concrete reinforcement.
IS:9103
Specification for admixtures for concrete.
10
IS:2645
Specification for integral cement waterproofing

compounds.
11
IS:4990
Specification for plywood for concrete shuttering

work.
Material Testing
IS:4021
Methods of physical tests for hydraulic cement.

(Parts-1 to 13)
PAGE 48 OF 281
397 of 2461
MMRDA
IS:4032
Method of chemical analysis of hydraulic cement.
IS:650
Specification for standard sand for testing of

cement.
IS:2430
Methods for sampling of aggregates for concrete.
IS:2386
Methods of test for aggregates for concrete.

(parts-I to VIII).
IS:3025
Methods
of
sampling
and
test
(physical and
chemical) water used in industry.
IS:6925
Methods
of
water-soluble
test
for
chlorides
determination
of
in concrete
admixtures.
Materials Storage
IS: 4082
Recommendations on stacking and storing of

construction materials at site.
Concrete Mix Design
IS: 10262
Recommended guidelines for concrete mix

design.
SP:23
Handbook on Concrete Mixes (S & T).
Method of sampling and analysis of concrete.
Concrete Testing
IS:1199
PAGE 49 OF 281
398 of 2461
MMRDA
IS:516
Method of test for strength of concrete.
IS:9013
Method of making, curing and determining

compressive
strength
of accelerated cured
concrete test specimens.
IS: 8142
Method of test for determining setting time of

concrete by penetration resistance.
IS: 9284
Method of test for abrasion resistance of

concrete.
IS: 2770
Methods of testing bond in reinforced concrete.
Equipment
IS: 1791
Specification for batch type concrete mixers.
IS: 2438
Specification for roller pan mixer.
IS: 4925
Specification for concrete batching and mixing

plant.
IS: 5892
Specification for concrete transit mixer and

agitator.
IS: 7242
Specification for concrete spreaders.
IS: 2505
General Requirements for concrete vibrators:

Immersion type.
IS: 2506
General Requirements for screed board concrete

vibrators.
PAGE 50 OF 281
399 of 2461
MMRDA
IS: 2514
Specification for concrete vibrating tables.
IS: 3366
Specification for pan vibrators.
10
IS: 4656
Specification for form vibrators for concrete.
11
IS: 11993
Code of practice for use of screed board

concrete vibrators.
12
IS: 7251
Specification for concrete finishers.
13
IS: 2722
Specification
batchers
for
for
portable
concrete
swing
weigh
(single and double
bucket type).
14
IS: 2750
Specification for steel scaffoldings.
Code of practice for plain and reinforced
Codes of Practice
IS:456
concrete.
IS:457
Code of practice for general construction of

plain
and
reinforced concrete for dams and
other massive structures.
IS:3370
Code of practice for concrete structures for

storage of liquids. (parts-I to IV)
IS:3935
Code of practice for composite construction.
IS:2204
Code of practice for construction of reinforced

concrete shell roof.
IS:2210
Criteria for the design of reinforced concrete

shell structures and folded plates.
PAGE 51 OF 281
400 of 2461
IS:2502
MMRDA
Code
of
practice
for
bending
and
fixing
of bars for concrete reinforcement.
IS:5525
Recommendation for detailing of reinforcement

in reinforced concrete works.
IS:2751
Code of practice for welding of mild steel

plain and deformed bars used for reinforced
concrete construction.
10
IS: 9417
Specification for welding cold worked bars

for reinforced concrete construction.
11
IS: 3558
Code
of
practice
for
use
of
immersion
vibrators for consolidating concrete.
12
IS: 3414
Code of practice for design and installation of

joints in building.
13
IS: 4326
Code of practice for earthquake resistant

construction of building.
14
IS:4014
Code of practice for steel tubular scaffolding.

(parts-I & II).
15
IS: 2571
Code of practice for laying in-situ cement

concrete flooring.
16
IS: 7861
Code
of
practice
for
extreme
weather
concreting.
Part-I: Recommended practice for hot weather

concreting.
Part-II: Recommended practice for cold weather
concreting.
PAGE 52 OF 281
401 of 2461
17
IS: 13920
MMRDA
Ductile Detailing of Reinforced Concrete Structure

subjected to 1993seismic forces.
18
SP-
16(S&T) -
Design Aids for Reinforcement Concrete to

IS:456-1978.
1980
19
SP-24
Explanatory Handbook on IS:456-1978.
20
SP-
Handbook on Concrete Reinforcement and
34(S&T) -
Detailing.
1987
Construction Safety
IS:3696
Safety code for scaffolds and ladders.(Parts-I &

II)
IS:7969
Safety code for handling and storage of building

materials
IS:8989
Safety code for erection of concrete framed

structures
Measurement
IS:1200
Method
of
measurement
of
building
and
engineering works.
IS:3385
Code of practice for measurement of civil

engineering works.
1.5.3 Materials for Standard Concrete

PAGE 53 OF 281
402 of 2461
a.
MMRDA
The ingredients to be used in the manufacture of concrete

shall consist solely of Ordinary Portland Cement or Sulphate
Resistant
Cement
of
approved
make
clean sand, natural
coarse aggregate, clean water, and admixtures.
b.
Cement
1.
The Contractor will have to make own arrangements for

procuring cement and steel.
Cement remaining in bulk storage at the mill, prior to

shipment for more than 6 months or cement in bags in
local storage in the hands of vendor for more than 3
months after completion of tests may be retested before
use and may be rejected if it fails to conform to any of the
requirement of IS 269-1976.
2.
The
Contractor
will
have
to
make
his
own
arrangements for transport from supplier godown and

storage of adequate quantity of cement. Contractor will
construct cement godown at site as per Employer
rules. Cement in bulk may be stored in bins or silos,
in batches of 10x10, which will provide complete
protection from dampness, contamination and minimize
caking and false set. Cement bags shall be stored in a
dry enclosed shed (storage under tarpaulins will not be
permitted), well away from the outer walls and insulated
from the floor to avoid contact with moisture from the
ground and so arranged as to provide ready access.
Damaged or reclaimed or partly set cement will not be
permitted to be used
site.
be
and shall be removed from the
The storage bins and storage arrangement shall

approved
by
the
Consignments of cement shall be stored as received and

PAGE 54 OF 281
403 of 2461
MMRDA
shall be consumed in the order of their delivery. Stacking

of cement shall be done as per IS and in such a way that
first come cement shall be used first.
3.
Cement held in storage for a period of ninety (90) days or

longer shall be tested.
Should at any time the Employers representative have
reasons to consider that any cement is defective, then
irrespective of its origin, date of manufacture and or
manufacturers test certificate, such cement shall be
tested
immediately
at
the Contractors cost at an
approved laboratory and until the results of such tests are

found satisfactory, it shall not be used in any work. Testing
certificates for each batch
submitted
by
the
of
Contractor
cement
to
the
should
be
Employers
representative, before starting the concreting work. The

Contractor shall not be entitled to any claim of any nature
on this account.
4.
Aggregates
i)
General
Aggregate in general designates both fine and
coarse inert materials used in the manufacture of
concrete (Vide BIS 456 & BIS 383) and conforming
to tests as per BIS 2386 (Part I to VI)
Coarse Aggregate is aggregate most of which is
retained when passed through on 4.75 mm BIS
sieve.
All fine and coarse aggregates proposed for use in

the works shall be subject to the Employer Quality
PAGE 55 OF 281
404 of 2461
MMRDA
Control Department approval and after specific

materials
have
been
accepted, the source of
supply of such materials shall not be changed

without
prior
approval
of
the
Employers
representative.
Aggregates shall consist of natural sands, stone

(crushed or uncrushed) and gravel from a source
known
to
produce
satisfactory
aggregate
for
concrete and shall be chemically inert, non-flaky,

strong,
hard,
durable
against
weathering,
of
limited porosity and free from deleterious materials

that may cause corrosion of the reinforcement or
may impair the strength and or durability of
concrete. The grading of aggregates shall be such
as to produce a dense concrete of specified strength
and consistency that will work readily into position
without segregation and shall be based on the
mix design and preliminary tests on concrete
specified.
ii)
Sampling and testing
Samples of the aggregates for mixed design

and determination of suitability shall be taken
under
the
supervision
of
the
Employers
representative and delivered to the laboratory,

well in advance of the scheduled placing of
concrete. Records of tests, which have been made
on proposed aggregates and on concrete made
from this source of aggregates, shall be furnished
to Employers representative in advance of the
work, for use in determining aggregate suitability.
The costs of all such tests, sampling etc. shall
be borne by the Contractor.
PAGE 56 OF 281
405 of 2461
iii)
MMRDA
Storage of aggregates
All coarse and fine aggregates shall be stacked

separately in stock piles in the material yard near
the work site in bins properly constructed to
avoid
inter
mixing of
different aggregates.
Contamination with foreign material and earth

during storage and while heaping the materials
shall be avoided.
The aggregates must be of
specified quality not only at the time of receiving at

site but more so at the time of loading into mixer.
Rakers shall be piled in layers not exceeding 1.20 m
in height to prevent coning or segregation. Each
layer shall cover the entire area of stockpile before
succeeding layers are started. Aggregates that have
become segregated shall be rejected.
iv)
Specific Gravity
Aggregates having a specific gravity below 2.4

(saturated surface dry basis) shall not be used.
1.5.4 Fine Aggregate
a)
Fine aggregate shall consist of natural or crushed sand

conforming to BIS 383 confirming to tests as per BIS 2386 part I
to VI. The sand shall be clean, sharp, hard, strong and durable
and shall be free from dust, vegetable substances, adherent
coating, clay, alkali, organic matter, mica, salt, or other
deleterious
substances, which can be injurious to the setting
qualities/strength/durability of concrete.
b)
Screening and Washing: Sand shall be prepared for use by

such screening or washing, or both, as necessary, to remove
PAGE 57 OF 281
406 of 2461
all
MMRDA
objectionable
foreign
matter
while separating the sand
grains to the required size fraction.
c)
Foreign
Material
limitations : The percentage deleterious
substances in sand delivered to the mixer shall not exceed the

following:
Table showing Foreign Material Limitations in Fine Aggregate
S. No.
Foreign Material
Percentage by Weight
Uncrushed
Material finer than 75
Crushed
3.0
15.0
micron BIS sieve

2
Shale
1.0
Coal & Lignite
1.0
Clay Lumps
1.0
5.0
17.0
Total
d)
Gradation: Unless otherwise directed or approved by the

Employers representative, the grading of sand shall be within
the limits indicated hereunder:
Table showing Grading of Sand for Fine Aggregate
Sieve
Grading
Grading
Grading
Grading
Designation
Zone I
Zone II
Zone III
Zone IV
100
100
100
100
4.75 mm
99-100
90-100
90-100
95-100
2.36 mm
60-95
75-100
85-100
95-100
1.18 mm
30-70
55-90
75-100
90-100
600 microns
15-34
35-59
60-79
80-100
300 microns
5-20
8-30
12-40
15-50
150 microns
0-10
0-10
0-10
0-15
10 mm
Where the grading falls outside the limits of any particular grading
PAGE 58 OF 281
407 of 2461
MMRDA
zone of sieves, other than 600 microns IS sieve, by total

amount not exceeding 5%, it shall be regarded as falling
within that grading zone. This tolerance shall not be applied
to percentage passing the 600 micron IS sieve or to percentage
passing any other sieve on the coarser limit of grading zone I or
the finer limit of grading zone IV. Fine aggregates conforming to
grading zone IV shall be used.
Mix designs and preliminary
tests shall show its suitability for producing concrete of specified

strength and workability.
e)
Fineness Modulus
The sand shall have a fineness modulus of not less than

2.0 or more than 3.5.
by
adding
the
The fineness modulus is determined
cumulative
percentages
retained
on
the
following IS sieve sizes (4.75 mm, 2.36 mm, 1.18 mm, 600
microns and 150 microns) and dividing the sum by 100.
1.5.5 Coarse Aggregate
a)
Coarse aggregate for concrete, except as noted above, shall

conform to IS 383 & IS2386. This shall consist of crushed stone
and shall be clean and free from elongated, flaky or laminated
pieces, adhering coatings, clay lumps, coal residue, clinkers, slag,
alkali, mica, organic matter or other deleterious matter.
b)
Screening and Washing: Crushed rock shall be screened

and or washed for the removal of dirt or dust coating, if so
requested by the Employers representative.
c)
Grading
i)
Coarse aggregate shall be either in single size or graded,

in both cases the grading shall be within the following
limits:
PAGE 59 OF 281
408 of 2461
BIS
MMRDA
Percentage Passing for Single Sized
Percentage passing for graded of
aggregate of normal size
aggregate of normal size
Sieve
size
40
20
16
12.5
10
40
20
16
12.5
(mm)
mm
mm
mm
mm
mm
mm
mm
mm
mm
63
100
100
40
85-100
100
95-100
20
0-20
85-100
100
30-70
100
16
85-100
100
90-100
12.5
85-100
100
10
0-5
0-20
0-30
0-45
85-100
4.75
0-5
0-5
0-10
2.36
ii)
95-100
90-100
10-35
25-35
30-70
40-85
0-20
0-5
0-10
0-10 0-10
0-5
The pieces shall be angular in shape and shall have

granular or crystalline surfaces. Friable,
flaky
and
laminated pieces, mica and shale, if present, shall be

only within tolerance limits which will not affect adversely
the strength and or durability of concrete. The maximum
size of coarse aggregate shall be 20mm for M-15 to M-30
concrete, or as directed by the Employers representative
or specified. The maximum size of coarse aggregate shall
be the maximum size specified above but in no case
greater than 1/4th
of the minimum thickness of the
member,
that
provided
the concrete can be placed
without difficulty so as to surround all reinforcement

thoroughly and fill the corners of the form.
For plain
concrete the maximum size of aggregate shall be of 40

mm.
For heavily reinforced concrete members, the
nominal maximum size of the aggregate shall be 5 mm

less than the minimum clear distance between the
reinforcing main bars or 5 mm less than the minimum
cover to reinforcement whichever is smaller.
d)
Foreign material limitations
PAGE 60 OF 281
409 of 2461
MMRDA
The percentage of deleterious materials in the aggregate

delivered to the mixer shall not exceed the following:
Table showing Foreign Material Limitations in Coarse Aggregate
S. No. Foreign Material
Percentage by Weight
Uncrushed
Material finer than 75
Crushed
3.0
3.0
micron BIS Sieve

2
Coal and lignite
1.0
1.0
Clay Lumps
1.0
1.0
Soft Fragments
3.0
Total
8.0
5.0
1.5.6 Water
a)
Water used for washing, mixing and curing shall be free from
injurious amounts of deleterious
materials.
Potable
water is
generally satisfactory for mixing and curing concrete. Physical

and chemical analysis of the water should be submitted to
the Employers representative, before starting the work.
b)
In case of doubt, the suitability of water for making concrete shall

be ascertained by the compressive strength and initial setting
time test specified in BIS 456.
The sample of water taken for
testing shall be typical of the water proposed to be used for

concreting, due account being paid to seasonal variation. The
sample shall not receive any treatment before testing other than
that envisaged in the regular supply of water proposed for use in
concrete. The sample shall be stored in a clean container
previously rinsed out with similar water.
c)
Average 28 days compressive strength of at least three 15

cm concrete cubes prepared with water proposed to be used
PAGE 61 OF 281
410 of 2461
MMRDA
shall not be less than 90% of the average strength of three

similar concrete cubes prepared with distilled water.
The
cubes shall be prepared, cured and tested in accordance with the

requirements of BIS 516.
d)
The initial setting time of test block must be made with the
appropriate test cement and the water proposed to be used. It
shall not be less than 30 minutes and shall not differ by more than
+/-30 minutes from the initial setting time of control test block
prepared with the appropriate test cement and distilled water.
The test block shall be prepared and tested in accordance with
the requirements of BIS 4031.
e)
Where water can be shown to contain an excess of acid,

alkali, sugar or salt, Employers representative may refuse to
permit its use.
As a guide, the following concentrations
represent the maximum permissible values.
1)
To
neutralise
200
ml
sample
of
water,
using
phenolphthalein as indicator, it should not require more

than 2 ml of 0.1 normal NaOH. The details of test shall be
as given in BIS 3025.
2)
To neutralise 200 ml sample of water, using methyl orange

as an indicator, it should not require more than 10 ml of 0.1
Normal HCl.
The details of test shall be as given in BIS
3025.
3)
Percentage of solids, when tested in accordance with

the
method
indicated below shall not exceed the
following:
Solids
Percent
Method of Test
PAGE 62 OF 281
411 of 2461
MMRDA
Solids
Percent
Ref. to col. no in IS:3025)
Method of Test
0.02
10 and 11
Inorganic
0.03
11(ignited residue)
Sulphates (as So4)
0.05
20
Alkali Chlorides (as Cl)
0.20
24
Suspended matter
0.20
12
Organic(organic solid = total

solids minus ignited residue)
The pH value of water shall not generally be less than 6.
1.5.7 Steel and Aluminium Members encased in Concrete
Structural steel and aluminum ladders etc. to be encased in

concrete shall be without paint. Primer should be used for encasing
purpose. The encasing shall be done in concrete with 10 mm,
maximum size aggregate and a works cube strength not less than 150
kg/sq.cm. at 28 days unless otherwise specified. The member shall be
wrapped with galvanized aluminum wire mesh of adequate size. The
galvanized aluminum wire mesh shall be kept 20 mm from the edge or
surface of the member and shall be held in position securely.
The
member will have a minimum cover of 50 mm unless otherwise indicated

in the drawings. Where the clear cover is more than 75 mm, concrete
with 20 mm coarse aggregate can be used.
1.5.7.1
Anchor Bolts, Anchors, Sleeves, Inserts
The Contractor shall build in to concrete work all such

items shall embed them partly or fully as directed and
secure the same as may be required. The materials, shall
be as specified
and
be
of
best
quality
available
according to relevant Indian standards of approved

manufacture and to the satisfaction of the Employers
representative. Exposed surface of embedded materials
is to be painted with one coat of approved anti-corrosive
PAGE 63 OF 281
412 of 2461
MMRDA
paint and/or bituminous paint without any extra cost to

the owner. If welding is to be done subsequently on
the exposed surface of embedded material the paint shall
be cleaned off the member to a minimum length of 50 mm
beyond each side of the weld line.
Necessary templates, jigs, fixtures, supports etc. shall

be
used
as
may
be
required
or directed by the
1.5.8 Controlled Concrete

All concrete in the works shall be Controlled Concrete as defined in IS:
456 except for M-7.5 and M-10 for which normal mix concrete shall be
used. Whether reinforced or otherwise, all concrete works to be carried
out under this specification shall be divided into the following
classifications:
Minimum Compressive Strength Of 15 cm cubes at 7 days and 28

days after mixing, conducted in accordance with IS: 516. Any
operation of concrete done at atmospheric temperature above 40
degree C or where the temperature of concrete at the time of
placement is expected to be beyond 40 degree C may be
categorize as hot weather concreting and should be confined to the
requirement of IS 7861(Part-I) 1975 and SP-23 (S&T)-1982.
Class
Preliminary Test
Works Tests
Max. Size
Locations for
N/mm2
N/mm2
of
Use
Aggregate
mm
At 7 Days At 28 Days At 7 Days At 28 Days
M 40
33.5
50.0
27.0
40.0
20
As indicated
M 35
30.0
44.0
23.5
35.0
20
in the
M 30
25.0
38.0
20.0
30.0
40 or 20
specifications
PAGE 64 OF 281
413 of 2461
MMRDA
M 25
22.0
32.0
17.0
25.0
40 or 20
or as
M 20
17.5
26.0
13.5
20.0
40 or 20
required
M 15
13.5
20.0
10.0
15.0
40 or 20
Note: It shall be very clearly understood that whenever the grade of

concrete such as M-20, etc. is specified it shall be Contractors
responsibility to ensure the minimum crushing strength stipulated for
the respective grade of concrete is obtained at works.
1.5.9 Mix Design
1.5.9.1
General
i)
This is essential for investigating the grading of

aggregates, water-cement ratio, workability and the
quality of cement required to give preliminary and
works cubes of the minimum strength specified.
The proportions of the mix shall be determined by
weight.
Adjustment of aggregate proportions
due to moisture present in the aggregate shall

be made.
Determination of mix proportions
shall be carried out according to Recommended

guidelines for Concrete Mix Design conforming to
IS: 10262.
ii)
Whenever there is a change either in required

strength of concrete, or water-cement ratio or
workability or the source of aggregates and/or
cement, preliminary tests shall be
repeated
to
determine the revised proportions of the mix to

suit
the
proportions,
altered conditions.
over-wet
mixes
While designing
shall
always
be
avoided.
iii)
Mix Design may be done without changing its
PAGE 65 OF 281
414 of 2461
MMRDA
minimum cement content mentioned in NIT
iv)
While fixing the value for water/cement ratio for

preliminary mixes, assistance may be derived from
the graph (Appendix A, BIS 456 showing the
relationship between the
28
strengths
mixes
of
concrete
day
compressive
with
different
water/cement ratios and the 7-day compressive

strength of cement tested in accordance with IS:
269.
1.5.9.2
Preliminary Tests
Test specimens shall be prepared with at-least two

different water/cement ratios for each class of concrete,
consistent with work ability required for the nature of the
work.
The materials and proportions used in making
preliminary tests shall be similar in all respects to those to

be actually employed in the works as the object of these
tests is to determine the properties of cement, aggregates
and water necessary to produce concrete of required
consistency and to give the specified strength, it will be
Contractors sole responsibility to carry out these tests and
he shall therefore furnish to Employers representative a
statement of proportions proposed to be used for the
various concrete mixes. For preliminary tests, the following
procedure shall be followed.
Materials shall be brought to the room temperature

and all materials shall be in a dry condition. The
quantities of water cement and aggregates for each
batch shall be determined by weight to an accuracy of 1
part in 100 parts.
Mixing concrete shall be done by hand (for small

PAGE 66 OF 281
415 of 2461
MMRDA
quantities, as directed by Employers representative) or in

a small batch mixer as per IS: 516 in such a manner as
to avoid loss of water. The cement and fine aggregate
shall first be mixed dry until the mixture is uniform in
color. The coarse aggregate shall then be added, mixed
and water added and the whole batch mixed thoroughly
for a period of not less than two minutes until the
resulting concrete is uniform in appearance. Each batch of
concrete shall be such a size as to leave about 10%
excess concrete, after moulding the desired number of
test specimens.
The consistency of each batch of concrete shall be

measured immediately after mixing, by the slump test in
accordance with IS: 1199. If in the slump test, care
is taken to ensure that no water or other material is lost,
the material used for the slump test may be re-mixed with
the remainder of the concrete for making the specimen
test cubes.
The period of re-mixing shall be as short as
possible yet sufficient to produce a homogeneous mass.
The samples for compression tests of concrete shall be

made as per IS: 516 on 15 cm cubes. Each mould shall
be provided with a metal base plate having a plate surface
so as to support the mould during filling without leakage.
The base plate shall be preferably attached to the mould
by springs or screws.
The parts of the mould hen
assembled shall be positively and rigidly held together.

Before placing concrete, the mould and base plate shall
be cleaned and oiled. The dimensions and internal faces
of the mould shall be accurate within the following limits.
Height and distance between the opposite faces of the
mould shall be of specified size +0.2 mm.
The angle
between the adjacent internal faces and between internal

faces and top and bottom faces of mould shall be 90SECTION 6B.1: CIVIL WORKS
PAGE 67 OF 281
416 of 2461
MMRDA
degree +0.5 degree.
The interior faces of the mould
shall be plane surfaces with a permissible variation of

0.03 mm.
Concrete test cubes shall be moulded by placing fresh

concrete in the mould and compacted as specified in IS
516.
Curing shall be as specified in IS 516. The cubes shall be

kept in moist air of at least 90% relative humidity at a
temperature of 27 degree C + 2 degree C for 24
hours +2 hours from the time of adding water to the
dry ingredients. Thereafter they shall be removed from
the moulds and kept immersed in clean, fresh water and
kept at 27 degree C +2 degree C temperature until
required for test.
seven days.
Curing water shall be renewed every
A record of maximum and minimum
temperatures at the place of storage of the cubes shall be

maintained during the period they remain in storage.
The strength shall be determined based on not less than

five cube test specimens for each age and each water
cement ratio.
All these laboratory test results shall be
tabulated and furnished to the Employers representative.

The test results shall be accepted by the Employers
representative if the average compressive strengths of the
specimens tested
is not less than the compressive
strength specified for the age at which specimens are

tested subject to the condition that only one out of the five
consecutive tests may give a value less than the specified
strength for that age. The Employers representative may
direct the Contractor to repeat the tests if the results
are not satisfactory and also make such changes as
he
considers necessary to
meet
the
requirements
specified. All these preliminary tests shall be conducted by

PAGE 68 OF 281
417 of 2461
MMRDA
the Contractor at his own cost in an approved laboratory of

Employer.
1.5.10 Proportioning, Consistency, Batching and Mixing of Concrete
The determination of the water cement ratio and proportion of

aggregates to obtain the required
strength
shall
be
made
from
preliminary tests by designing the concrete mix. Controlled concrete

shall
be
used
on
all
concrete
work
complying
with
all
the
requirements of IS: 456. Cube tests shall be carried out by the

Contractor on the trial mixes before the actual concreting operation
starts. Based on the strength of the concrete mix sanction for the use
has to be obtained from Employers representative.
If during the execution of the works it is found necessary to revise the

mix because of the cube tests showing lower strengths than the required
one due to inconsistency of quality of material or otherwise, The
Employers representative shall ask for fresh trial mixes to be made
by the Contractor. No claim to alter the rates of concrete work shall be
entertained due to such change in mix variations, as it is the Contractors
responsibility to produce the concrete of the required grade.
Great care shall be exercised when mixing the actual works

concrete using the proportions of the selected trial mix. The final
concrete mix shall have the same proportions and same source of
cement, fine and coarse aggregates and water as that of the approved
selected mix.
A reasonable number of bags should be weighed separately to

check the Net weight, where the weight of cement is determined
by accepting the manufacturer's weight per bag at the site. Proper
control of mixing water is deemed to be of paramount importance.
If mixers with automatic addition of water are used, water should be

either measured by volume in calibrated buckets, tins or weighed.
PAGE 69 OF 281
418 of 2461
MMRDA
All measuring equipment shall be maintained in a clean serviceable

condition and their accuracy periodically checked and certified and the
Employers representatives approval obtained.
The Employers representative may require the Contractor to carry out
moisture content tests in both fine and coarse aggregates. The amount
of the added water shall then be adjusted to compensate
for
any
observed variations in the moisture contents. BIS: 2386 shall be

referred to for determination of moisture content.
No substitution in material, used on the work or alteration in the

established proportions shall be made without additional tests to show
that the quality and strength of concrete are satisfactory. No alterations
shall be permitted without the prior sanction of the Employers
representative.
1.5.10.1
Mixing of Concrete
The mixing of concrete shall be strictly carried out in an

approved type of mechanical Concrete mixer. The mixing
equipment
shall
be
capable
of
combining
the
aggregates. Cement and water within the specified time

into a thoroughly mixed and uniform mass, and of
discharging the mixture without segregation. The entire
batch shall be discharged before recharging. Mixing
periods shall be measured from the time when all of the
solid materials are in the mixing drum, provided that
all of the mixing water shall be introduced before one
fourth of the mixing time has elapsed. The mixing time in
no case shall be less than two minutes. The mixer speed
shall not be less than 14 nor more than 20 revolutions per
minute.
Mixing shall be continued until there is a uniform

distribution of the materials and the mass is uniform in
PAGE 70 OF 281
419 of 2461
MMRDA
color and consistency. Hand mixing of concrete shall not

be permitted at all.
1.5.10.2
Grade of Concrete
The different grades of concrete specified shall conform to

the strengths as required by IS:
456-1987.Standard
deviation shall be calculated as stated in 14.5 of IS:

456-1978. The acceptable criteria for concrete shall be as
stated in clause 15 of IS: 456 -1978.The assumed standard
deviations as given in table 6 of IS: 456-1978 has to be
followed and are given here under. However, the minimum
cement content shall be as per Table no. 7: Minimum
Cement Content in Concrete in this tender document.
Table showing Grade of Concrete
Grade of Concrete
Assumed Standard Deviation

N/sq.mm
M 20
4.6
M 25
5.3
In order to get a quick idea of quality of concrete the

optional tests are conducted as stipulated in 14.1.1 of IS:
456-1978 and the results are analyzed according to table 5
on page 41 of IS: 456-1978.
a)
Controlled Concrete
Controlled
concrete
shall
concreting
works
except
be
used
where
on
all
specified
otherwise the mix proportions for all grades of

concrete shall be designed to obtain strengths
corresponding to the values specified in table
below for respective grades of concrete.
PAGE 71 OF 281
420 of 2461
MMRDA
Table showing Compressive Strengths at 28 days
Grade
Specified Characteristic Compressive

Strength at 28 days (N/sq.mm)
M15
15
M20
20
M25
25
M30
30
M35
35
The maximum Water : Cement ratio for all

controlled concrete works shall be as specified in
IS: 456-1978 as Preliminary tests as specified in the
BIS code and required by
the
Employers
representative shall be carried out sufficiently

ahead of the actual commencement of the work
with different grades of concrete made from
representative samples of aggregates and cement
expected to be used on the job to ascertain the
ratios by weight of cement of total quantity of fine
and coarse aggregates and the water cement ratio
required to produce a concrete of specified strength
and desired workability.
The minimum cement content for each grade of

concrete shall be as per table below.
Table
showing
Minimum
Cement
Content
in
Concrete
Grade of
Minimum Cement Content in
Concrete
Concrete (kg/cum of finished

Concrete)
PAGE 72 OF 281
421 of 2461
MMRDA
M 15
300
M 20
330
M 25
360
M 30
400
M35
450
At least 4 (four) trial batches are to be made and 7

test cubes should be taken for each batch noting the
slump on each mix. These cubes shall then be
properly cured and two cubes from each mix shall
be tested in a testing laboratory approved by the
Employers representative at 7 days and others at
28 days for obtaining the ultimate compressive
strength. The test reports shall be submitted to the
Employers representative. The cost of mix design
and testing shall be borne by the Contractor. On the
basis of the preliminary test reports for trial mix, a
proportion of mix by weight and water cement ratio
will be approved by the Employers representative,
which will be expected to give the required
strength.
Consistency and workability and the
proportions so decided for different grades of

concrete shall be adhered to during all concreting
operations.
If
however
at
any
time
the
Employers representative feels that the quality of

material, being used has been changed from those
used for preliminary mix design, the Contractor
shall have to run similar trial mixes to ascertain
the mix proportions and consistency.
The
mix
without
once
prior
approved
approval of
must not be varied

the
Employers
representative. However should the Contractor

anticipate any change in the quality of future
supply of materials than that used for preliminary
PAGE 73 OF 281
422 of 2461
MMRDA
mix design, he shall inform the same to the

Employers representative and bring fresh samples
sufficiently ahead to carry out fresh trial mixes. The
Employers representative shall have access to all
places and laboratory where design mix is prepared.
Design mix will indicate by means of graphs and
curves etc. the extent of variation in the grading of
aggregates which can be allowed.
In designing the mix proportions of concrete, the

quantity of both cement and aggregate shall
be
determined by weight. All measuring equipment

shall
be
maintained
in
clean and serviceable
condition and their accuracy periodically checked.
To keep the water cement ratio to the designed

value, allowance shall be made for the moisture
contents in both fine and course aggregates and
determination of the same shall be
made
frequently
the
Employers
determination
of moisture
as
representative.
directed
The
by
as
contents shall be according to IS: 2386 (Part III).

Absorption of water by dry aggregates shall not be
more than 5%.
b)
Strength Requirements
Where ordinary Portland cement conforming to

IS: 269 or Portland blast furnace slag cement
conforming to IS: 455 is used the compressive
strength requirements for various grades
of
concrete shall be as shown in table below.

Where rapid hardening Portland cement is used
the 28 days compressive strength requirements
specified in Table- hereunder shall be met in 7
PAGE 74 OF 281
423 of 2461
MMRDA
days. The strength requirements specified in table

shall apply to both controlled concrete and ordinary
concrete. Strength Requirements of Concrete.
Grade of
Minimum Compressive Strength Concrete in
Concrete
Accordance with IS: 516 (In kg/cm)

As per IS: 456-1978
For 15 cm cube
For 15 cm cube
specimens at 7
specimens at 28
days
days
Work Test
Preliminary
Work Test
M 15
100
200
15c
M 20
135
260
20c
M 25
170
320
25c
M 30
200
380
30c
M 35
250
440
35c
Other requirements of concrete strength as may

be desired by the Employers representative shall
be in accordance with Indian Standard IS: 456
(latest revision). The acceptance of strength of
concrete shall be as per clause 5.4 Sample size
and Acceptance Criteria of IS:
revision)
subject
to
456
(latest
stipulation
and/or
modifications stated elsewhere in this specification

if any.
Concrete work found unacceptable shall have to

be dismantled and replaced to the satisfaction of
the Employers representative by the Contractor free
of cost to the Owner. No payment will
for
the
formwork
dismantled
concrete,
be
the
made
relevant
and reinforcement, embedded mixtures
etc. wasted in the dismantled portion shall be made.
PAGE 75 OF 281
424 of 2461
MMRDA
In the course of dismantling if any damage is done

to the embedded items or adjacent structures, the
same shall also be made good free of charge
by
the
Contractor
to
the satisfaction of the
Employers representative. If the water quantity has

to be increased in special cases, cement also has
to be increased proportionately to keep the ratio
of water to cement same as adopted in trial mix
design for each grade of concrete.
c)
Workability
The workability of concrete shall be checked at

frequent intervals by slump test. Where facilities
exist
and
if
required
by
the
Employers
representative, alternatively the compacting factor

test in accordance with IS: 1199 shall be carried
out. The degree of workability necessary to allow
the concrete to be well consolidated and to be
worked into the corners of form work and round
the reinforcement to give the required surface
finish shall depend on the type and nature of the
structure and shall be based on experience and
tests. The limits of consistency for structures are as
specified in the table below:
Table showing Limits of Consistency
Placing Conditions
Degree of
Values of Workability
Workability
Concreting of shallow
Very low
sections with vibration
20-10 seconds Veebee

time
or
0.75-0.80
compacting factor
Concreting
of
lightly
Low
reinforced sections with

10-5 seconds or 0.800.85 compacting factor

PAGE 76 OF 281
425 of 2461
MMRDA
Placing Conditions
Degree of
Values of Workability
Workability
vibration
Concreting
of
reinforced
without
lightly
Medium
sections
vibration
heavily
5-2 seconds Veebee time

or 0.85-0.92 compacting
or
factor or 25-75 mm slump
reinforced
for 20 mm aggregate
section with vibration

Concreting
of
heavily
High
Above 0.92 compacting
high reinforced sections
factor
compacting
slumps
without
vibration factor
1.5.10.3
or
75-125
for
20
mm
mm
aggregate
Workmanship
All workmanship shall be according to the latest relevant

standards. Before starting a pour the Contractor shall
obtain the approval of the Employers representative
and all other concerned department including safety
dept, in a Pour Card maintained for this purpose. He
shall obtain complete instructions about the material
and proportion to be used, slump, workability of water per
unit of cement, number of test cubes to be taken, finishing
to be done and any admixture to be added etc.
1.5.11 Sampling and Testing of Concrete in the Field
Sampling and Testing of Concrete shall conform to IS: 456 2000.
a)
Facilities required for sampling materials and concrete including

whether proof buildings to house the facilities in the field, shall be
provided by the Contractor at no extra cost. The following
equipment with operator shall
be made available in serviceable
conditions.
PAGE 77 OF 281
426 of 2461
i.
MMRDA
Concrete
cube-testing
machine
1 no.
suitable for 15 cm cubes of100

tonnes
capacity
with
proving
calibration ring
ii.
Cast iron cube moulds 15 cm size
iii.
Slump cone complete with tamping
12 nos.
1 set
rod
iv.
Laboratory balance to weigh upto5 kg
1 no.
with sensitivity of 10 gm
v.
BIS sieves for coarse and fine
1 set
aggregates
vi.
Set of measures from 5 litres to 0.1
1 set
litre
vii.
Electric oven with thermostat upto
1 no.
120C
viii.
Flakiness gauge
1 no.
ix.
Elongation index gauge
1 no.
x.
Sedimentation pipette
1 no.
xi.
Calibrated glass jar 1.0 litre capacity
2 nos.
xii.
Glass flasks and metal containers
As required
xiii.
Chemical
As required
reagents
like
sodium
hydroxide, tannic acid, litmus paper

etc.
xiv.
Laboratory balance of 2 kg capacity
1 no.
and sensitivity of 1 gm xv.
Weighing Machine for cement bags of 6
2 no.
Nos.:
b)
xvi.
Vernier Calipers
As required
xvii.
Thermometer for concrete
1 no.
No concrete of any kind may be placed until the field

concrete
testing
laboratory
as specified is provided to the

shall notify the Employers representative in
The Contractor
advance
of
all
PAGE 78 OF 281
427 of 2461
MMRDA
concrete and concrete material testing as provided in the

clause
to
provide
the
Employers representative with
an
opportunity to witness all prescribed tests.
c)
At least 6 test cubes of each class of concrete shall be made of

every 50cum concrete or part thereof or from different batches as
directed by Employers representative.
Such samples shall be
drawn on each day for each type of concrete. Of each set of 6

cubes, three shall be tested at 7 days age and three at 28 days
age. The cubes must be casted from various batches to arrive at
an average strength.
The laboratory test results shall be
tabulated and furnished to the Employers representative. The

Employers representative will pass the concrete if average
strength of the specimens tested is not less than the strength
specified, subject to the condition that only one out of three
consecutive tests may give a value less than the specified
strength but this shall not be less than 90% of the specified
strength.
d)
Consistency: Slump tests shall be carried out as often as

requested by the Employers representative and invariably from
the same batch of concrete from which the test cubes are made.
Slump tests shall be done immediately after sampling.
1.5.12 Concrete Tests

The Employers representative, may order tests to be carried out
on cement, sand, coarse aggregate, water in accordance with the
relevant Indian standards.
Tests on Cement shall include:
Fineness test
Test for normal consistency
Test for setting time
PAGE 79 OF 281
428 of 2461
MMRDA
Test for soundness
Test for tensile strength
Test for compressive strength
Test for heat of hydration (by experiment and by calculations)

in accordance with BIS 269
Tests on Sand shall include:
Sieve test
Test for organic impurities
Decantation test for determining clay and silt content
Specific gravity test
Test for unit weight and bulkage factor
Test for sieve analysis and fineness modulus
Tests on Coarse Aggregate shall include:
Sieve analysis
Specific gravity and unit weight of dry, loose and rodded aggregate
Soundness and alkali aggregate reactivity
Petrography examination
Deleterious materials and organic impurities
Test for aggregate crushing value
Any or all these tests would normally be ordered to be carried out only if
the Employers representative feels the materials are not obtained and
shall be performed by the Contractor at a test laboratory approved by
Employer.
The Contractor shall bear the charges of these optional
tests.
Concrete not made to the requirements of specification in all respects

may be rejected by the Employers representative in which case it shall
be removed and reconstructed entirely at the expense of the Contractor.
PAGE 80 OF 281
429 of 2461
1.5.12.1
MMRDA
Load Test on Members or Any Other Tests
i)
In
the event of
any work being suspected of
material or workmanship or both, the Employers

representative
requiring
its
removal
and
reconstruction may order, or the Contractor may

request that it should be load tested in accordance
with the following provisions.
ii)
The test load shall be 125% of the maximum

superimposed load for which the structure was
designed.
Such test load shall not be applied
before 56 days after the effective

concrete.
hardening
of
During the test, struts strong enough
to take the whole load shall be placed in position

leaving a gap under the members.
The test load
shall be maintained for 24 hours before removal.
iii)
If within 24 hours of the removal of the load, the

structure does not show a recovery of at least 75%
of the maximum deflection shown during the 24
hours under load, the
test
loading
shall
be
repeated after a lapse of at least 72 hours.

The structure shall be considered to have failed to
pass the test if the recovery after the second test is
not at least 75% of the maximum deflection shown
during the second test. If the structure is certified
as failed by the Employers representative, the
cost of all the new construction and the load tests
iv)
Any other tests, e.g. taking out in an approved

manner concrete cores, examination and tests on
such cores removed from such parts of the structure
as directed by the Employers representative, sonic
PAGE 81 OF 281
430 of 2461
MMRDA
testing
etc.
shall
be
carried
out
by
the
Contractor, if so directed, at no extra cost.
1.5.12.2
Unsatisfactory tests
Should the results of any test prove unsatisfactory, or

the
structure
shows
signs
of weakness,
undue
deflection or faulty construction, the Contractor shall

remove and rebuild the member or members involved or
carry out such other remedial measures as may be
required by the Employers representative.
1.5.13 Admixtures
1.5.13.1
General
Admixtures may be used in concrete where required,

only with the approval of the Employers representative.
How ever it should be seen that, with the passage of time,
neither the compressive strength nor its durability is
reduced.
Calcium chloride shall not be used for
accelerating
set
of
the
cement
containing
reinforcement
for
any
concrete
or embedded steel parts.
When calcium chloride is permitted to be used, such as in

mass concrete works, it shall be dissolved in water
and added to the mixing water in an amount not to
exceed 1.5% of the weight of the cement in each batch of
concrete. When admixtures
concrete
mix
shall
be
are
used,
corrected
the
designed
accordingly.
Admixtures shall be used as per manufacturers instruction

and in the manner and with the control specified by the
1.5.13.2
Air Entraining Agents
PAGE 82 OF 281
431 of 2461
MMRDA
Neutralized Vinson resin or other approved air in the

concrete mix agents shall conform to the requirements of
ASTM standard 6.260; Air Entraining Admixtures for
Concrete. The recommended total air content of the
concrete is 4% + 1%.
The method of measuring air
content shall be as per IS: 1199.
1.5.13.3
Water Reducing Admixtures
Water reducing lignosulfonate admixture may be added

in quantities approved by the Employers representative.
The admixtures shall be added in the form of a solution.
1.5.13.4
Retarding Admixtures
Retarding agents may be added to the concrete mix

in quantities approved by the Employers representative.
1.5.13.5
Water Proofing Agent
Water proofing agents shall conform to IS: 2645.
1.5.13.6
Other Admixtures
The Employers representative may at his discretion
allow the Contractor to use any other admixture in the
concrete.
1.5.14 Preparation Prior to Concrete Placement, Final Inspection and Approval
a.
Before the concrete is actually placed in position, the insides of

the formwork shall be inspected to see that they have been
cleaned and oiled.
Temporary openings shall be provided to
facilitate inspection, especially at bottoms of columns and wall

forms, to permit removal of sawdust, wood shavings, binding wire,
PAGE 83 OF 281
432 of 2461
MMRDA
dirt etc. Openings shall be placed or holes drilled so that these

materials and water can be removed easily. Such openings/holes
shall be suitably plugged later.
b.
The various agencies shall be permitted ample time to install

drainage and plumbing lines, floor and trench drains, conduits,
hangers, anchors, inserts, sleeves, bolts, frames and other
miscellaneous embedment to be cast in the concrete as specified
or required or as is necessary for the proper execution of the work
as specified in the drawings.
c.
All embedded parts, inserts, etc. supplied by the Employer

or the Contractor shall be correctly positioned and securely
held in the forms to prevent displacement during depositing
and vibrating of concrete.
d.
All anchor bolts shall be positioned and kept in place with

the
help
of
properly manufactured
templates
unless
specifically waived in writing by the Employers representative.
e.
Slots, openings, holes, pockets etc. shall be provided in the

concrete work in the position specified in drawing or required or
f.
Reinforcement and other items to be cast in concrete shall have

clean surfaces that will not impair bond.
g.
Prior to concrete placement, all work shall be inspected and

approved
by
the Employers representative
and
if
found
unsatisfactory, concrete shall not be poured until after all

defects have been corrected.
h.
Approval by the Employers representative of any and all

materials and work as required herein shall
not relieve the
Contractor from his obligation to produce finished concrete in

PAGE 84 OF 281
433 of 2461
MMRDA
accordance with the requirements of the specifications.
i.
Rain or wash water
No concrete shall be placed in wet weather or on a watercovered surface. Any concrete that has been washed by heavy
rains shall be entirely removed, if there is any sign of cement and
sand having been washed away from the concrete mixture. To
guard against damage, which may be caused by rains, the works
shall be covered with tarpaulins immediately after the concrete
has been placed and compacted before leaving the work
unattended. Any water accumulating on the surface of the newly
placed concrete shall be removed by approved means and no
further concrete shall be placed thereon until such water is
removed. To avoid flow of water over/around freshly placed
concrete, suitable drains and sumps shall be provided. During
summer season, temperature of water should be maintained,
as per the criteria and for the same, icing should be done for
concreting work.
j.
Bonding Mortar
Immediately
before
concrete
placement
begins,
prepared
surfaces except formwork, which will come in contact with the

concrete to be placed, shall be covered with a bonding mortar as
specified.
k.
The
corrosive
matters
on
the
reinforcement
should
be
removed by means of wire brush.
l.
Laitance should be removed by means of chiseling from top

concrete layer which was earlier concreted
1.5.15 Transportation
PAGE 85 OF 281
434 of 2461
1.5.15.1
MMRDA
General
All buckets, containers or conveyors used for transporting

concrete shall be mortar-tight, leak proof irrespective of
the method of transportation adopted, concrete shall
be delivered
with
the
required
consistency
and
plasticity without segregation or loss of slump. However,

chutes shall not be used for transport of concrete without
the written permission of the Employers representative
and concrete shall not be re-handled before placing.
1.5.15.2
Retempered or Contaminated Concrete
Concrete must be placed in its final position before it

becomes too stiff to work. On no account, water shall be
added after the initial mixing. Concrete, which has become
stiff or has been contaminated with foreign materials
shall be rejected and disposed off as directed by the
1.5.15.3
Avoiding Segregation
Concrete shall, in all cases, be deposited as nearly

as practicable directly, in its final position and shall not
be re-handled to flow in a manner which will cause
segregation, loss
of
materials,
displacement
of
reinforcement, shuttering or embedded insets, or impair

its strength.
For locations where direct placement is not
possible, and in narrow forms, the Contractor shall provide

suitable drop and Elephant Trunks to confine the
movement of concrete.
Special care shall be taken
when concrete is dropped from a height, especially if

reinforcement is in the way, particularly in column and the
walls.
PAGE 86 OF 281
435 of 2461
1.5.15.4
MMRDA
Placing by Manual Labour

Except when otherwise approved by the Employers
representative, concrete shall be placed in the shuttering
by shovels or other approved implements, and shall not be
dropped from a height more than 1.0 m or handled in a
manner, which will cause segregation.
1.5.15.5
Placing by Mechanical Equipment
The following specification shall apply when placing

concrete by use of mechanical equipment is warranted
considering the nature of work involved. The control of
placing shall begin at the mixer discharge.
Concrete shall
be discharged by a vertical drop into the middle of the

bucket or hopper and this principle of a vertical discharge
of concrete shall be adhered to throughout all stages of
delivery until the concrete comes to rest in its final position.
a)
Types of Buckets
Central-bottom-dump
buckets
of
type
that
provides for positive regulation of the amount

and rate of deposition of concrete in all dumping
positions, shall be employed.
b)
Operation of Bucket
In placing concrete in large open areas, the

bucket shall be spotted directly over the position
designated and then lowered for dumping.
The
open bucket shall clear the concrete already in

place and the height of drop shall not exceed 1.0 m.
The bucket shall be opened slowly to avoid high
vertical bounce. Dumping of buckets on the swing
PAGE 87 OF 281
436 of 2461
MMRDA
or in any manner, which results in separation of

ingredients or disturbance of previously placed
concrete, will not be permitted.
1.5.15.6
Placement of Restricted Forms
Concrete
placed
in
restricted
forms
by
barrows,
buggles, cars, short chutes or hand shoveling shall be

subject to the requirement for vertical delivery of
limited height to avoid segregation and shall be deposited
as nearly as practicable in its final position.
1.5.15.7
Chuting
Where it is necessary to use transfer chutes, specific

approval of Employers representative must be obtained
to type, length slopes, baffles, vertical terminals and
timing of operations. These shall be so arranged that
an almost continuous flow of concrete is obtained at
the discharge and without segregation. Concrete should
flow smoothly in the chute and there should not be any
obstruction to the flow.
To allow for the loss of mortar
against the sides of the chutes, the first mixes shall have
less coarse aggregate.
During cleaning of chutes, the
wastewater shall be kept clear of the forms. Concrete shall

not be permitted to fall from the end of the chutes by more
than 1.0 m. Chutes, when approved for use shall have
slopes not flatter than 1 vertical, 3 horizontal and not
steeper than 1 vertical, 2 horizontal.
Chutes shall be
of metal or metal lines end of rounded cross section.

The slopes of all chute sections shall be approximately the
same.
The slopes of all chute sections shall be
approximately the same. The discharge end of the chutes

shall be maintained above the surface of the concrete in
the forms.
PAGE 88 OF 281
437 of 2461
1.5.15.8
MMRDA
Placing by Pumping/Pneumatic Placers
Concrete may be conveyed and placed by mechanically

operated equipment e.g., pumps or pneumatic placers only
with
the
written
permission
of
Employers
the
representative at no extra cost. The slump shall be held to

the minimum necessary for conveying concrete by this
method.
When pumping is adopted, before pumping of concrete is

started, the pipeline shall be lubricated with one or two
batches of mortar composed of one part cement and two
parts sand. Care shall be taken to avoid stoppages in work
once pumping has started.
When a pneumatic placer is used, the manufacturers
advice on layout of the pipeline shall be followed to
avoid blockages and excessive wear. Restraint shall be
provided at the discharge box to cater for the reaction at
this
end.
Manufacturers
recommendations
shall
be
followed regarding concrete quality and all other related

matters when pumping/ pneumatic placing equipment is
used. It should be noted that no extra payment is made for
these items, if required and directed by Employers
representative.
1.5.15.9
Concrete in Layers
Concreting, once started, shall be continuous until the pour

is completed.
Concrete shall be placed in successive
horizontal layers of uniform thickness ranging from 15 cm

to 45 cm directed by Employers representative.
These
shall be placed as rapidly practicable to prevent the

formation
of
cold
joints
or
planes
of
weakness
PAGE 89 OF 281
438 of 2461
MMRDA
between each succeeding layer within the pour.
The
thickness of each layer shall be such that it can be

deposited before the previous layer has stiffened.
The
bucket loads or other units of deposit, shall be spotted

progressively along the face of the layer with such overlap
as will facilitate spreading the layer to uniform depth
and texture with a minimum shoveling.
Any tendency
to segregation shall be corrected by shoveling stones

into mortar rather than mortar on to stones.
Such a
condition shall be corrected by redesign of mix or

other means, as directed by the Employers representative.
1.5.15.10
Cover Blocks
Cover blocks of required size depending on the cover of

the reinforcement as mentioned in the drawings shall be
prepared in 1:3 cement mortar with fine aggregates
and minimum compressive strength of 300 kg/sq.cm.
1.5.15.11
Bedding of Layers
The top surface of each pour and bedding planes

shall
be
approximately
horizontal unless otherwise
instructed. Top layer should be rough and with key for

further extension of work.
1.5.15.12
Compaction
Concrete shall be compacted during placing with approved

vibrating
equipment
until
the
concrete
has
been
consolidated to the maximum practicable density, as

specified in the IS,
is
free
of
pockets
of
coarse
aggregate and fits tightly against all form surfaces,

reinforcement and embedded fixtures.
Particular care
shall be taken to ensure that all concrete placed

PAGE 90 OF 281
439 of 2461
MMRDA
against the form faces and into corners of forms

against hardened concrete at joints is free from voids or
cavities.
The use of vibrators shall be consistent with the
concrete mix and caution exercised not to over vibrate the

concrete to the point that segregation results.
a)
Type of Vibrators
Vibrators shall conform to BIS specifications. Type

of vibrator to be used shall depend on the structures
where concrete is to be placed. Shutter vibrators to
be effective, shall be
firmly
secured
to
the
formwork which must be sufficiently rigid to

transmit the vibration and strong enough not to be
damaged by it.
Immersion vibrators in sufficient
numbers and each of adequate size shall be

used
to
properly
consolidate
all
concrete.
Tapping or external vibrating of forms by hand tools

or immersion vibrators will not be permitted.
b)
Use of Vibrators
The exact manner of application and the most

suitable machines for the purpose must be carefully
considered and operated by experienced men.
Immersion vibrators shall be inserted vertically at
points not more than 450 mm apart and withdrawn
when air bubbles cease to come to the surface.
Immersion vibrators shall be withdrawn very slowly.
In no case shall immersion vibrators be used to
transport concrete inside the forms.
Particular
attention be paid to vibration at the top of a lift e.g. in

a column or wall.
c)
Melding Successive Batches
PAGE 91 OF 281
440 of 2461
MMRDA
When placing concrete in layers, which are

advancing
great
horizontally
care
shall
be
as
the work progresses,
exercised
to
ensure
adequate vibration blending and melding of the

concrete between the succeeding layers.
d)
Penetration of Vibrators
The immersion vibrator shall penetrate the layer

being placed and also penetrate the layer below
while the under layer is still plastic to ensure
good
bond
and
homogeneity between the two
layers and prevent the formation of cold joints.
e)
Vibrating against Reinforcement/Formwork
Care shall be taken to prevent contact of immersion

vibrators against reinforcement steel. Immersion
vibrators
shall
not
be
allowed
to
come
in
contact with reinforcement steel after start of initial

set.
They shall also not be allowed to come in
contact with forms or finished surfaces.
f)
Use of Form Attached Vibrators
Form attached vibrators shall be used only with

specific
authorization
of
the
Employers
representative.
g)
Use of Surface Vibrators
The use of surface vibrators will not be permitted

under normal conditions.
However, for thin slabs,
surface vibrating by specially designed vibrators

PAGE 92 OF 281
441 of 2461
MMRDA
may be permitted, upon approval of Employers

representative.
h)
Stone Pockets And Mortar Pondages
The
formation
of
stone
pockets
and
mortar
pondages in corners and against faces of forms

shall not be permitted.
Should these occur, they
shall be dug out, reformed and refilled to sufficient

depth and shape for thorough bonding, as directed
1.5.15.13
Placement Interval
Except when placing with slip forms, each placement of

concrete in multiple lift work, shall be allowed to set for at
least 24 hours after the final set of concrete and before the
start of a subsequent placement.
1.5.15.14
Special Provision in Placing
When placing concrete in walls with openings, in

floors of integral slabs and beam construction and
other similar conditions, the placing shall stop when
the concrete reaches the top of the opening in walls or
bottom horizontal surface of the slab, as the case may be.
Placing shall be resumed before the concrete in place

takes initial set, but not until it has had time to settle as
determined by the Employers representative.
1.5.15.15
Placing Concrete Through Reinforcing Steel
When
care
placing
shall
be
concrete
taken
to
through
reinforcing
steel,
prevent segregation of the

PAGE 93 OF 281
442 of 2461
MMRDA
coarse
aggregate. Where
makes
placing difficult, it may be necessary to obtain
Employers
representative
the
congestion
permission
of
steel
for temporarily
moving the top steel aside for proper placement & for
restoring reinforcement as per drawing.
1.5.15.16
Bleeding
Bleeding or free water on top of concrete being

deposited into the forms, shall be the cause to stop the
concrete pour and the conditions causing this defect
corrected before any further Concreting is resumed.
1.5.16 Application of Araldite for Bonding of New and Old Concrete
1.5.16.1
General
Araldite epoxy resins will be used to bond fresh concrete to

concrete that is fully cured, to give a monolithic bond
capable of transmitting high stresses when traditional
bonding agents such as cement slurry cannot always
be relied upon to provide good adhesion which is
particularly the case when large areas are involved.
a.
The Araldite based formulation shall be applied to a

suitably prepared concrete substrata and the fresh
concrete poured as soon as possible, but always
during the open time of the adhesive.
b.
Materials used shall be of best quality like CIBA,

FOSROC or ROFF and approved by the Employers
representative.
c.
Manufacturers instructions shall be followed in all

respects.
PAGE 94 OF 281
443 of 2461
d.
MMRDA
No separate payment shall be paid for this item of

work.
1.5.16.2
1.5.16.3
Formulation
ARALDITE
Hardener
GY250
HY825
100
20
Parts by weight
Parts by weight
Hardener
Hardener
Silica Flour
HY830
HY850
20
20
20
Parts by weight
Parts by weight
Parts by weight
Application
The application of the adhesives shall be as per

manufacturer standards.
a)
Preparation of the Substrata
To obtain good adhesion, it is necessary to have

clean and sound substrata.
carried
out
including
using
chemical
Preparation can be
variety
treatment
of
techniques
and mechanical
methods such as grinding, milling, abrading, planing

and sand blasting.
resulting
from
the
Dust and
loose
pretreatment
particles
should
be
removed by vacuum cleaning or oil-free or blast.
b)
Mixing
The resin and hardener should be thoroughly mixed

in the dry filler. The mixed, ready to use adhesive
should not contain lumps of unwetted filler and
should be of uniform color. For a total weight of 1
kg or less hand mixing should be sufficient. For
quantities
in excess of 1 kg, the use of a
PAGE 95 OF 281
444 of 2461
MMRDA
mechanical mixer is recommended.
c)
Pot life and Open time
The pot life is the period during which the ready to

use ARALDITE based formulation must be applied.
After this period, the mix can no longer be worked
and will have begun to set in its container.
The
table below indicates the pot life at different

temperatures:
Mix Temperature
Pot life in minutes
25C
90 Minutes
30C
60 Minutes
35C
45 Minutes
(The figures in this table are for batches less than 1

kilogram).
The Open time is the maximum period of time
allowable between application of the ARALDITE
adhesive
and
pouring
the
fresh
concrete.
Exceeding the Open time would result

considerably reduced adhesion.
in
The adhesive
should be applied to the pre- treated substrata as

soon as the components have been mixed and fresh
concrete poured immediately afterwards.
Accurate knowledge of the Open time is essential
in case the work is interrupted.
Table gives the Open time of ARALDITE based
formulations as a function of substrata temperature.
In all cases, the adhesives shall be applied
PAGE 96 OF 281
445 of 2461
MMRDA
immediately after mixing. Any delay between mixing

and application will reduce the Open time. Fresh
concrete must be poured before the adhesive
begins to gel.
is
New to old concrete bonding
not recommended
at temperatures below 5-
Degree Centigrade, as curing cannot be assured

under these circumstances.
d)
Methods of Application
The shape and size of the concrete structure

will determine the method of application used.
The ARALDITE based adhesive may be applied by
hand using brushed, brooms or any other suitable
applicator.
e)
Suitability of Fresh Concrete
Best results are obtained when the water/ cement

ratio of the new concrete is low as is practicable.
f)
Coverage
One kilogram of the mixed ARALDITE adhesive

including hardeners and filler covers an area of 2
to 3 sq.m. when applied with a stiff nylon
bristle
brush.
However,
the coverage is very
much dependent on the finish in the concrete.
1.5.17 Handling Precautions
Epoxy resins can cause irritation of the skin in sensitive person if

incorrectly handled. Certain safety precautions must therefore be
observed and those handling the resins and hardeners
should
be
given suitable instructions. Those working with epoxy resins should,

PAGE 97 OF 281
446 of 2461
MMRDA
above all, be instructed that personal cleanliness at the place of work is

essential. The resin and hardener should not be allowed to come into
direct contact with the skin.
The most effective protection is achieved by wearing rubber or

polythene gloves, the latter having the advantage that they can be
replaced when dirty. They are more pleasant to wear if cotton gloves
are worn underneath. Parts of the skins, which have come into contact
with the resin or hardener, should be washed with lukewarm water
and a mild soap. Special cleaning creams may be used as they have
proved to be highly suitable.
1.5.18 Construction Joints
a)
A construction joint is defined as a joint in the concrete introduced

for convenience in construction at which special measures are
taken to achieve subsequent continuity without provision for
further relative movement.
b)
No concreting shall be started until the Employers representative

has approved the method of placing the positions and form
of the construction joints and lifts. The construction joints
shall be so located as not to impair the strength of the structure.
Water stops shall be inserted.
c)
Concrete placed to form the face of a construction joint

shall have all Laitance removed and the aggregate exposed
prior to the placing of fresh concrete.
The Laitance shall
wherever practicable be removed by spraying the concrete where

it is still green.
The whole of the concrete surface forming
part of the joint shall be hacked to expose the aggregate to

the
1/3rd
size
of
maximum
size
of
aggregate. Where
aggregate is damaged during hacking, it shall be removed from

the concrete face by further hacking.
All loose matter shall be
removed and the exposed surface thoroughly cleaned by wire

PAGE 98 OF 281
447 of 2461
MMRDA
brushing, air blasting or washing, leaving the surface clean

and damp. Immediately before fresh concrete is placed, a 12 mm
thick layer of sand/cement mortar mixed in the same proportions
as in the concrete shall be spread in the horizontal face of the
construction joint. A drier mix shall be used for the top lift of
horizontal face of the construction joint. A drier mix shall be used
for the top lift of horizontal pours to avoid Laitance.
The new
concrete shall be well worked against the prepared face before

the mortar sets. Special care shall be taken to obtain thorough
compaction and to avoid segregation of the concrete along the
joint plane.
1.5.19 Movement Joints
a)
Movement
joints
accommodate
are
defined
as
all
joints
intended
to
relative movement between adjoining parts of
a structure, special provision being made where necessary

for
maintaining
the
water
tightness
of
the
joint.
The
Contractor shall comply with the instructions of manufacturers of

proprietary jointing materials and
Employers representative,
shall,
demonstrate
if
required
that
the
by
the
jointing
materials can be applied satisfactorily.
b)
The surface of set concrete in a movement joint shall, as shown

on the drawings, be painted with two coats of bituminous paint
and new concrete shall be placed against it only when the paint is
dry. Expansion joints shall be formed by a separating strip of
approved preformed joint filler.
c)
Caulking grooves shall be provided. At all joints where a caulking

groove is formed, immediately prior to caulking, the groove shall
be wire brushed and loose material removed and blown out by
compressed air.
After the groove has dried, it shall be primed
and caulked with approved sealing compound applied in

accordance with the manufacturers instructions. At all caulked
PAGE 99 OF 281
448 of 2461
MMRDA
joints, the face of the caulking strip and a width of concrete on

either side shall be painted with two coats of paint having the
same base as the sealing compound.
1.5.20 Water Stops and Joint Fillers
1.5.20.1
Water stops
a)
At all construction, contraction and expansion joints

in the water retaining structures and wherever
specified
or
directed
by
Employers
the
representative, water stops shall be provided.
The
water stops shall be PVC type or of any other

equivalent material as approved by the Employers
representative.
PVC water stops shall have a
tensile strength of not less than 14 MN/m2 and

elongation
at break
Water stops
shall
of not less
not
be
than
exposed
to
300%.
direct
sunlight for long periods. Before being concreted

in water stops shall be cleaned of all foreign
materials. Wherever provided, water stops shall be
placed in such a manner that they are embedded in
the adjacent sections of the panels for equal width.
b)
As far as possible, jointing on site shall be confined

to the making of butt joints in straight runs of water
stops and all the joints should be monolithic.
Where
it
is agreed
with
the
Employers
representative that it is necessary to make an

intersection or change of direction of any joint,
other than a butt joint in a straight run on site,
a preliminary
joint,
intersection
or
change
of
direction piece shall be made and submitted to

such tests as the Employers representative may
require.
PAGE 100 OF 281
449 of 2461
c)
MMRDA
Flexible water stops shall be fully supported in the

form work, free of nails and clear of reinforcement
and other fixtures.
Damaged water stops shall
be replaced and during concreting care shall be

taken to place the concrete so that water stops do
not bend or distort or displace.
d)
The different types of water stops to be used in

liquid retaining structures will be as follows:
Table showing Types of Water Stops
S. No.
1
Type of Joint
Type of Water Stops
Partial/complete
230 mm wide, ribbed
Contraction
joint with hollow centre bulb
in walls and slabs
&
mm
minimum
thickness
2
Expansion joints in 230 mm wide, ribbed

walls and slabs
with hollow centre bulb

&
mm
minimum
thickness
3
Construction joint in 230 mm wide, ribbed

raft

&
mm
minimum
thickness
4
Construction joint in 230 mm wide, ribbed

wall

&
mm
minimum
thickness
5
Expansion joint raft
230 mm wide, ribbed

&
mm
minimum
thickness
PAGE 101 OF 281
450 of 2461
MMRDA
S. No.
6
Type of Joint
Type of Water Stops
Partial/complete
230 mm wide, ribbed
Contraction joint in with hollow centre bulb

raft
&
mm
minimum
thickness
1.5.20.2
Jointing fillers
Joint fillers shall be of durable, compressible and nonextruding material.
Details of jointing material required
here. Type of joint, size or width of joint and joint filler

material to be used with preferred brands if any.
1.5.21 Sealing Compounds
Horizontal joints shall, where used in water-retaining structures be

sealed with a cold pouring polysulphide rubber sealing compound
of quality equal to, or better than serviced Paraseal.
Horizontal
joints in roofs, floors and other non-water retaining structures shall

be sealed with an approved sealant with properties equal to or better
than serviced Paraplastic 41. Vertical joints and joints in the soffits of
slabs in both water retaining as well as non-water retaining structures
shall be sealed with a trowel or gun applied
sealing
compound
such
as
serviced
polysulphide
Vertiseal
rubber
or equivalent.
Sealing compounds shall be fully cured before water is permitted to

come in contact. At 40
C, the curing time would be approximately
7 weeks for polysulphide compounds like CIBA, FOSROC or ROFF as

approved by Employers representative.
1.5.22 Tolerances in Concrete Surfaces
Concrete surfaces for the various classes of unformed and

formed finishes specified in various clauses shall comply with the
tolerances shown in Table hereunder, except where different
tolerances are expressly required by the specification
PAGE 102 OF 281
451 of 2461
MMRDA
In the table line and level and dimension shall mean the lines,
levels and cross- sectional dimensions as specified and required
Surface
irregularities
shall
be
classified
as
abrupt
or
gradual. Abrupt irregularities include by shall not be limited to

offsets and fins caused by displaced or misplaced formwork,
loose knots and other defects in formwork materials, and
shall be tested by direct measurement.
shall
be
tested
Gradual irregularities
by means of a straight template for plane
surfaces and 1.5 m long formed surfaces
Maximum Tolerance (mm) in

Class of
Line &
Abrupt
Gradual
Dimension
Finish
Level
Irregularity
Irregularity
U1
12
U2
U3
F1
12
+12-6
F2
+12-6
F3
+6-
1.5.23 Curing, Protecting, Repairing and Finishing
1.5.23.1
Curing
All concrete shall be kept continuously in a damp or

wet condition by ponding or by covering with a layer of
sacking, canvas, hessian or similar materials and kept
constantly wet for atleast seven days from the date of
placing concrete in case of OPC and 10 days in case of
mineral admixture or blended cements are used. The
period of curing shall be not less than 10 days for concrete
exposed to dry and hot weather condition
PAGE 103 OF 281
452 of 2461
1.5.23.2
MMRDA
Curing with Water
Fresh concrete shall be kept continuously wet for a

minimum period of 10 days from the date of placing of
concrete, following a lapse of 12 to 14 hours after laying of
concrete. The curing of horizontal surfaces exposed to
the drying winds shall however begin as soon
as
the
concrete has hardened. Water shall be applied to

formed
surfaces immediately upon removal of forms.
Quantity of water applied shall be controlled so as to

prevent erosion of freshly placed concrete.
1.5.23.3
Continuous Spraying
Curing shall be assured by use of an ample water supply

under pressure in pipes, with all necessary appliances of
hose, sprinklers and spraying devices.
Continuous
fine mist spraying or sprinkling shall be used, unless

otherwise
specified
or
approved
the Employers
by
representative.
1.5.23.4
Alternate Curing Methods
Whenever
in
the
judgement
of
Employers
the
representative, it is necessary to omit the continuous

spray method, a covering of clean sand or other approved
means such as wet gunny bags, which will prevent loss
of moisture from the concrete, may be used. No type of
covering will be approved which would stain or damage the
concrete during or after the curing period.
Covering shall
be kept continuously wet during curing period. For curing of

concrete in sidewalks, floors, flat roofs of other level
surfaces, the ponding method of curing is preferred.
The method of containing the ponded water shall be
approved by the Employers representative.
Special
PAGE 104 OF 281
453 of 2461
MMRDA
attention shall be given to edges and corners of the

slabs to ensure proper protection to these areas.
The
ponded areas shall be kept continuously filled with water

during the curing period.
1.5.23.5
Curing Compound
Surface coating type-curing compounds shall be used

only by special permission of Employers representative.
Curing
compounds
shall
be
liquid
type
white
pigmented, conforming to US Bureau of Reclamation

specification.
No curing compound shall be used on
surfaces where future blending with concrete, water of acid

proof membrane or painting is specified. Curing compound
shall be used only after getting sufficient / satisfactory
test results at site.
1.5.23.6
Curing Equipment
All equipment and materials required for curing shall

be on hand and ready for use before concrete is
placed.
1.5.23.7
Protecting Fresh Concrete
Fresh concrete shall be protected from defacements

and damage due to construction operations by leaving
forms in place for an ample period. Newly placed concrete
shall be protected by approved means such as tarpaulins
from rain, sun and winds.
Steps as approved by the
Employers representative shall also be taken to protect

immature concrete from damage by debris, excessive
lading, vibration,
abrasion
or
contact
with
other
materials, etc. that may impair the strength and/or

durability of the concrete.
Workmen shall be warned

PAGE 105 OF 281
454 of 2461
MMRDA
against and prevented from disturbing green concrete

during its setting period.
If it is necessary that the
workmen enter the area of freshly placed concrete, the

Employers representative may require that bridges be
placed over the area.
1.5.23.8
Repair and Replacement of Unsatisfactory Concrete
a)
General
Immediately after the shuttering is removed, the

surface of concrete shall be very carefully gone
over
and
attention
all
of
defective
the
areas
called
to
the
Employers representative who
may permit patching of the defective areas or also

reject the concrete unit either partially or in its
entirety. Rejected concrete shall be removed and
replaced by the Contractor.
Holes shall be filled
with mortar composed of one part of cement to one

and half parts of sand passing 2.36 mm I.S sieve
after removing any loose stones adhering to the
concrete. Concrete surfaces shall be finished as
described in specifications or as directed by the
Employers
representative.
Superficial
honey
combed surfaces and rough patches shall be

similarly made good immediately after removal
of shuttering, in the presence of the Employers
representative and superficial water and air holes
shall be filled in. The mortar shall be well worked
into the surface with a wooden float. Excess water
shall be avoided. Unless instructed otherwise by
the Employers representative, the surface of the
exposed concrete placed against shuttering shall
be
rubbed
down
immediately
on removal
of
shuttering to remove fine or other irregularities,

PAGE 106 OF 281
455 of 2461
care
MMRDA
being
taken
to
avoid damaging
the
surface.
Surface irregularities
grinding.
shall
be
removed
by
If reinforcement is exposed or the
honeycombing occurs at vulnerable positions e.g.

ends of beams or columns, it may be necessary to
cut out the member completely or in part and
reconstruct.
The decision of the Employers
representative shall be final in this regard. If only

patching is necessary,
the
edges being cut
perpendicular to the affected surface or with a small

under cut if possible. Anchors, tees or dovetail
slots shall be provided whenever necessary to
attach the new concrete securely in place.
An
area extending several centimeters beyond the

edges and the surfaces of the prepared voids
shall
be saturated with water for 24 hours
immediately before the patching material is placed.

For small repairs the Employers representative
shall permit to repair the same and shall be
repaired at his directions. For major repairs
Contractor shall submit the method of statement
and on approval of same shall carry such repairs
with strict compliance to the method of statement.
b)
Use of Epoxy
The use of epoxy for bonding fresh concrete

used for repairs will be permitted upon written
approval of the Employers representative. Epoxies
shall be applied in strict accordance with the
instructions of the manufacturer.
PAGE 107 OF 281
456 of 2461
c)
MMRDA
Method of Repair
Small size holes having surface dimensions about

equal to the depth of the hole, holes left after
removal of form bolts, grout insert holes and slots
cut for repair of cracks shall be repaired as follows.
The hole to be patched shall be roughened and

thoroughly soaked with clean water until absorption
stops. A 5 mm thick layer of grout of equal parts of
cement and sand shall be well brushed into the
surface to be patched, followed immediately by
the
patching concrete which shall be well
consolidated with a wooden float and left slightly

protrude of the surrounding surface. The concrete
patch shall be built up in 10 mm thick layers, after
an
hour
or
more,
depending
upon
weather
conditions, it shall be worked off flush with a wooden

float and a smooth finish obtained by wiping with
hessian.
A steel trowel shall be used for this
purpose. The mix for patching shall be of the same

materials and in the same proportion as that used in
the
concrete
being
repaired,
although
some
reduction in the maximum size of the coarse

aggregates may be necessary and the mix shall
be kept as dry as possible. Mortar filling by air
pressure (gunniting) shall be used for repair of areas
too large and/or too shallow for patching with
mortar. Patched surfaces shall be given a final
treatment to match the colour and texture of
the surrounding concrete. White cement shall be
substituted for ordinary cement, if so directed by the
Employers representative, to match the shade of
the patch with the original concrete.
PAGE 108 OF 281
457 of 2461
d)
MMRDA
Curing of Patched Work
The patched area shall be covered immediately

with an approved non-staining, water- saturated
material such as gunny bags which shall be
kept continuously wet and protected against sun
and wind for a period of 24 hours. Thereafter,
the patched area shall be kept wet continuously by
a fine spray, or sprinkling for not less than 10 days.
All
fillings
concrete
shall
and
be
shall
tightly
be
bounded
sound,
to
free
the
from
shrinkage cracks after the fillings have been cured

and dried.
e)
Approval by the Employers representative
All materials, procedures and operations used in the

repair work shall be subject to the approval of the
1.5.23.9
Finishing
a)
General
The type of finish for formed concrete surfaces shall

be
as
follows,
unless
varied
by
the
design/architectural drawings and specifications.
When the structure is in service all the surfaces

shall receive no special finish, except repair of
damaged or defective concrete, removal of fine and
abrupt irregularities, filling defective concrete, filling
of holes left by form ties and rods and clean up
of loose or adhering debris.Surfaces which will
be exposed to the weather and which would
PAGE 109 OF 281
458 of 2461
MMRDA
normally be level, shall be sloped for drainage.

Such surfaces shall be provided finishes using
formliners / patterns designed by M/s. Reckli or
equivalent and approved by the Employer.
Unless a horizontal surface or the slope required is

specified, the tops of narrow surfaces such as
stair treads, walls, curbs and parapets shall be
sloped across the width approximately 1 in 30.
Broader surfaces such as walkways, and platforms
shall be sloped about 1 in 50. Surfaces that will be
covered by backfill or concrete, subfloors to be
covered with concrete topping, terrazzo or quarry
tiles and similar surfaces shall be smooth ascended
and leveled to produce even surfaces. Surface
irregularities shall not exceed 6 mm.
Surfaces
which will not be covered by backfill, concrete or

tile toppings
galleries
such as outside decks,
and sumps, parapets,
floors of
gutters,
side-
walks, floors and slabs, shall be consolidated,

screened and floated. Excess water and laitance
shall be removed before final finishing.
Floating
may be done with hand or power tools and started

as soon as the screened surface has attained a
stiffness to permit finishing operations and these
shall be the minimum required to produce
surface
uniform
screened
marks
in
or
texture
and
free
from
other imperfections.Joints
and edges shall be tooled as specified or as

b)
Standard Finish For Exposed Concrete
Exposed concrete shall mean any concrete, other

than floors or slabs, exposed to
view upon
PAGE 110 OF 281
459 of 2461
MMRDA
completion of the works. Unless

specified,
concrete
the
shall
standard
be
an
finish
approved
otherwise
for exposed
finish
using
formliners / patterns designed by M/s. RECKLI or

equivalent. The finish shall be obtained with the use
of lined or plywood forms having smooth and even
surfaces and edges.
Panels of forms shall be of
uniform size and be as large as practicable and

installed with closed joints. Upon removal of forms
the joint marks shall be smoothed off and all
blemishes, protections etc., removed leaving the
surfaces smooth.
c)
Integral Cement Concrete Finish
When specified, an integral cement concrete finish

of specified thickness for floors and slabs shall be
applied either monolithic or bonded, as specified
or directed by the Employers representative. The
surface shall be tested with a straight edge and any
high and low spots eliminated. Floating or trowelling
of the finish shall be permitted only after all surface
water has evaporated. Dry cement or a mixture of
dry cement and sand shall not be sprinkled directly
on the surface of the cement finish to absorb
moisture or to stiffen the mix.
d)
Rubbed Finish
A rubbed finish shall be provided only on exposed

concrete surfaces.
Upon removal of forms, all fins
and other projections on the surfaces shall be

carefully removed, offsets leveled
and
voids
and/or damaged sections immediately saturated

with water and repaired by filling with a concrete or
PAGE 111 OF 281
460 of 2461
MMRDA
mortar of the same composition as was used in the

surface.
The surfaces shall then be thoroughly
wetted and rubbed with carborundun or other

abrasive.
Cement mortar may be used in the
rubbing, but the finished surfaces shall not be

brush coated with either cement or grout after
rubbing. The
finished surfaces shall present a
uniform and smooth appearance.
e)
Protection
All concrete shall be protected against damage until

final acceptance by the Employers representative.
1.5.24 Hot Weather Requirement
a.
All Concrete work performed in hot weather shall be in

accordance with IS:456, except as herein modified.
b.
Admixtures may be used only when approved by the Employers

representative.
c.
Adequate provisions shall be made to lower give limit concrete

temperatures by cool ingredients,
mixing,
preventing
exposure
of
eliminating
mixers
excessive
and conveyors to
direct sunlight and the use of reflective paint on mixers, etc.

The temperature of the freshly placed concrete shall not be
permitted to exceed 38 degrees centigrade.
d.
Consideration shall be given to shading aggregate stockpiles from

direct rays of the sun and spraying stockpiles with water, use
of cold water when available, and burying, insulating, shading
and/or painting white the pipelines and water storage tanks
and conveyance.
PAGE 112 OF 281
461 of 2461
e.
MMRDA
In order to reduce loss of mixing water, the aggregate,

wooden forms, subgrade, adjacent concrete and other moisture
absorbing surfaces shall be well wetted prior to concreting,
placement and finishing shall be done as quickly as possible.
f.
Extra precautions shall be taken for the protection and

curing
of
concrete. Consideration shall be given to continuous
water curing and protection against high temperatures and drying

hot winds for a period of at least 7 days immediately after
concrete has set and after which normal curing procedures may
be resumed.
1.5.25 Placing Concrete Underwater
a)
Under
all
ordinary
conditions,
all
foundations
shall
be
completely dewatered and concrete placed in the dry. However,

when concrete placement under water is necessary, all work shall
conform to IS:456 and the procedure shall be as follows:
Method of Placement
Concrete shall be deposited underwater by means of

tremises, or drop bottom buckets of approved type.
Direction, Inspection and Approval
All work requiring placement of concrete underwater shall

be designed, directed and
to
local circumstances
inspected with due regard

and purposes. All underwater
concrete shall be placed according to specifications

b)
Special precautions shall be taken for prevention of lifting of

concrete due to uplift pressure of subsoil water.
PAGE 113 OF 281
462 of 2461
MMRDA
1.5.26 Precast Concrete
1.5.26.1
General
Precast concrete units, whether manufactured on or off

site, shall comply in every way with the provisions of the
contract for in situ concrete. Wherever possible, precast
units shall be hydraulically pressed.
When ready for
incorporation in the works, precast units shall
be
responsible for the accuracy of the level, shape of the

bed or platform.
A suitable serial number and the date
of casting shall be impressed or painted on each unit.
1.5.26.2
Striking Forms
Side shutters shall not be struck in less than 24 hours after

depositing concrete and no precast unit shall be lifted until
the concrete reaches strength of at least twice the stress to
which the concrete may be subjected to at the time of
lifting.
1.5.26.3
Precast Units
The lifting and removal of precast units shall be

undertaken without causing shock, vibration or undue
bending stresses to or in the units.
removal takes place,
Contractor
Before lifting and

shall
satisfy
the
Employers representative or his representative that the

methods he proposes to adopt for these operations will not
over-stress or otherwise effect seriously the strength of
the precast units.
The reinforced side of the units
shall be distinctly marked.
1.5.26.4
Curing
PAGE 114 OF 281
463 of 2461
MMRDA
All precast work shall be protected from the direct rays of

the sun for at least 7 days after casting and during that
period each unit shall be kept constantly watered or
preferably be completely immersed in water if the size of
the unit so permits.
1.5.27 Slots, Openings, etc.
1.5.27.1
General
Slots,
openings
provided
in
the
or
holes,
concrete
pockets,
work
etc.,
in
shall
be
the approved
positions as per design drawings and as directed by

Employers representative
and extra
reinforcement
should be provided as per design requirement.
Short
pipes with puddle collar shall be fixed in the side wall of

suction pipes.
time
during
They shall be supplied at the appropriate

construction.
Any
deviation
from
the
approved drawings shall be made good by Contractor at

his own expense, without damaging any other work.
Sleeves, bolts, inserts etc., shall also be provided in
concrete work where so required.
1.5.27.2
Grouting
a)
Standard Grout
The proportions of grout shall be such as to produce

a flowable mixture consistent with minimum water
content and shrinkage.
The grout
proportions
shall be limited as follows:
Table shows Proportions for Standard Grout
PAGE 115 OF 281
464 of 2461
S. No.
MMRDA
Use
Grout thickness
Mix proportions
W/c
ratio (max.)
Fluid
Under 25 mm
One part
0.44
Portland cement
to one part sand
2
General
25mm &
One part Portland
less than 50mm
cement to parts of
2 0.53
sand
3
Stiff Mix
50mm & over
One part Portland
3 0.53
cement to parts of
sand
Sand shall be such as to produce a flowable

grout without any tendency to segregate.
Sand for general grouting purposes, shall be graded

within the following limits:
Passing BIS 2.36 mm sieve
95
to
65
to
100%
Passing BIS 1.18 mm sieve

95%
Passing BIS 300 micron sieve
10 to 30%
Passing BIS 150 micron sieve
3 to 10%
Sand for fluid grouts, shall have the fine material

passing the 300 and 150 micron sieves at the upper
limits specified above. Sand, for still grouts,
shall
meet
the
usual grading specifications for
concrete laitance. Anchor bolts, anchor bolt holes

and the bottoms of equipment and column base
plates shall be cleaned of all oil, grease, dirt
PAGE 116 OF 281
465 of 2461
MMRDA
and loose material. The use of hot, strong caustic

solution for this purpose will be permitted. Prior to
grouting, the hardened concrete surfaces to be
grouted shall be saturated with water.
Water in anchor boltholes shall be removed

before grouting is started. Forms around base
plates shall be reasonably tight to prevent leakage
of the grout. Adequate clearance shall be provided
between forms and base plate to permit grout to be
worked properly into
place.
Grouting,
once
started, shall be done quickly and continuously

to prevent segregation, bleeding and breakdown of
initial set. Grout shall be worked from one side of
one end to the other to prevent entrapment of air.
To distribute the grout and to ensure more complete
contact between base plate and foundation and to
help release trapped air, link chains can be used
to work the grout into place. Grout throughout
holes in base plates shall be by pressure grouting.
Variations in grout mixes and procedures shall be
permitted
if
approved
by
the
Employers
representative.
b)
Non-Shrinking Grout for Equipment Foundation
Non-shrinking grout shall be used for grouting

of
machine
anchoring
base
devices
plates,
and
anchor
at
bolts, other
locations
where
ordinary grouts are ineffective due to shrinkage.

It shall be composed of a type of expansive
hydraulic
sheeting binder
and select-graded
aggregates. It shall have properties as mentioned

below:
PAGE 117 OF 281
466 of 2461
MMRDA
Table showing Proportions for Non-Shrinking Grout
S. No. Properties
Values
Maximum grain size 6 mm
Water % (for 80% flow)

15.17
Density
of
hardened
2.27 - 2.30 gm/m1
grout
4
Compressive strength
N/mm2
Minimum 3 days
23
7 days
34
28 days
45
Expansion %
Free
0.10 - 0.20
Restrained
0.08 - 0.12
Restrained
0.08 - 0.12
Mixing, batching, cleaning, preparation of surface

and
curing
done
Brands
as
of
non-shrinking
per
like
grout shall
manufacturers
FOSROC
be
instructions.
/ BUILDMASTER etc
or equivalent brand as approved by Employers

representative shall be used as per manufacturer
specifications.
1.5.28 Inspection
a.
All materials, workmanship and finished construction shall be

subject to continuous inspection and approval of the Employers
representative.
b.
All materials supplied by the Contractor and all work or

construction performed by the Contractor which is rejected as not
being in conformity with the specifications and requirements,
shall be immediately replaced.
PAGE 118 OF 281
467 of 2461
c.
All concrete shall
MMRDA
be
protected against
damage until final
acceptance by the Employers representative.
1.5.29 Clean-Up
a.
Upon completion of the concrete work, all forms, equipment,

construction tools, protective coverings and any debris resulting
from the work shall be removed from the premises.
b.
All debris i.e. empty containers, scrap wood, etc., shall be

removed to dump daily, or as directed by the Employers
representative.
c.
The finished concrete surfaces shall be left in a clean

condition satisfactory to the Employers representative.
1.5.30 Records of Concreting
An accurate and up to date record showing times, dates, weather

and temperature conditions when various positions of all the concrete
structures forming the works were concreted will be kept by the
Contractor and shall be countersigned by the Employers representative.
If
the
Contractor
fails
to
sign
the
Employers representatives
record, it shall nevertheless be regarded as correct and binding on the

Contractor.
The Contractor has to submit concrete pour card in duplicate duly

to
be
signed
to
the Employers representative for each type of
concreting work. Contractor shall keep copy of it, after Employers

representative has checked and signed the pour card.
1.5.31 Supply of Cement
The Contractor shall procure / purchase the cement and shall be sacked
PAGE 119 OF 281
468 of 2461
MMRDA
and well maintained as specified in the earlier sections. Contractor

shall procure cement in those quantities required for maximum one
month of concreting work and more than the prescribed time limit is not
allowed.
For
any
damage
to
cement
Employer
will
not
be
responsible and the damaged cement will not be used in the work.
1.5.32 Foundation Bedding, Bonding and Jointing
In no case foundation shall rest on any loose strata or loose pockets etc.
even though it has reached level shown on design drawings and
referred back to design engineer / Employers representative
a.
All surfaces upon or against which concrete will be placed shall

be suitably prepared by thoroughly cleaning, washing and
dewatering, as specified or as the Employers representative may
direct, to meet the various situations encountered in the work.
b.
Soft or spongy areas shall be cleaned out and backfilled with lean
concrete or clean sand fill compacted.
c.
Prior to construction of formwork for any item where soil will act
as bottom form, approval shall be obtained from the Employers
representative for the suitability of the soil.
1.5.33 Preparation of Rock Strata of Foundations
a.
To provide tight bond with rock foundations, the rock surface shall
be prepared and the following general requirements shall be
observed.
b.
Concrete shall not be deposited on large sloping rock surfaces.

Where required by the
Employers representative,
the
rock
shall be cut to form rough steps or benches to provide

roughness or a more suitable bearing surface.
PAGE 120 OF 281
469 of 2461
c.
MMRDA
Rock foundation stratum shall be prepared by picking, barring,

wedging and similar methods which will leave the rock in an
entirely sound and unshattered condition.
d.
Shortly before concrete is placed, the rock surface shall be

cleaned with high pressure water and air jet even though it may
have been previously cleaned in that manner.
e.
Prior to placing concrete, the rock surface shall be kept wet for
a period of 2
to 4 hours unless otherwise directed by the
f.
Before placing concrete on rock surfaces all water shall

be
removed
from depressions to permit thorough inspection
and proper bonding of the concrete to the rock.
1.6
Formwork
1.6.1 Formwork, Fixing and General
a)
All formwork shall be constructed of waterproof Marine grade

plywood or preferably sheet metal. Plywood used for form work
shall be conforming to BIS:4990 i.e. Specification for plywood for
concrete shuttering works.
The
materials
for
formwork
shall got approved by the Employers representative before

starting
the
work.
Formwork
shall
be firmly supported,
adequately strutted, braced and tied to withstand the placing

and vibrating of concrete and the effects of weather.
The
tolerance on line and level shall not exceed 3 mm and the soffits
of beams other than pre-stressed beams shall in the absence of
any specified camber, be erected with an upward camber of
6 mm for each 3 meters of span.
b)
The Contractor shall be responsible for the calculations

and
designs
for the formwork, and if required, shall submit
PAGE 121 OF 281
470 of 2461
MMRDA
them to the Employers representative for approval before

construction. On form work to external faces, which will be
permanently, exposed, all horizontal and vertical formwork joints
shall be so arranged that joint lines will form a uniform pattern
on the face of the concrete. Where the Contractor proposes to
make up the form work for standard sized manufactured
form work panels, the size of such panels shall be approved by
the Employers representative before they are used in the
construction of the Works. The finished appearance of the entire
elevation of the structure and adjoining structures shall be
considered when planning the pattern of joint lines caused by
form work and by construction joint to ensure continuity of
horizontal and vertical lines.
c)
Faces of form work in contact with concrete shall be free

from adhering foreign matter, projecting nails and the like, splits
or other defects, and all form work shall be clean and free from
standing water, dirt, shavings, chippings or other foreign
matter. Joints shall be sufficiently watertight to prevent the escape
of mortar or the formation of fins or other blemishes on the
face of the concrete and no bleeding should be allowed
through the joints.
d)
Form work shall be provided for the top surfaces of sloping work
where the slope exceeds fifteen degrees from the horizontal
(except where such top surface is specified as spaded finish)
and shall be anchored to enable the concrete to be properly
compacted and to prevent flotation, care being taken to
prevent air being trapped.
e)
Openings for inspection of the inside of the form work and for the
removal of water used for washing down shall be provided and so
formed as to be easily closed before placing concrete. Before
placing concrete, all bolts, pipes or conduits or other fixtures
which are to be built in shall be fixed in their correct positions,
PAGE 122 OF 281
471 of 2461
MMRDA
and cores and other devices for forming holes shall be held fast
by fixing to the formwork or otherwise.
Holes shall not be cut in
any concrete without approval of the Employers representative.
f)
All exterior angles on the finished concrete of 90 degree or less

shall be given
20 mm x 20 mm chamfers unless otherwise
ordered by the Employers representative.
g)
No ties or bolts or other device shall be built into the

concrete for the purpose of supporting formwork without the
prior approval of the Employers representative.
The whole
or part of any such supports shall be capable of removal

so that no part remaining embedded in the concrete shall be
nearer than 50 mm from the surface in the case of reinforced
concrete and 150 mm in the case of un-reinforced concrete.
Holes left after removal of such supports shall be neatly filled with
well rammed dry- pack mortar.
h)
Formwork in contact with the concrete shall be treated with

suitable non-staining mould
oil
to
prevent
adherence
of
the concrete except where the surface is subsequently to

be rendered. Care shall be taken to prevent the oil from coming
in contact with reinforcement or with concrete at construction
joints. Surface retarding agents shall be used only where ordered
i)
No
formwork
shall
be
started
or
placed
unless
the
requirement work is fully completed and checked by Employers

representative.
j)
Necessary cover blocks shall be provided before starting

connection.
1.6.2 Removal of Formwork

PAGE 123 OF 281
472 of 2461
a)
MMRDA
Formwork shall be so designed as to permit any removal

without resorting to hammering or levering against the surface of
the concrete.
b)
The periods of time elapsing between the placing of the concrete

and the striking of the loads likely to be imposed on the concrete
and shall in any case be not less than the periods shown in Table
below. Where soffit formwork
is
constructed
in
a manner
during and after such removal of a sufficient number of adequate

supporting props in an undisturbed condition, the Contractor
may, with the agreement of the Employers representative,
remove the formwork at the earlier times listed below provided
that the props are left in position.
Table showing Period for Formwork
Position of formwork
Days for striking
Walls
Sides of beams and columns
Slabs (Drops left under)
Props to slabs (span not exceeding 4.5m)
Props to slabs (span exceeding 4.5 m)
14
Beams soffits (props left under)
Props to beams (span not exceeding 6 m)
14
Props to beams (span exceeding 6 m)
21
Circular structures, domes, cantilever
21
portions etc.
c)
Notwithstanding the foregoing, the Contractor shall be held

responsible for any damage arising from removal of formwork
before the structure is capable of carrying its own weight and any
incidental loading.
PAGE 124 OF 281
473 of 2461
d)
MMRDA
Striking shall be done slowly with utmost care to avoid damage to

projections and without shock or vibration, by gently easing
the wedges.
If after removing the formwork it is found that
timber has been embedded in the concrete. It shall be

removed and made good as specified earlier.
e)
Reinforced temporary openings shall be provided, as directed

by
the
Employers representative, to facilitate removal of
formwork which otherwise may be inaccessible.
f)
The rods, clamps, form bolts, etc. which must be entirely

removed from walls or similar structures shall be loosened not
sooner than 24 hours not later than 40 hours after the concrete
has been deposited. Ties, except those required to hold forms in
place, may be removed at the same time.
Ties, withdrawn
from walls and grade beams shall be pulled toward the inside
face. Cutting ties back from the faces of the walls and grade
beams will not be permitted.
g)
For liquid retaining structures, no sleeves for through bolts

shall be used nor shall through bolts be removed as indicated
above. The bolts, in this case, shall be cut at 25 mm depth or
more from the surface and then the hole shall be made
good by cement sand mortar of the same proportions as the
concrete just after striking the form work.
1.6.3 Formed Surfaces - Classes OF Finish
a.
Finishes to formed surfaces of concrete shall be classified as F1,

F2, or F3, or such other special finish as may be particularly
specified. Where the class of finish is not specified the concrete
shall be finished to Class F1.
b.
Form work for Class F3 finish shall be lined with as large panels
as possible of non-staining material with a smooth unblemished
PAGE 125 OF 281
474 of 2461
MMRDA
surface such as sanded plywood or hard compressed
fiber
board, arranged in a uniform approved pattern and fixed to

back form work by oval nails. Unfaced wrought boarding or
standard steel panels shall not be permitted.
c.
Form work for Class F2 finish shall be faced with wrought

tongued
and
grooved boards or plywood or metal panels
arranged in a uniform approved pattern free from defects likely to

detract from the appearance of the surface.
d.
Form work for Class F1 finish shall be constructed in sheet

metal. Surfaces subsequently to be rendered, plastered or
tiled shall be adequately scrabbled or hacked as soon as the
form work is removed to reduce the irregularities to not more than
half the thickness of such rendering, plastering or bedding
for tiles and to provide a satisfactory key.
1.6.4 Defects in Formed Surfaces
a.
Workmanship in formwork and concreting shall be such that

concrete shall normally require no making good, surfaces being
perfectly compacted and smooth.
b.
If any blemishes are revealed after removal of formwork, the

Employers
representatives
decisions
measures shall be obtained immediately.
concerning
These
remedial
measures
may include, but shall not be limited to the following:
Fins, pinhole bubbles, surface discolouration and minor

defects may be rubbed down with sacking immediately
after the formwork is removed
Abrupt and gradual irregularities may be rubbed down with

carborundun and water after the concrete has been fully
cured. These and any other defects shall be remedied
PAGE 126 OF 281
475 of 2461
MMRDA
by methods approved by the Employers representative

which may include using a suitable epoxy resin or, where
necessary, cutting out to a regular dovetails shape at least
75 mm deep and refilling with concrete over steel mesh
reinforcement sprung into the dovetail
c.
The
form
work
shall
be
checked
by
the
Employers
representative before the form work starts and form found

defective shall be rejected and the same can be used after
rectifying the defects and with due approval of the Employers
representative.
1.6.5 Holes to be Filled
1.
Holes formed in concrete surfaces by form work supports or the

like shall be filled with dry-pack mortar made from one part by
weight of ordinary Portland cement and one part fine aggregate
passing BIS sieve 1.18 mm. The mortar shall be mixed with only
sufficient water to make the materials stick together when being
moulded in the hands.
2.
The Contractor shall thoroughly clean any hole that is to be

filled
with
dry-pack mortar and where the surface has been
damaged, the Contractor shall break out any loose, broken or

cracked concrete or aggregate.
The concrete surrounding the
hole shall then be thoroughly soaked after which the surface shall
be dried so as to leave a small amount of free water on the
surface.
The surface shall then be dusted lightly with ordinary
Portland cement by means of a small dry brush until the whole

surface that will come into contact with the dry-pack mortar has
been covered and darkened by absorption of the free water
on the surface. The surface shall then be dusted lightly with
ordinary Portland cement by means of a small dry brush until the
whole surface that will come into contact with the dry-pack mortar
has been covered and darkened by absorption of the free water
PAGE 127 OF 281
476 of 2461
MMRDA
by the cement. Any dry cement in the hole shall be removed.
3.
The dry-pack material shall then be placed and packed in layers

having a compacted thickness not greater then 15 mm.
The
compaction shall be carried out by use of a hardwood stick and

a hammer and shall extend over the full area of the layer,
particular care being taken to compact the dry-pack against
the sides of the hole. After compaction, the surface of each
layer shall be scratched the dry-pack fill and striking the block
several times.
Steel finishing tools shall not be used and
water shall not be added to facilitate finishing.
1.6.6 Tolerances
Tolerance is a specified permissible variation from lines, grade or

dimensions given in approved drawings. No tolerance specified for
horizontal or vertical building lines or footings shall be construed to
permit encroachment beyond the legal boundaries. Unless otherwise
specified, the following tolerances will be permitted:
Tolerances for RCC Structures
i.
Variation from the plumb
In the lines and surfaces of columns, piers, walls 5 mm per 2.5 m

or 25 mm, whichever is less.
For exposed corner columns and other conspicuous lines
In any bay or 5 m maximum
In 10 m or more
ii.
5 mm
10 mm
Variation from the level or from the grades indicated on the

approved drawings
PAGE 128 OF 281
477 of 2461
MMRDA
In slab soffits, ceilings, beam soffit, and in arises
In 2.5 m
5 mm In any bay or 5 m maximum
In 10 m or more
15 mm
10 mm
For exposed lintels, sills, parapets, horizontal grooves and other

conspicuous lines

In 10 m or more
iii.
5 mm
10 mm
Variation of the linear building lines from established position

in plan and related position of columns, wall and partitions

In 10 m or more
iv.
10 mm
20 mm
Variation in the sizes and locations of sleeves, openings in walls

and floors Except in the case of and for 5mm anchor bolts
v.
Variation in cross sectional dimensions of columns and beams

and in the thickness of slabs and walls
vi.
Minus
5 mm
Plus
10 mm
Footings
Variation in dimension in plan
vii.
Minus
5 mm
Plus
10 mm
Misplacement or eccentricity 2% of footing width in the direction of
PAGE 129 OF 281
478 of 2461
MMRDA
misplacement but not more than 50 mm Reduction in thickness:

Minus 5% of specified thickness subject to a maximum of 50 mm
viii.
Variation in steps
In a flight of stairs
Rise
3 mm Tread 5 mm In consecutive steps
Rise
1.5 mm
Tread
3 mm
Tolerances in other Concrete Structures
ix.
All structures
Variation of the constructed linear outlines from established

position in plan
In 5 m
10 mm
In 10 m or more
15 mm
Variations of dimensions to individual structural features from

established positions
In 20 m or more
25 mm
In buried construction
50 mm
Variation from plumb, from specified batter or from curved

surfaces of all structures
In 2.5 m
10 mm
In 5 m
15 mm
In 10 m or more
25 mm
twice the above amounts
PAGE 130 OF 281
479 of 2461
MMRDA
Variation from level or grade indicated on approved drawings

in slab, beams, soffits, horizontal grooves and visible arises
In 2.5 m
5 mm
In 7.5 m or more
10 mm
Twice the above amounts
Variation in cross-sectional dimensions of columns, beams,

buttresses, piers and similar members
Minus 5 mm
Plus
x.
10 mm
Footings for columns, piers, walls, buttresses and similar

members
Variation of dimensions in plan

Minus 10 mm Plus 50 mm Misplacement or eccentricity
2% of footing width in the direction of misplacement but not more

than 50 mm. Reduction in thickness
5% of specified thickness subject to a maximum of 50 mm
xi.
Tolerance
in
other
types
of
structures
shall
generally
conform to those given in Clause 2.4 of Recommended

Practice for Concrete Formwork (American Concrete Institute
Act 347).
xii.
Tolerance in fixing anchor bolts shall be as follows:
Anchor bolts without sleeves
+ 5 mm
Anchor bolts with sleeves
+ 5 mm for bolts up to 20 mm dia
3 mm for bolts
above 32 mm dia
Embedded parts
+ 5 mm in all directions
PAGE 131 OF 281
480 of 2461
MMRDA
1.6.7 Bracing, Struts and Props
a.
Form
work
shall
be
braced,
strutted,
propped
and
so
supported that it shall not deform under weight and pressure of

the concrete and also due to the movement of men and other
materials. Bamboo shall not be used as props or cross bearers.
b.
The formwork for beams and slabs shall be so erected that the
formwork on the sides of the beams and under the soffit of
slabs can be removed without disturbing the beam bottoms.
Repropping of beams shall not be done except when props have
to be reinstated to take care of construction loads anticipated to
be in excess of the design load.
Vertical props shall be
supported on wedges or other measures shall be taken whereby

the props can be gently lowered vertically while striking the
formwork.
c.
If the formwork for a column is erected for the full height of the
column, one side shall be left open and built up in sections
as placing of the concrete proceeds, or windows may be left
for pouring concrete from the sides to limit the drop of concrete to
1.0 m as directed by the Employers representative.
The Contractor shall submit the detailed design and methodology with
applicable drawings if any of Formwork system for different members for
approval of Employers representative.
1.7
Reinforcement
IS:432
Mild steel and medium tensile steel bars & hard

drawn steel wire for concrete reinforcement
PAGE 132 OF 281
481 of 2461
IS:1786
MMRDA
Cold twisted steel bars for concrete reinforcement

(CTD)
IS:2502 (1963)
Code
of
practice
for
bending
and
fixing
of bars for concrete reinforcement
IS:55225(1969)
Recommendations for detailing of reinforcement

in RCC works
IS:2751
C.P. for welding of MS bars used for RCC
IS:9417
Recommendations for welding cold worked

steel bars for RCC
IS:10790
Methods of sampling of reinforced steel
1.7.2 General
Reinforcement shall be CTD and high strength deformed corrosion

resistant (CRS) bars as per IS:1786 Fe415.
Wire mesh or fabric
shall be in accordance with IS:456. Substitution of reinforcement will

not be permitted except upon written approval from the Employers
representative.
1.7.3 Storage
a.
The reinforcement shall not be kept in direct contact with the

ground but stacked on top of an arrangement of timber sleepers
or the like.
b.
If the reinforcing rods have to be stored for a long duration, they

shall be coated with cement wash before stacking and/or be kept
under
cover
or
stored
as
directed
by
the
Employers
representative.
PAGE 133 OF 281
482 of 2461
c.
MMRDA
Fabricated reinforcement shall be carefully stored to prevent

damage, distortion, corrosion and deterioration.
d.
It should be seen that the reinforcement will not be exposed to

direct sunlight and preventive measures should be taken for the
same.
1.7.4 Quality
All reinforcements shall be clean, free from grease, oil paint, dirt, loose
mill scale, loose rust,
dust
bituminous
material
or
any
other
substances that will destroy or reduce the bond. All rods shall be
thoroughly cleaned before being fabricated. Pitted and defective rods
shall not be used.
No welding of rods to obtain continuity shall be
allowed unless approved by the Employers representative. If welding is

approved, the work shall be carried out as per IS:1786 - Fe415
according to the best modern practices and as directed by the
In all cases of important connections, tests
shall be made to prove that the joints are of full strength of bars welded.
Special precautions, as specified by the Employers representative, shall
be taken in the welding of cold worked reinforcing bars and bars other
than mild steel.
1.7.5 Laps
Laps and splices for reinforcement shall be as per IS:456-2000. Splices

in adjacent bars shall be staggered as mentioned in structural drawings
and locations of all splices shall be approved by the Employers
representative.
Also Contractor shall submit the Bar bending schedule for approval
of Employers representative and shall follow same unless and until
changed by any design changes.
1.7.6 Bending
PAGE 134 OF 281
483 of 2461
a)
MMRDA
Reinforcement bars supplied bent or in coils, shall be straightened

before they are cut to size. Straightening of bars shall be done
cold and without damaging the bars.
b)
All bars shall be accurately bent according to the sizes and

shapes shown on the approved detailed working drawings/bar
bending
schedules.
They
shall
be
bent gradually
by
machine or other approved means. Reinforcing bars shall not

be straightened and re-bent in a manner that will injure the
material; bars containing cracks/splits shall be rejected. They
shall be bent cold, except bars of over 25 mm in diameter, which
may be bent hot if specifically, approved by the Employers
representative.
Bars, which depend for their strength of cold
working, shall not be bent hot. Bars bent hot shall not be trea ted
beyond cherry red colour (nor exceeding 845C) and
after
bending shall be allowed to cool slowly without quenching.

Bars incorrectly bent shall be used only if the means used for
straightening and re-bending be such
as
shall not,
in
the
opinion of the Employers representative, injure the material.

No reinforcement shall be bent when in position in the work
without
approval, whether or not it is partially embedded in
hardened concrete. Bars having kinks or bends other than those

required by design shall not be used.
1.7.7 Fixing
Reinforcement shall be accurately fixed by any approved means and

maintained in the correct position shown in the approved Drawings
by the use of blocks, spacers and chairs, as per IS:2502 to
prevent displacement during placing and compaction of concrete.
Bars intended to be in contact at crossing points shall be securely
bound together at all such points with number 16 gauge GI wire.
The vertical distances required between successive layers of bars
in beams or similar members shall be maintained by the provision of
PAGE 135 OF 281
484 of 2461
MMRDA
mild steel spacer bars at such intervals that the main bars do not
perceptibly sag between adjacent spacer bars. No binding wire shall
protrude in cover area and shall bent inside.
1.7.8 Cover
Unless indicated otherwise, clear concrete cover for reinforcement

(exclusive of plaster or other decorative finish) shall be as follows:
a.
At each end of a reinforcement bar, not less than 25 mm

nor less than twice the diameter of the bar whichever is greater
b.
For a longitudinal reinforcing bar in a column, not less than 40

mm, nor less than the diameter of the bar. In case of columns of
minimum dimension of 20 cm or under with reinforcing bars of 12
mm and less in diameter, a cover of 25 mm may be used.
c.
For longitudinal reinforcing bars in a beam, not less than 40 mm

nor less than the diameter of the bar, whichever is greater
d.
For tensile, compressive, shear or other reinforcement in a

slab, or wall, not less than, 20 mm, nor less than the diameter
of such reinforcement.
e.
For any other reinforcement, not less than 20 mm, nor less than
the diameter of such reinforcement.
f.
For footing and other principal structural members in which the

concrete is poured on a layer of lean concrete, the bottom cover
shall be reduced to 60 mm.
g.
For concrete surfaces exposed to the weather or the ground after

removal of forms, such as retaining walls, grade beams, footing
sides and tops, etc. not less than 40 mm for bars larger than 16
mm diameter and not less than 30 mm for bars 16 mm
PAGE 136 OF 281
485 of 2461
MMRDA
diameter or smaller.
h.
For liquid retaining structures, the minimum cover to all steel shall
be 40 mm or the diameter of the main bar, whichever is greater.
i.
The correct cover shall be maintained by cement mortar

cubes or other approved means. Reinforcement for footings,
grade beams and slabs on subgrade shall be supported on
precast concrete blocks as approved by the Employers
representative. The use of pebbles or stones shall not be
permitted.
j.
The 28 day crushing strength of cement mortar cubes/precast

concrete cover blocks shall
be
at
least
equal
to
the
specified strength of concrete in which these cubes/blocks

are embedded.
k.
The minimum clear distance between reinforcing bars shall

be in accordance with IS:456.
1.7.9 Inspection
After final erection of
reinforcement,
it shall be
intimated to
Employers representative in writing or through pour cards. Erected and

secured reinforcement shall be inspected and approved by the
Employers representative prior to placement of concrete.
1.7.10 Welding of Reinforcement
a)
Reinforcement which is specified to be welded shall be welded by

any process which conforms
with
the
requirements
of
IS:2751 and which the Contractor can demonstrate by bend

and tensile tests will ensure that the strength of the parent metal
is not reduced and that the weld possesses a strength not less
than that of the parent metal. The
welding
procedure
PAGE 137 OF 281
486 of 2461
established
by
MMRDA
successful
test welds
shall
be maintained
and no deviation from this procedure shall be permitted.
b)
Welds in positions other than those shown on the approved

Drawings shall not be permitted. Tack welding to lightly secure
reinforcement in place will be permitted subject to approval of the
1.7.11 Supply of Reinforcing Bars
Steel reinforcement, such as MS bars HYSD bars etc. required for

the works shall be procured by Contractor. The Contractor shall
arrange for transport, loading, unloading and storage at the work
sites. The Contractor should plan the procurement of steel in such
a way that at least required quantity of steel of specified sizes is
available at site for 3 months period.
Steel brought on site shall be stored in proper manner as approved by

Employers representative so as to avoid distortion, deterioration and
corrosion. The Contractor shall maintain proper register for the steel
account, showing the steel received at site, steel used, and the balance
stock on site, to the entire satisfaction of the Employers representative.
1.8
Structural Steel Work
IS:2062
Specification for Structural Steel (Fusion Welding

Quality)
IS:800
C.P. for general construction in steel
IS:808
R.S. beam, channel and angel sections
IS:814
Covered electrodes for metal arc welding of
PAGE 138 OF 281
487 of 2461
MMRDA
structural steel
IS:1148
Hot rolled steel rivet bars for structural purpose
IS:1363
Black hexagon bolts, nuts, and lock nuts (dia

6 to 39mm) & black hexagon screws (dia 6 to
24mm)
IS:2062
Structural steel (fusion welding quality)
IS:3954
Hot rolled steel channel sections for general

engineering purposes
SP-6 (I
ISI Handbook for Structural Engineers
Handbook on structures with steel portal frames
VII)
SP-40
(without cranes)
1.8.2 General
Structural steel fabrication work shall include all types of steel structural
work required for installation of platform for operation and installation of
equipment where rolled steel sections are joined together either by
bolting or riveting or welding as
specified
in
the drawings/bill of
quantities/directed by the Employers representative. It shall also include

fabrication and installation of air vessels/pressure vessels etc. Covers for
ducts for electrical panels along with their seating arrangements are
also
classified
under
this
heading
unless
they
are provided
separately under a different heading. Reaction tanks or storage vessels

are also classified under this heading.
1.8.3 Materials
The MS structural members such as MS angles, channels, flats, I

sections etc. shall conform IS 2062. Structural steel that is used for
PAGE 139 OF 281
488 of 2461
MMRDA
fabrication shall be conforming to any of the following grades of steel as

specified to each of the works:
IS:2062
Specification for Structural Steel (Fusion Welding

Quality)
IS:1977-1975 :
Structural steel (ordinary quality)
IS:2062-1980 :
Weldable Structural steel (fusion quality)
Whenever the Contractor supplies steel, he shall on demand the test

certificates from the manufacturer.
The welding rods used for fabrication shall conform to IS:814-1974

(parts I and II). The fasteners like bolts, nuts etc., shall conform to
IS:1367. Rivets shall conform to IS:1184-1982. Plain washers shall
conform to IS:2016-1967. Spring washers shall conform to IS:30631972.
MS rivets shall conform to IS:1148 and IS:1929-1967 bolts and

nuts shall conform to IS:1363 - 1967.
If metal arc welding is to be done as per design or as ordered by the

Employers representative the electrodes used for strength welds shall
conform to IS: 814 and shall be of such shape and size approved by the
Employers representative and shall be prevented from oxidation and
shall be kept in clean condition.
Paints used shall be of approved manufacture and shade and

shall conform to the ISI standards.
1.8.4 Fabrication and Erection
All the shop drawings shall be prepared by the Contractor and

submitted in advance of atleast
15
days
to
the
Employers
PAGE 140 OF 281
489 of 2461
MMRDA
representative for his approval.

in triplicate.
The drawings shall be submitted
The fabrication work shall not be taken in hand until the
shop drawings are approved by the Employers representative.

Approval of the shop drawings however shall not relieve the Contractor
of his responsibility of correct conformation to the designs and
fabrications of the
structure
to
meet
the
requirements
of
the
contract. One copy of the approval drawings shall be given to the

Contractor for going ahead with the fabrication work.
In the shop drawings to be submitted by the Contractor, standard

symbols as described in the IS:813-1961 shall be followed.
Fabrication work shall be carried out as laid down in IS:800-1984 Code

of practice for general construction in steel.
Welding shall be carried out in accordance with the following

specifications as applicable:
IS:803 - 1976
Code of practice
for design
fabrication
and
erection of vertical mild steel cylindrical welded oil

storage tanks
IS: 816 - 1969 :
Code of practice for use of metal and welding

for general construction in mild steel
IS:822 - 1970
Code of practice for manual and welding of mild

steel
IS:9595 - 1980 :
Recommendations for metal are welding of carbon

Radiographic tests are required to be carried out
as directed by the Employers representative in
case of pressure vessels
IS:818 - 1968
Code
of
practice
requirements
in
for
safety
and
health
electric and gas welding and

PAGE 141 OF 281
490 of 2461
MMRDA
cutting operations
IS:3016-1982
Code of practice for fire precautions in welding

and cutting operations
IS:7205 1973 :
Safety code for erection of structural steel work
The sections shall be fixed absolutely vertical or to the specified angle

as shown in the drawings/as desired/directed by the Employers
representative.
All connections like angle brackets, cleats, gusset plates, anchor

bolts, bearing plates shall all be fixed as shown in the drawings or as
The items of work shall include supply of materials, fabrication and

erection in position on site as shown in the drawings. This shall also
include all labour consist, materials and equipment required for all
fabrication, hoisting, erection, and satisfactory completion of the item of
work.
The supply of materials includes all structural members like rolled

sections, plates, brackets, rivets, bolts and nuts and welds.
The steelwork shall be painted as specified in the drawings,

specification
or as
directed
by the
Unless otherwise provided for in the bill of quantities separately, the

rate quoted for the item is inclusive of all costs for painting like cost of
paint, cost of labour, scaffolding etc. Welding work shall be done
generally using electric arcs welding. Where public electricity is not
available, generators shall be arranged by the Contractor himself.
Gas welding shall not be allowed to be resorted to for welding.

Under
special circumstances if in the opinion of the Employers
PAGE 142 OF 281
491 of 2461
MMRDA
representative it cannot be avoided, gas welding can be done with the

prior permission of the Employers representative.
However gas
welding shall not be used where structural strength is the criteria for
consideration.
All arrangements shall be made by the Contractors for access for

inspection by the Employers representative or his representative to
the workshop where the welding work is being carried out
and
necessary equipment like gauges, measuring instruments etc.,

shall be made available to the inspecting personnel.
Painting work shall not be started without the express approval of the
Employers representative and the painting shall be started only after
his inspection and approval of the works after carrying out surface
preparations.
All holes shall be carefully marked. Holes shall have their axis
perpendicular
to
the surfaces bored through.
Holes being made
through two or more members shall be truly concentric. Holes shall not
be formed cutting process.
All the temporary connections of parts during assembly shall be done

in the following ways. For welded structures. Tack welding fixtures.
After welding is over, the surface on the joint should be ground and
made smooth and even. The welding should be so perfect so as
to give required strength as taken for designed purpose at joints
in particular. The Contractor will make necessary arrangements
for testing of joints as required by Employers representative.
Welded joints shall be free from defects that would impair the service
performance of the construction.
All the welds shall be free from
incomplete penetration, incomplete fusion, slag inclusion, burns, unwelded
creators
undercuts
and
cracks
in
the
welded
metal,
porosity etc. All the defects shall be rectified as directed by the

PAGE 143 OF 281
492 of 2461
MMRDA
Employers representative. Defective portions shall be removed to the

sound metal and re-welded. Rectification of the welds by caulking shall
not be permitted.
All welds shall be cleaned of stag and other deposits after completion.
1.8.5 Painting
Painting shall generally comply with IS subject to addition and

alterations as may be prescribed in the special provisions for any
particular item.
It shall also comply with the requirements of the
manufactures specifications. One priming coat of red lead shall be

applied immediately after fabrication. Two coats of oil paint of approved
shade shall be applied after complete erection. The structural steel to
be embedded in concrete shall not be painted.
Inspection and testing shall be carried out in conformity with IS:800.
Riveting, welding and bolting shall not be started until such time
as the Employers representative has personally satisfied himself
that the alignment is correct, in the vertical plumb, the camber
correct with camber packs, screwed tight, all joints and cover
plates fixed tightened with service bolts and field rivet holes coinciding.
While assembling holes in different components shall be made
concentric with the use of drills before service bolts are fixed.
Welding if required shall be done as per standard practice and

as approved by the Employers representative.
All permanent machine fitted nuts and bolts must be perfectly tight and
shall be burred or otherwise checked to prevent nuts from becoming
loose.
No unfitted rivet or bolt holes are to be left in any of the
structure.
Structural Steel
PAGE 144 OF 281
493 of 2461
MMRDA
All structural steel shall conform to IS:2062-1984. The steel shall

be free the defects mentioned in IS given above and shall have a
smooth finish.
The material shall be free from loose mild scale, rust
pits or other defects affecting the strength and directly.
1.8.5.1
General
Approval of the Employers representative shall be
obtained before commencing the painting work. All paints
and preserves shall be of approved make and colour and
their application shall conform to the manufactures
instructions. Where more than one undercoat is specified
it shall be applied
Workmanship
shall
in
coats
conform to
of
distinctive
the
tints.
requirement of
IS:2395
Unless the manufacturers instructions state otherwise48
hours drying time shall elapse between successive
applications of any primer and 24 hours between
applications of all subsequent coats. The surface of
bituminous paints shall be left at least 3 days before
further handling.
No paints in any coats shall be applied until the

Employers representative is satisfied that the surface is
clean and dry. And that any previous coat is satisfactory
and has hardened adequately. When a surface has been
approved, it must be painted immediately.
Paint work shall be rubbed down with a glass paper

between coats. No paint shall be applied to a surface,
which is damp, dirty or otherwise inadequately prepared.
1.8.5.2
Ironwork and Ungalvanised Steelwork
PAGE 145 OF 281
494 of 2461
MMRDA
Structural steelwork shall be shot blasted to a "white

metal" finish, and grease and oil removed prior
painting.
Priming
cleaning
and
shall
no cleaned
immediately
surface
follow
shall
be
to
blast
left
unprimed for more than four hours. Only primers that

chemically inhibit corrosion shall be used. Where the iron
or steelwork is not in contact with raw or treated water,
the primer shall be red lead complying with IS: 57.
Where there is a possibility that the steel or ironwork
may come in contact with water, the priming treatment
shall be non toxic, zinc chromate or equivalent. Where it is
anticipated that further welding will be required. an
approved welding primer shall be applied to the areas to
be welded and re primed with the main primer when
welding has been completed. Primer coats shall not be
less than 0.05 mm each.
After erection, all damaged areas shall be made good,

and re primed where the original coat has spread under
the primer, the affected surface shall be cleaned
down to bare metal to the satisfaction of the Employers
representative and then re primed.
Repainting shall be carried out as soon as possible after

erection. If` it is to he exposed to weather or
condensation, it shall receive one further coal of primer.
Metalwork in intermittent or permanent contact with raw or

treated water shall have two finishing coats of an
approved coal tar pitch epoxy paint such as "Epilux 5" by
Berger Paints, or equivalent. The total coating shall be
minimum of 0.125 mm thick.
After the second coat of primer is hard dry, the entire

PAGE 146 OF 281
495 of 2461
MMRDA
surface shall be wet rubbed cutting down to a smooth

uniform surface. When the surface becomes dry, be
undercoat
of synthetic enamel paint conforming-to
IS:2932 of optimum thickness shall be applied by brushing

with minimum of brush marks. The coat shall be
allowed to hard dry. The under coat shall then be
wet rubbed cutting down to a smooth finish, taking
adequate care to ensure that at no place the undercoat
is
completely removed. The
surface
shall then be
allowed to dry.
The
first finishing coat of paint shall be
applied
by
brushing and allowed to hard dry. The gloss from the

entire surface shall then be gently removed and the
surface dusted off. The second finishing coat shall then
be applied by brushing.
At
least
24
hours
shall
elapse
between
the
application of successive coats. Each coat shall very

slightly in shade and this shall be got approved by the
1.9
Brick Work and Stone Masonry
These specifications deal with all types of brickwork required for buildings,
manholes, drains, retaining walls or any construction made out of bricks.
IS:1077
Common burnt clay building bricks
IS:2180
Heavy duty burnt clay-building bricks
IS:2212
C.P. for brickwork
PAGE 147 OF 281
496 of 2461
IS:3495 (I
MMRDA
Method of test for clay building bricks
Method of sampling of clay building bricks
IV)
IS:5454
1.9.2 Materials
1.9.2.1
Bricks
Bricks used for the construction of brick masonry

shall be sound, hard, rectangular in shape and size
and well burnt of uniform deep red, cherry or copper
colour and shall conform to IS:1077-1986.
The bricks shall be brought from approved brick kilns.

The bricks shall be free from cracks, chippings flaws,
stones or lumps of any kind.
show
any signs of
The bricks shall not
efflorescence and
shall be
homogeneous in texture.
They should emit a clear metallic sound on being

struck and shall have a minimum compressive strength
of 50 kg/sq.cm. They shall not absorb water more than
specified in the Indian Standard Specifications, of its dry
weight when soaked in cold water for 24 hours.
1.9.2.2
Mortar
The proportion of the cement mortar used for the masonry

work shall be as specified on the various drawings for
different
places / types
of
construction,
bills
of
quantities, specifications for each part of the work.
Mortar should be prepared by volume using boxes of

appropriate sizes on clean platform or this sheet to avoid
mixing of foreign material and maintain consistency of
PAGE 148 OF 281
497 of 2461
MMRDA
mortar.
Sharp coarse sand is mixed with the required quantity of

cement for the preparation of the mortar. Mortar shall be
prepared in accordance with IS:2250-1981.
The sand
used for the masonry mortar shall meet the requirements

as specified in IS:2116-1980.
mortars.
Sand for
masonry
Sand and cement of required proportions
are mixed in small quantities in a dry state first and then

water is added to make the mortar of required the
consistency suitable for the type of work it is required
No left
over mortar shall be used and therefore only that

much quantity of mortar that can be consumed within 30
minutes shall be mixed in batches.
1.9.3 Construction
The brick masonry shall be constructed as per the Indian Standard

Code of Practice for Brick Work - IS:2212-1962.
The thickness of the
joints shall not be thicker than those specified in of the above Code of
Practice.
The bricks shall be thoroughly soaked in water before using them on

the work for at least six hours and all the air bubbles shall come
out during soaking process. The soaked bricks shall be stacked on
wooden planks/platforms so as to avoid sticking of the earth and other
materials on to the surfaces of bricks. Bricks required for construction
in mud mortar or lime mortar shall not be soaked. Brickwork shall
be laid in English Bond unless otherwise specified. Half bricks shall
not be used except when need to complete the bond.
Each course
shall be perfectly straight and horizontal. The masonry shall be true to

plumb in case of vertical walls and in case of battered construction the
batter or slope shall be truly maintained.
The level of the courses
completed shall be checked at every metre interval or less as required.

PAGE 149 OF 281
498 of 2461
MMRDA
The bricks shall be laid frogs upwards. While laying the bricks they
shall be thoroughly bedded and flushed in mortar and well trapped
into position with wooden mallets and superfluous mortar shall be
removed.
No part of the structure shall be raised more than one meter above
than the rest of the work. In case it is unavoidable the brickwork shall
be raked back at an angle of not more than 45 degrees so as to
maintain a uniform and effectual bond, but raking shall not start within
60 cms from a corner.
In cases of construction of buttresses, counterforts, returns they

are built course by course carefully bound into the main walls. At
all junctions of walls the bricks at alternate courses, shall be carried
into each of the respective walls so as to thoroughly unite both the
walls
together.
The brickwork shall not be raised
more than 14
courses per day.
All the beds and joints shall be normal to the pressures applied upon
them i.e. horizontal in vertical walls, radial in arches and at right
angles to the face in battered retaining walls.
Vertical joints in alternate courses shall come directly one over the
other and shall be truly vertical.
Care shall be taken to ensure
that all the joints are fully filled up with mortar, well flushed up
where
no
pointing
is
proposed,
neatly
struck
as
the
work
proceeds. The joints in faces, which are plastered or painted, shall be

squarely raked out to a depth not less than 12 mm while the mortar is
still green. The raked joints shall be well brushed to remove the loose
particles and the surfaces shall be cleaned with a wire brush so as to
remove any splashes of mortar sticking to the surfaces during the
construction.
All iron fixtures, pipes, bolts, conduits, sleeves, holdfasts etc., which are
PAGE 150 OF 281
499 of 2461
MMRDA
required to built into the walls shall be embedded in cement mortar or

cement concrete as shown in the drawings/indicated in
specifications directed during the
execution by the
the
Employers
representative as the work proceeds and no holes be left for fixing them
at a later date unless authorised by the Employers representative.
1.9.4 Curing
Fresh work shall be protected from rain by covering the work suitably.
Masonry work as it progresses shall be thoroughly kept wet by
watering on all the faces for atleast 7 (Seven) days after completion
of the parts of the work.
Proper watering cans, flexible pipes, nozzles
shall be used for the purpose. The top of the masonry work shall be
kept flooded at the close of the days work by constructing fillets of
mortar 40 mm high all around the edges of the top course. In case of
fat lime mortar curing shall start two days after construction of masonry
and shall continue for seven days.
No additional payment is
admissible for curing and the rates quoted are deemed to be inclusive
of the cost of curing.
1.9.5 Scaffolding
Double scaffolding sufficiently strong so as to withstand all loads that

are likely to come upon it and having two sets of vertical supports shall
be provided.
Where two sets of vertical supports are not possible
the inner end of the horizontal supporting pole shall rest in a hole
provided in a header course only. Only one header for each pole shall
be left cut. Such holes, however shall not be permitted in pillars under
one meter in width or immediately near the skewbacks of arches. Such
holes shall be filled up immediately after removal of the scaffoldings.
Safety Code for Scaffolds and Ladders, IS:3696-1987 (Parts I and II)
shall be followed. The cost of scaffolding is deemed to be included in
the rates quoted.
1.9.6 Stone Masonry for Retaining Walls

PAGE 151 OF 281
500 of 2461
MMRDA
Stone masonry in general is to be used for retaining walls as per

Employers representative instructions and as per drawings, which will
be supplied during course of construction to suit site conditions.
Following Indian Standards shall be applicable:
IS:1122-1974
Methods of determination of specific gravity

and porosity of natural building stones
IS:1200
Method of measurement of stone masonry
IS:1597
Code of practice of construction of rubble stone

masonry
IS:1805
Glossary of terms relating to stone quarrying

and dressing
IS:4101
Stone facing
IS:1121
Determination of strength, properties of natural

building stones
1.9.7 Uncoursed Stone Masonry
Uncoursed stone masonry shall be built in layers not exceeding 450

mm in height. No stone shall be less in breadth than 14 times its
height and less in length than twice its height. Every stone whether
large or small, shall be laid in its natural bed and set flush in mortar, and
the small stones used for wedging or filling being carefully selected to fit
the interstices between the large stones. Care shall be taken to see that
no dry work or hollow space is left in the masonry. The stones shall be
so arranged as to break joints at least every 80 mm and long vertical
joints of joints shall be avoided. The joints at the face shall be
finished off neatly, being struck and smoothed with a trowel while the
PAGE 152 OF 281
501 of 2461
MMRDA
mortar is fresh. The upper surface of the work shall be brought to a

uniform level at the height of each course. The faces of masonry walls
shall be kept in perfect plumb and where batter has to be given it shall,
be uniform. The stones at all comers and junctions of walls shall be of
large sizes and hammer dressed to the correct angle.
Each stone shall be thoroughly wetted before being used in the work.
The masonry shall be kept thoroughly wet during the progress of
the work, (care being taken to water it even on Sundays and
Holidays, special labour being employed if so required for this
purpose) until it becomes hard. As far as practicable, the whole of the
masonry shall be raised in one uniform level and no part of the masonry
shall he allowed to rise more than 1 metre above the rest to avoid
unequal settlement. If raising one part of wall before the other becomes
unavoidable the end of the raised portion shall be racked back in steps
to prevent cracks developing at the junction of the old and new work.
Care shall be taken to see that the sides of the wall are not built
separately from the hearting, the faces and internal filling being
done simultaneously .The stones shall overlap and cross each other as
much as possible. No course shall be laid unless the previous course is
perfectly set.
Al least one header or through stone per square metre of` wall face
shall be built into the work. The headers or through stones shall be at
least 0.05 m in area al face and shall have at least 0.025 m area at
the back face. Where the thickness of the wall is more than 600 mm a
series of through stones shall be laid through the work so as to form a
tie from front to back, breaking joints or overlapping each other for at
least 150 mm.
No stone whose length is less than 600 mm shall be
used in such work as a header.
All the through stones shall be marked inside and outside and the
marks shall be retained until
ordered
by
the
Employers
representative to be removed. Sufficient number of headers shall

be collected on site before commencing any masonry work. Where
PAGE 153 OF 281
502 of 2461
MMRDA
adequate sized through stones are not available in required quantities,

the use of pre-cast plain concrete headers in M-20 mix may be
permitted at the discretion of the Employers representative. No extra
payment will be made for the provision of substitute headers in concrete
Quoins shall be 150 mm high and formed of header stones at least 300
mm long. They shall he laid lengthwise alternately along each face and
square on their beds, which shall be dressed to a depth of at least 80
mm.
Weep holes 80 mm wide and 150 mm in height shall be provided in

retaining walls at the rate of one per square metre as specified or
directed. They shall he pointed with 1:2 cement sand mortar after
raking the joints to a minimum depth of 25 mm.
Completed masonry shall be kept wet for a minimum period of 14 days.

In wet weather newly laid masonry shall be protected from the effects of
heavy rainfall by tarpaulins or other approved material.
1.9.7.1
Pointing of Uncoursed Masonry
Joints in exposed masonry faces shall be formed while the

mortar is still green and shall be finished as flush joints,
weathered
joints,
recessed joints
representative.
round-recessed
as directed
joints or
by he
square-
Employers
Masonry which is to be rendered or
plastered shall have the joints raked out to a depth of 15

mm to form a key.
1.9.8 Stone Pitching
Stone pitching: to slopes shall be carried out where specified or

as directed by the Employers representative. Stone for pitching
shall be obtained from an approved source and shall be hard,
sound, durable, clean and generally as specified.
The minimum
PAGE 154 OF 281
503 of 2461
MMRDA
dimension of any stone shall be, at least equal to the specified

thickness of the pitching.
After excavation and trimming, slopes to be pitched shall be spread with

a 75mm thick layer of crusher run rock or graded coarse aggregate
ranging from 75mm particle size to fines. The slope shall then be hand
packed with hard broken rock to a total thickness of 150 mm, each
stone being individually placed and rammed home, with smaller
stones edged into the cracks. 50mm dia weep-holes shall be
provided where specified at intervals not exceeding two meter's in
both directions. Joints in stone pitching shall be flushed up with
sand/cement mortar on completion.
1.9.9 Rubble Packing
Rubble used for packing under floors, foundations, etc. shall be hard
and durable rock, free from veins, flaws and other defects. The
quality and size of the rubble shall be subject to the approval of the
Rubble shall be hand packed as directed by the Employers
representative. They shall be laid closely in position on the sub-grade.
All interstices between the stones shall be wedged in with smaller
stones of suitable size well driven to ensure tight packing and complete
filling of interstices.
Such filling shall be carried out simultaneously
with the placing in position of rubble stones and shall not lag behind.
Small interstices shall be filled with hard clean sand and well watered
and rammed.
1.9.10 Concrete Block Masonry
1.9.10.1
Materials
Masonry units of hollow and solid concrete blocks shall

PAGE 155 OF 281
504 of 2461
MMRDA
conform to the requirements of IS : 2185 (Part I).
Masonry
units
of
hollow
and
solid
light-weight
concrete blocks shall conform to the requirements of

IS:2185(Part 3).
Masonry units of autoclaved cellular concrete blocks shall

conform to the requirements of IS:2l85(Part 3).
The height of the concrete masonry units shall not exceed

either its length or six times its width.
The nominal dimensions of concrete block shall be as under.
Length 400, 500 or 600 mm
Height 100 or 200 mm
Width 100 to 300 mm in 50 mm increments
Half blocks shall be in lengths of 200, 250 or 300mm

to
correspond
to
the
full-length blocks. Actual
dimensions shall be 10mm short of
the nominal
dimensions.
The maximum variation in the length of the units shall

not be more than
5 mm and maximum variation In
height or width of the units shall not be more than 3mm.
Concrete blocks shall be either hollow blocks with

open or closed cavities or solid blocks.
Concrete blocks shall be sound, free of cracks, chipping

or other defects, which impair the strength or performance
of the construction. Surface texture shall as specified.
PAGE 156 OF 281
505 of 2461
MMRDA
The faces of the units shall be flat and rectangular,

opposite faces shall be parallel and all arises shall be
square. The bedding surfaces shall be at right angles to
the faces of the block.
The concrete mix for the hollow and solid concrete

blocks/light weight concrete blocks shall not be richer
than one part of cement to six parts of combined
aggregates by volume.
Concrete blocks
shall be of
approved
manufacture,
which satisfy the limitations in the values of water

absorption, drying shrinkage and moisture movement,
as specified for the type of block as per relevant IS code.
Contractor shall furnish the test certificates and also
supply the samples for the approval of Employers
reprentative.
1.9.10.2
Workmanship
The type of the concrete block, thickness and
grade
based on the compressive strength for use in load bearing

and/or non-load bearing walls shall be as specified. The
minimum nominal thickness of nonload bearing internal
walls shall be 100mm. The minimum nominal thickness
of external panel walls in framed construction shall be 200
mm.
The workmanship
shall
generally
conform
to
the
requirements of IS:2572 for concrete block masonry,

IS:6042 for light weight concrete block masonry and
15:6041 for autoclaved cellular concrete block masonry
works.
From considerations of durability, generally concrete

PAGE 157 OF 281
506 of 2461
MMRDA
block masonry shall be used in superstructure works

above the damp-proof course level.
Concrete blocks shall be embedded with a mortar,

which is relatively weaker than the mix of the blocks in
order to avoid the formation of cracks. Cement mortar of
proportion 1:6 shall be used for the works.
The thickness of both horizontal and vertical joints shall be

10mm. The first course shall be laid with greater care,
ensuring that it is properly aligned, leveled and plumb
since this will facilitate in laying succeeding courses to
obtain a straight and truly vertical wall. For the horizontal
(bedding) joint, mortar shall be spread over the entire top
surface of the block including front and rear shells as well
as the webs to a uniform layer of 10mm. For vertical
joints, the mortar shall be applied on the vertical
edges of the front and rear shells of the blocks. The
mortar may be applied either to the unit already placed on
the wall or on the edges of the succeeding unit when it is
standing vertically and then placing it horizontally, well
pressed against the previously laid unit to produce a
compacted vertical joint. In case of two cellblocks with
slight depression on the vertical sides these shall also be
filled up with mortar to secure greater lateral rigidity. To
assure satisfactory bond, mortar shall not be spread too
far ahead of actual laying of the block as the mortar will
stiffen and lose its plasticity. Mortar while hardening
shrinks slightly and thus pulls away from the edges of the
block. The mortar shall be pressed against the units with a
jointing tool after it has stiffened to effect intimate contact
between the mortar and the unit to obtain a weather tight
joint. The mortar shall be raked to a depth of 10mm as
each course is laid to ensure good bond for the plaster.
PAGE 158 OF 281
507 of 2461
MMRDA
Dimensional stability of hollow concrete
blocks is
greatly affected by variations of moisture content in the

units. Only well dried blocks should be used for the
construction. Blocks with moisture content more than 25%
of' maximum water absorption permissible shall not be
used. The blocks should not be wetted before or during
laying in the walls. Blocks should be laid dry except
slightly moistening their surfaces on which mortar is to be
applied to obviate absorption of water from the mortar.
As per the design requirements and to effectively

control cracks
in
the
masonry,
RCC bound
beam/studs, joint reinforcement shall be provided at

suitable locations. Joint reinforcement shall be fabricated
either from mild steel wires conforming to IS:280 or
welded wire fabric/high strength deformed basis.
For jambs of doors, windows and openings, should

concrete blocks shall be provided. If hollow units are used,
the hollows shall be filled with concrete of mix 1:3:6. Hold
fasts of doors/windows should be arranged so that they
occur at block course level.
At Intersection of walls, the courses shall laid up at the

same time with a true masonry bond between atleast 50%
of the concrete blocks.
Curing of the mortar joints shall be carried out for atleast 7

days. The walls should only be lightly moistened and shall
not be allowed to become excessively wet.
Double scaffolding shall be adopted for execution of block

masonry work.
Cutting of the units shall be restricted to a minimum.

PAGE 159 OF 281
508 of 2461
All
MMRDA
horizontal
and
vertical dimensions shall be
in
respectively, adopting modular co-ordination for walls,

opening locations for doors, windows etc.
Concrete blocks shall be stored at site suitably to avoid

any contact with moisture from the ground and covered to
protect against wetting.
1.9.11 Damp-Proof Course
1.9.11.1
Materials and Workmanship
Where specified, all the walls in a building shall be

provided with damp-proof course cover plinth to prevent
water from rising up the wall. The damp-proof course shall
run without a break throughout the length of the wall even
under the door or other openings. Damp-proof course
shall consist of 50 mm thick cement concrete of 1:2:1
nominal mix with approved water-proofing compound
admixture confirming to IS: 2645 in proportion as directed
by the manufacturer. Concrete shall be with 10 mm
down graded coarse aggregates.
If he surface of brickwork/stone masonry work shall

be
leveled
and
prepared
before laying the cement
concrete. Side shuttering shall be properly fixed to ensure

that slurry does not leak through and is also not disturbed
during compaction. The upper and side surface shall be
made rough to afford key to the masonry above and to the
plaster.
Damp-proof course shall be cured properly for atleast

seven days after which it shall be allowed to dry for taking
up further work.
PAGE 160 OF 281
509 of 2461
1.10
MMRDA
Plastering
IS:1542
Sand for plaster
IS:1661
C.P. for application of ferrous metals in building
IS:2394
C.P. for application of lime plaster finish
1.10.2 Plastering
Cement mortar used for plastering shall be of the mix proportions

and
thickness
as specified on the drawings specifications for the
various different parts of the works.
The materials used i.e. cement, sand and water shall be of the same
quality and of the same specifications as indicated for plain and
reinforced cement concrete works in the Section D2 of this tender.
Sand further shall meet the specifications as laid down in IS:1542-1977

Specification for sand for plaster.
For plastering on old existing surfaces polymers shall be added as

bonding agents.
The surfaces that are to be applied with plaster shall be thoroughly

cleaned to remove dust, dirt, loose particles, oil, soil, slats etc. that
may be sticking to the surfaces. The surfaces shall be washed clean
and watered properly for 4 hours before applying plaster.
Plaster shall not, in any case, be thinner than specified.

uniform specified thickness.
It shall have
When smooth finishing is required the
cement plastering shall be floated over with neat cement within 15

PAGE 161 OF 281
510 of 2461
MMRDA
minutes after application of the last coat of plastering.
The plaster shall be protected from the sun and rain by such means as
the Employers representative may approve. The plastered surfaces
shall be cured for 7 (seven) days. Construction joints in plastering
shall be kept at places approved by the Employers representative.
When the thickness of the plaster specified is to be made up in more
than one layer, the second layer shall be applied only when the
lower coat is still green. After applying the first layer the surface
should be roughed and wherever specified, approved brands of
additives like water proofing compounds shall be added in specified
quantities as recommended by the manufacturer of the compound, or
Wherever scaffolds are necessary for plastering they shall be provided.

Stage scaffolding shall be provided for ceiling plaster. To ensure even
thickness and true surface, patches of plaster about 15 cms x 15 cms
shall be first applied both horizontally as vertically 2 m apart. Plastering
shall be done from top to bottom and care shall be taken to avoid joints
on continuous surface.
Sand face plaster shall consist of first layer of 16mm average

thick cement plaster in cement mortar 1: 6 (One part cement and Six
parts coarse sand).
A second layer of 4 mm average thick in cement
mortar 1:4 (one part cement and four part coarse sand) shall be
applied. After the application of final coat, the surface shall be
finished with the application of sponge rubber or as directed to
obtain a uniform sand particle surface finish.
In case any other finish like rough cast finish or dry dash finish
is specified the same shall be provided as directed by the
Employers representative. Surfaces, which are to be plastered, shall
be roughened while they are still green or raked so as to give proper
bond between the surface and plaster.
PAGE 162 OF 281
511 of 2461
MMRDA
All corner, edges, junctions shall be truly vertical or horizontal as the

case may be and carefully finished. Rounding or chamfering of corners
shall be carried out with proper templates to the required size and
shapes.
No additional charges for works like scaffolding curing etc. are payable
over and above the rates quoted for brickwork. The rates quoted shall
be deemed to be inclusive of all such works.
1.10.3 Putti
1.10.3.1
Material
Neeru shall be made of the best description of lime slaked

with fresh water and sifted. The lime to be reduced to fine
powder by grinding it on a stone or in a hand mill, with a
thick solution of mussalla to be made or as may be
desired by the Employers representative. The neeru thus
prepared shall be kept moist until used and the quantity to
be prepared at one time shall be such that it can be
consumed in eight days.
1.10.3.2
Workmanship
All stone or brick masonry shall be thoroughly wetted and

joints raked out to a depth of at least 20mm and walls
washed before any plastering is done. The surface
shall
then rendered with fine sand, to the specified
thickness and roughness. The surface shall then be

floated or set with a thin coat, 3mm thick of cement and
polished, well with a trowel or flat board. The cement
mortar shall be used within 30 minutes after it leaves
the mixing board or mill. Before any plasterwork is
started patches of plaster 150mm x 150mm shall be
put on at every 3 meters apart as gauges so as to
PAGE 163 OF 281
512 of 2461
ensure
an
MMRDA
even thickness
throughout
the
work.
Cement plaster shall be done in even square or

strips. Care shall be taken to keep the whole surface
thoroughly wetted for at least a week. The finishing
surface shall be as specified and directed. If neeru finish
is specified then the same shall be applied to the prepared
and partially set but somewhat plastic surface with steel
trowel to a thickness slightly exceeding 1.5 mm and
rubbed
down
to
1.5mm thickness and polished to a
perfectly smooth and even finish working from top to

bottom. The surface shall be then colored, if required with
3 coats of white or
colour wash for which no extra
payment shall be made.
1.11
Flooring
IS:777
Glazed earthen ware tiles
IS:1237
Cement Concrete flooring tiles
IS:1443
C.P. for laying & finishing of cement concrete flooring

tiles
IS:2114
C.P. for laying in-situ terrazzo floor finish
IS
Vitrified Ceramic Tiles
1.11.2 General
The materials and workmanship conform to the provisions of the

following codes
and standards. In particular and with such other
standards as mentioned hereinafter. BIS: 269, 385, 515, 653, 712, 809,
1077, 1195, 1196, 1197, 1198, 1237, 1344, 1443.
PAGE 164 OF 281
513 of 2461
MMRDA
1.11.3 Cement Concrete Flooring
1.11.3.1
General
Flooring shall consist of a sub-base laid on the compacted

earth or sand fill as required, a base course laid on the
sub-base and then a finishing layer of concrete, Terrazzo
or any other material as specified to be laid.
The
materials for filling shall be brought from the source as

1.11.3.2
Filling
The surface to receive the filling shall be first cleared

free of all roots, vegetation and wetted. Filling in plinth or
other specified levels shall proceed in layers of 15 cm.
Along with the construction of building, it shall be
watered and well rammed in layers as mentioned
above
and
compacted
to
the
satisfaction
of
the
Care shall be taken to remove all roots, vegetation,

foreign
matter,
etc.
from
the
earth used
for
filling.After thorough consolidation, required quantity

of the filling corresponding to the thickness of floor shall
be scrubbed to make space for the flooring. Where sand
filling is specified, the sand shall be clean, free from
vegetation and other deleterious materials and same
procedure followed as for earth filling.
In case of sand
filling, if required, flooding shall be done to achieve

required compaction.
a)
Preparation of Bed
PAGE 165 OF 281
514 of 2461
MMRDA
The bed for flooring shall be prepared either level

or sloped as per relevant drawings or as instructed
by Employers representative.
Care
shall
be
taken that there are no roots, vegetation, foreign

matter, etc.
b)
Sub-Base
On the prepared bed as indicated above, boulder,

or gravel or broken bricks or sand or cement
concrete (1:4:8 as per BIS: 465) shall be laid to
thickness as specified. This layer shall be beaten
with rammers until thoroughly consolidated. All the
material used shall conform to the required
specifications.
The
materials proportion, mixing, laying, and
curing, etc. for cement concrete shall be carried

out as specified.
The finished work shall be of uniform depth over

the whole floor with surface even and parallel to the
prepared bed as per drawing or as directed by
i.
Boulders as Sub-base Course
Boulders shall be laid over the prepared bed

as per general specification and shall be of
size 100 to 150 mm and shall be of
approved quality.
Boulders being used
shall be free from decay, weathering and be

stacked in such heaps in place as directed
by Employers representative, the thickness
being as specified in the relevant drawings.
PAGE 166 OF 281
515 of 2461
ii.
MMRDA
Sand Layer
Sand for sand layer to be laid over the

prepared bond shall be clean, free from
admixture as per specification. Sand layer
shall be spread in one or more layers to the
thickness watered and rammed.
1.11.3.3
Base Coarse
a)
Cement Concrete
It shall be of specified
mix and
shall generally
conform to Construction Specification for Cement

Concrete.
b)
Panels
To prevent
space
shall
rectangular
construction
be
panels.
cracks,
divided
The
into
base
the
floor
square
or
course
of
specified thickness shall be laid in alternate

panels or any other pattern as approved by
Employers representative. The panels shall be of
uniform size, not exceeding 4.0 m. in any direction
for a floor having thickness 40 mm and above.
Alternate panels shall be laid on different days.
Construction joints shall be formed in between the

sequential panels cast, with straight edges,
20
mm deep and 12 mm wide in groove form.

These joints on completion of work, shall be
cleaned and washed free of dust with the help of
brush and shall be treated with hot bitumen poured
PAGE 167 OF 281
516 of 2461
MMRDA
in the gap, over which fine sand shall be spread

to arrest the flow of bitumen.
c)
Shuttering
The panels shall be bounded by glass strips having

the same depth as the concrete floor. These shall
be fixed in position with their top at proper level,
giving slope. The floors shall butt against masonry
of wall before it is plastered.
d)
Concreting
Cement concrete shall be placed in position with or

without MS reinforcements as shown in drawings
and beaten with trowel and finished smooth or left
rough as directed by the Employers representative.
Beating shall cease as soon as surface is found
covered with cream of mortar. The surface shall be
checked with the help of straight edge and made
true.
The shuttering shall be removed next day.
Care
shall be taken to see that edges are not damaged

and fresh
mortar from adjacent panels
splashed over them.
is
not
The joints between panels
shall come out as fine straight line.
MS reinforcement used for concrete base course

with reinforcement shall conform to relevant BIS
Specifications as detailed in
placing
of
drawings.Before
those reinforcements, they shall be
cleared of scales with wire brush and oily stains

removed.
PAGE 168 OF 281
517 of 2461
1.11.3.4
MMRDA
Floor Finish Plain Cement Finish
Finishing of the surfaces shall follow immediately after the

completion of base course. The surface shall be left for
some time till the moisture disappears from it. Use of dry
cement or cement and sand mixture sprinkled on the
moisture shall not be permitted.
Fresh quantity of cement at 2.2 kg per square metre of

flooring shall be mixed with water to form thick slurry and
spread over the surface, while the concrete is still green.
It shall be pressed twice by means of iron floats, once
when the slurry is applied and second time when cement
starts setting.
The junction of floor with wall plaster, clods or skirting

shall be rounded off uniformly where so required upto
25 mm radius or as directed. The men engaged on
finishing operations shall be provided with raised wooden
platform to sit on, so as floor finish is specified, the top
surface of floor finish shall be chequered with mesh
or similar impression before the finish has set.
1.11.3.5
Curing
Each finished portion of floor, on completion, shall be kept

wet with ponding or moist sand or moist gunny bags as
per specifications.
At no time, cement concrete layer,
plain or reinforced shall be allowed to dry during curing

time.
1.11.4 Granolithic (IPS) Flooring
The requirement for filling, preparation of bed, sub-base and base

course concrete shall be same as in clauses above.
PAGE 169 OF 281
518 of 2461
1.11.4.1
MMRDA
Finished Layers
Granolithic finish of the thickness as indicated in drawings

or as specified shall consist of 2 layer of M15 grade
cement concrete. The first layer of concrete shall be laid
with 10 mm to 6 mm grade aggregate and well
compacted.
Within 15 minutes of laying this course
the second layer with 6 mm down aggregate shall be

laid. The cement and aggregates for the top layer shall be
mixed dry.
Sufficient quantity of washed sand and water shall be

mixed so as to make it plastic but not flowing.
This
mixture shall be laid on the first layer so that the two

layers firmly grip together. The top layer shall be well
tamped, spaded, trowelled and finished with neat cement
slurry or with non-skid finish as required.
At the junction
of adjoining panels a thin string shall be given.
The casting of the granolithic finish layer shall be done in

rectangular or square panels not exceeding 1.8 M on
any side, using glass strips of height equal to the
specified thickness of the floor finish. Required slope in
the floor shall be given in the base course concrete
without reduction in thickness.
1.11.4.2
Curing
Curing shall be done as per above mentioned clause.
1.11.5 Terrazzo (Mosaic) Tile
The tiles shall be approximately 22 mm thick of approved shade, color

and chips.
The tiles shall be pressure made conforming to IS:1237 in
PAGE 170 OF 281
519 of 2461
MMRDA
all respects. The sizes of the tiles shall be as given in table below:
Table showing Sizes of Terrazzo Tiles
S.
Nominal
No.
1
2
3
1.11.5.1
Actual
Nominal
Actual
Thickness
Length
Length
Breadth
Breadth
Not less
(cm)
(cm)
(cm)
(cm)
than(mm)
20
25
30
19.85
24.85
29.85
20
25
30
19.85
24.85
29.85
20
22
25
Tolerances
Tolerances on length and breadth shall be 1 mm.

Tolerance on thickness shall be 5 mm. The range of
dimension in any one direction of tiles shall not
exceed
mm
on length and breadth and 3 mm on
thickness.
1.11.5.2
Manufacture
The tiles shall be manufactured under hydraulic pressure

of not less than 140 kg/cm2 and shall be given the first
grinding with machine before delivery to the site.
The
proportion of cement to aggregate in the backing of the

tiles shall not be leaner than 1:3 by weight. Similarly the
proportion of cement to marble chips aggregate in the
wearing layer of the tiles and the proportion of pigment to
be used therein shall not exceed 10% by weight of cement
used in the mix. The finished thickness of the upper layer
shall not be less than 5 mm for size of marble chips from
the smallest up to 6 mm, and also, not less than 5 mm for
size of marble chips ranging from the smallest up to 12
mm, and not less than 6 mm for sizes of marble chips
varying from the smallest up to 20 mm.
PAGE 171 OF 281
520 of 2461
1.11.5.3
MMRDA
Laying
The sub-grade concrete or the R.C.C slab on which

the tiles are to be laid shall be cleaned, wetted and
mopped. The bedding for the tiles shall be with lime
mortar of either:
i.
1:1:2 (lime putty:surkhi :coarse sand)
ii.
1:3
(lime putty :surkhi)
iii.
1:3
(lime putty : coarse sand)
The bedding ingredients shall be thoroughly mixed by

volume in the dry form. Care shall be taken to ensure
that there are no hard lumps present. Water shall then be
added and the ingredients thoroughly mixed.
The
average thickness of the bedding mortar shall be 30 mm.
Lime mortar bedding shall be spread, tamed and

corrected to proper levels and allowed to be hardened for
a day before the tiles are set.
Over this bedding, neat
grey cement slurry of honey like consistency shall be

spread at the rate of 44 kg of cement per sq.m. over such
an area as would accommodate about twenty tiles. Tiles
shall be washed clean and shall be fixed in this grout
one after another each tile being gently tapped with
a wooden mallet till it is properly bedded and in level with
the adjoining tiles.
The joints shall be kept as thin as
possible not exceeding 1.5 mm and in straight lines or to

suit the required pattern.
The surface of the flooring during laying shall be the

frequently checked with a straight edge at least 2 m long,
PAGE 172 OF 281
521 of 2461
MMRDA
so as to obtain a true surface with the specified slope. In

situations where full size tiles cannot be fixed, these shall
be cut (sawn) to the required size and their edge rubbed
smooth to ensure a straight and true joint. Tiles, which
are fixed in the floor adjoining the wall, shall enter not
less than 12 mm under the plaster, skirting or dado.
The junction between the wall plaster and tile work shall
be finished neatly and without any waviness. After laying
the tiles, the surplus cement grout shall be cleaned off.
1.11.5.4
Curing, Polishing and Finishing
After laying the tiles the day after all the joints shall be cleaned of
the grey cement grout with a wire brush or trowed to a depth of 5
mm and all dust and loose mortar removed and
cleaned.
Joints shall then be grouted with grey or white cement

mixed with or without pigment to match the shade of the topping
of the wearing layer of the tiles. The same cement slurry shall
be applied to the entire surface of the tiles in a thin coat
for protecting the surface from abrasive damage and fill the pin
holes that may exist on the surface.
The floor shall then be kept wet for a minimum period of 7

days.
The surface shall thereafter be grounded evenly with
machine fitted with coarse grade grit blocks No.60. Water shall
be used profusely during grinding. The surface shall be washed
thoroughly with water to remove all grinding mud, cleaned and
mopped. Then it shall be corrected with a thin coat of grey or
white cement, mixed with or without pigment to match
the
colour of the topping of the wearing surface in order to fill any pin
hole that appear. The surface shall be again cured, the second
grinding shall then be carried out with machine fitted with fine
grade grit blocks No. 120.
The final grinding shall be carried out with the machine

PAGE 173 OF 281
522 of 2461
MMRDA
fitted with finest grade grit blocks No. 320, the same day after
the second grinding described above.
The small areas or where circumstances so required hand

polishing may be permitted in lieu of machine polishing after
laying. For hand polishing coarse grade stone No. 60.
Water shall be used for 1st rubbing stone of medium grade

No.80 for second rubbing and stone of fine grade No.120 for final
rubbing and polishing.
After the final polish oxalic acid shall be dusted over the
surface of 33 gm/sq.m sprinkled with water and rubbed hard
with a namdah block (pad or woolen rags). The following day
the floor shall be wiped with a moist rag and dried with a soft
cloth and finished clean.
If any tile is disturbed or damaged, it shall be refitted or replaced,

properly jointed and polished. The finished floor shall not sound
hollow when tapped with a wooden mallet.
1.11.6 Terrazzo (Mosaic) in-situ Flooring
The requirements for filling, preparation of bed, sub- base and base
course concrete shall be same as above.
Trained worker shall carry out terrazzo works.
1.11.6.1
Material
Best quality marble chips of uniform tint and color, 6

mm maximum and 3 mm minimum size, as approved
by Employers representative shall be used. They shall be
machine crushed, free from foreign matter and of
approved quality.
PAGE 174 OF 281
523 of 2461
1.11.6.2
MMRDA
Preparation of Surface and Laying Over Base Course

Concrete
Total
thickness
of
cast-in-situ
Terrazzo
shall
be
atleast 40 mm unless otherwise indicated. This shall

be in two layers bottom layer of M:15 concrete bedding
with 10 mm down aggregate of specified thickness
and the top layer of 10 mm thickness, consisting of a
mix of cement and marble chips in the proportion of 1:1/2
marble powder : 2 marble chips). The bottom layer shall
be laid in bays not exceeding 1.2 m on either side and
leveled 10 mm below the finished floor level.
The cement and marble chips including powder shall

be mixed dry.
Water shall be added gradually after
through mixing until the mix become plastic but flowing.
Within one hour of laying of the bottom layer of

cement concrete the upper layer of marble chips and
cement paste shall be laid over a coat of cement slurry
and the surface tamped lightly and finished to the required
level and slope.
While the bottom layer is still plastic glass dividing strips

35 mm wide x 16 SWG thick shall be fixed on the base
course concrete
with
proper anchoring features to
allow top edge to be flushed with the finished floor.

The strip shall be laid, forming panels not exceeding
1.2 m x 1.2 m size.
1.11.6.3
Curing, Polishing and Finishing
The floor shall then be kept wet for a minimum period of

six days. The surface shall thereafter be ground evenly
PAGE 175 OF 281
524 of 2461
MMRDA
to the satisfaction of the Employers representative with

machine grinders in three phase with grade stones from
coarse to fine grade.
The surface shall receive wash
of neat cement mixed with or without pigment and

cured before every grinding operation.
After final grinding, surface shall be cleaned and

oxalic acid shall be dusted over the surface @ 35
grams. per sq.m. sprinkled.
1.11.7 Glazed Tile Flooring
1.11.7.1
White Glazed Tiles
The glazed tiles shall conform to IS:777-1970. They shall

be flat and true to shape and free from cracks, crazing
spots, chipped edges and corners.
The glazing shall
be of uniform shade.
1.11.7.2
Size and Tolerance
The tiles shall be of nominal sizes such as 150 x

150 mm and 100 x 100 mm or as specified. The
thickness of the tiles shall be 5 mm, or 6 mm as specified.
The tolerance on facial dimension value shall be 1.0 mm
and 0.5 mm on thickness.
The top surface of the tiles shall be glazed.
The glaze
shall be either glossy or matt as specified. The underside

of the tiles shall be completely free form glaze in order
that the tiles may adhere properly to the base. The edge
of the tiles shall be preferably free form glaze, however
any glaze if unavoidable, shall be permissible on any one
edge of the tile.
PAGE 176 OF 281
525 of 2461
1.11.7.3
MMRDA
Coloured Tiles
The sizes and specifications shall be the same as

for the white glazed tiles described above. The only
difference shall be in the colour.
1.11.7.4
Decorative Tiles
The type and size of the decorative tiles shall be as follows:
a.
Decorated white background tiles shall be of 152 x

152 x 6 mm and 108 x 108 x 6 mm sizes.
b.
Decorated and having coloured background shall

be of 152 x 152 x 6 mm and 108 x 108 x 6 mm
sizes.
c.
Fantasy glazed tiles (108 x 108 x 6 mm) other

specifications will be the same as that of white
glazed tiles.
1.11.7.5
Vitrified Ceramic Tiles
Providing and laying vitrified floor tiles with soluble salt

printing, of various sizes with water absorption less
than0.5% and conforming to IS : 15622 of approved
make, shall be laid on 20mm thick cement mortar 1:4 (1
cement : 4 coarse sand) including grouting the joints with
white cement and matching pigments etc. complete or
Providing and laying vitrified floor tiles of sizes up to ans
including 1000 mm x 1000 mm with double charge/ multi
charge printing with water absorption less than 0.5% and
conforming to IS : 15622 of approved make in all colours
and shades and size mentioned below (+/- 10mm), laid on
20mm thick cement mortar 1:4 (1 cement : 4 coarse sand)
PAGE 177 OF 281
526 of 2461
MMRDA
including grouting the joints with white cement and

matching pigments etc. complete or fixing glazed/
Ceramic/ Vitrified floor tiles with cement based high
polymer modified quick-set tile adhesive (Water based)
conforming to IS: 15477, using 5kg. adhesive per sqm of
tile area, in average 3mm thickness in place of cement
mortar all as directed by the Employers representative.
1.11.7.6
Preparation of Surface and Laying
Sub grade concrete or the R.C.C slab on which the tiles

are to be laid shall be cleaned, wetted and mopped.
The bedding for the tile shall be with 1:3 (cement:
coarse sand) mortar or as specified, having average 10
mm thickness.
The bedding thickness under the tiles
shall not be less than 5 mm.
The mortar shall be spread, tamped and corrected to

proper levels and allowed to harden sufficiently to offer a
fairly rigid cushion for the tiles to be set and to enable the
mason to place wooden plank across and square on it.
Over this mortar bedding neat grey cement slurry of honey
- like consistency shall be spread at the rate of 3.3 kg of
cement per sq. m over
such
an
area
as would
accommodate about twenty tiles. Tiles shall be soaked

in water washed clean and shall be fixed in this
grout one after another each tile gently being tapped
with a wooden mallet till it is properly bedded and in
level with the adjoining tiles. The joints in between the
tiles shall be kept as thin as possible and in straight
lines or to suit the required pattern.
The surface or the flooring during laying shall be

frequently checked with a straight edge about 2 m long,
for obtaining a true surface with the specified slope.
PAGE 178 OF 281
527 of 2461
MMRDA
Where full size tiles cannot be fixed these shall be cut

(sawn) to the required size and their edge rubbed smooth
to ensure straight and true joints. The tiles, which are
fixed in the floor adjoining the wall, shall enter not less
than 10 mm under the plaster, skirting or dado.
After
laying the tiles the surplus cement grout shall be cleaned

off.
1.11.7.7
Pointing and Finishing
The joints shall be cleaned off the grey cement grout with
wire brush or trowel to a depth of 2 mm to 3 mm and
all dust and loose mortar removed. Joints shall then
be
flush pointed
with
white
cement
added
with
pigment if required to match the colour of the tiles.

The floor shall then be kept wet for 7 days.
After
curing, the surface shall be washed and cleaned. The

finish floor shall not sound hollow when tapped with
a wooden mallet.
1.11.8 Kota Stone Flooring
Kota Stone Slabs- shall be of selected quality hard, sound, dense

and homogeneous in texture, free from cracks, decay, weathering and
flaws.
They shall be hand or machine cut to the requisite thickness
and shall be of the colour indicated in the drawings or as directed.
The top (exposed) face of the slabs shall be polished before being
brought to site, unless otherwise specified. The slabs shall conform to
the size required and samples shall be got approved before starting the
work. 20, 30 or 40 mm or specified thickness slabs shall be used.
1.11.8.1
Tolerances
Of 2 mm shall be allowed for the thickness. In respect of

PAGE 179 OF 281
528 of 2461
MMRDA
length and breadth of slabs, a tolerance of 5 mm shall

be allowed.
1.11.8.2
Dressing
Each slab shall be cut to the required size and shape and
fine chisel dressed on the sides to the full depth, so that a
straight edge laid along the side of the stone shall be in
full contact with it. The sides (edges) shall be table
rubbed with coarse sand or machine rubbed before
paving.
All angles and edges of the tiles shall be
true, square and free from chipping and the surface

shall be true and plane.
1.11.8.3
Surface Preparation and Laying
Sub-grade concrete on the R.C.C slab on which the slabs

are to be laid shall be cleaned, wetted and mopped. The
bedding for the slabs shall be with cement mortar 1:4 or
with lime mortar 1:1:1 (lime putty : surkhi : coarse sand)
as given in the description of item. The
average
thickness of the bedding mortar under the slab shall

be 20 mm and the thickness at any place under the
slab not be less than 12 mm.
Mortar of the specified mix shall be spread under the area

of each slab, roughly to the average thickness as
specified. The slab shall be washed clean before laying.
It shall be laid on top, pressed, tapped with wooden mallet
and brought to level with the adjoining slabs.
It shall be
lifted and laid aside. The top surface of the mortar

shall
then
hallows.
be corrected by adding fresh mortar at

The mortar is allowed to harden a bit and
cement slurry of honey -like consistency shall be spread

over the same at the rate of 4.4 kg of cement per sq.m.
PAGE 180 OF 281
529 of 2461
MMRDA
The edge of the slab already paved shall be buttered with

grey or white cement with or without admixture of pigment
to match the shade of the kota stone slabs as given or
specified.
The slab to be paved shall then be lowered
gently back in position and tapped with wooden mallet till

it is properly bedded in level with and close to the
adjoining slabs with as fine joint as possible.
All the
subsequent slabs shall be laid in the same manner. After

each slab has been laid, surplus cement on the surface
shall be cleaned off. The flooring shall be cured for at
least 7 days.
Slabs, which are fixed in the floor adjoining the wall, shall
enter atleast 12 mm under the plaster skirting or dado.
The junction between wall plaster and floor shall be
finished neatly and without any wavings.
1.11.8.4
Polishing and Finishing
Shall be done as described in the above article of

Terrazzo Tile Flooring except that:
a.
First polishing with coarse grade carborundun

stone shall not be done.
b.
Cement slurry with or without pigment shall not

be applied on the surface before polishing.
1.11.9 Mosaic Finished Dado or Skirting
For skirting and dado the brickwork or concrete surface shall be raked
and shall be well watered for four hours. A dubbing coat of cement
mortar 1:3 (1 cement: 3 sand) of sufficient thickness shall be applied
so as to bring the surface in line with the plastered surface. The surface
shall be carried by lines with trowel so as to receive mosaic tiles or the
PAGE 181 OF 281
530 of 2461
MMRDA
top layer or cement and marble chips in proportion of 1:1/2:2 (1 cement:

marble powder: 2 marble chips) of 7 mm thickness with 3-5
mm size for flooring including dividing strips (20 mm x 15 SWG) @
600 mm c/c.
1.11.10 Hardonite Flooring

These specifications cover the guidelines for providing hardonite
topping (industrial flooring) for floor subjected to heavy wear and
tear viz., workshop and stores, engine room, and Generator room
etc.
The item includes providing hardonite topping as specified to

the
thickness
supply
of
all
and satisfaction of the Employers representative,

material,
labour,
tools
and
plant required for
completing the work in best workmanlike manner.
1.11.10.1
Workmanship
The person executing the topping shall be an experienced

mason familiar with flooring works of similar nature.
Flooring shall be laid uniformly, the tolerance for variation
of level being + 3 mm.
Hardonite
material
shall
be
mixed
with
cement
concrete thoroughly to give a uniform mix.
1.11.10.2
Preparation of Surface
Hardonite shall be laid over a wet concrete surface

screened to receive the topping.
The base shall be
leveled to within + 12 mm.
a)
Preparation of Topping
PAGE 182 OF 281
531 of 2461
MMRDA
Hardonite shall consist of a mixture of cement

concrete in proportion of 1:2:4 and well graded iron
fillings added in a proportion of 1.50 kg/bag of
cement.
b)
Application
Hardonite shall be placed uniformly in a layer of

specified thickness and finished with a steel troned.
Care shall be taken to place hardonite in a
separate layer while the base concrete is steel
wet.
c)
Trowelling
Surface of floor shall be finished with steel trowel

only and trowelled just sufficient so as to give a
finished surface. The surface shall be left for some
time till moisture disappears from it. Trowelling
shall be done three times at intervals so as to
produce a uniform hard surface in no case cement
should come up to the surface.
d)
Curing
The entire surface shall be kept uniformly wet for

seven days.
e)
Opening for use
The surface shall be allowed to be used only after

curing period is over.
1.12
Distempering and Painting
PAGE 183 OF 281
532 of 2461
MMRDA
1.12.1 General
Approval of Employers representative shall be obtained before
commencing the painting work. All paints and preserves shall be of
approved make and colour and their application shall conform to the
manufactures instructions. Where more than one undercoat is specified
it shall be applied in coats of distinctive tints. Workmanship shall
conform to the requirement of IS:2395 Unless the manufacturers
instructions state otherwise 48 hours drying time shall elapse between
successive applications of any primer and 24 hours between
applications of all subsequent
coats.
The
surface
of
bituminous
paints shall be left at least 3 days before further handling.

No paints in any coats shall be applied until the Employers
representative is satisfied that the surface is clean and dry. And that any
previous coat is satisfactory and has hardened adequately. When a
surface has been approved, it must be painted immediately.
Paint work shall be rubbed down with a glass paper between

coats. No paint shall be applied to a surface, which is damp, dirty or
otherwise inadequately prepared.
1.12.2 Concrete, Brickwork And Plaster
Where specified to be painted, concrete and plaster shall be

rubbed smooth and any cracks, blister holes and other imperfections
cut out, filled and made good. The surface shall be dried to the
satisfaction
of
the
before
painting
is
commenced and drying time if at least 28 days shall be allowed

after laying brickwork and plaster or stripping
concrete.
The
surface
shall
be
brushed
formwork
to
remove
from
any
efflorescence and then painted with the following:
1.
for interior brick work and concrete, apply two coats of oil paint up
to 1 meter height and for remaining part two coats of plastic
PAGE 184 OF 281
533 of 2461
MMRDA
emulsion paint over a coat of primer.
2.
for exterior brickwork and concrete, apply two coats of cement

based paint over a coat of primer with a water repellant coat of
siliconate solution of app[roved make.
Where painting with plastic emulsion is specified, all uneven surface

shall be made up by use of putty of appropriate quality, after the surface
has been thoroughly cleaned of all dust and dirt and sand papered.
1.12.3 Ironwork and Ungalvanised Steelwork
Structural steelwork shall be shot blasted to a "white metal" finish,

and
grease and oil removed
prior
to
painting.
Priming
shall
immediately follow blast cleaning and no cleaned surface shall be

left
unprimed
for
more
than
four
hours.
Only
primers
that
chemically inhibit corrosion shall be used. Where the iron or steelwork is

not in contact with raw or treated water, the primer shall be red
lead complying with IS: 57. Where there is a possibility that the
steel or ironwork may come in contact with water, the priming
treatment shall be non toxic, zinc chromate or equivalent. Where it is
anticipated that further welding will be required. an approved welding
primer shall be applied to the areas to be welded and re primed with
the main primer when welding has been completed. Primer coats
shall not be less than 0.05 mm each.
After erection, all damaged areas shall be made good, and reprimed
where the original coat has spread under the primer, the affected
surface shall be cleaned down to bare metal to the satisfaction of the
Employers representative and then re primed.
Repainting shall be carried out as soon as possible after erection. If` it is

to he exposed to weather or condensation, it shall receive one further
coal of primer.
PAGE 185 OF 281
534 of 2461
MMRDA
Metalwork in intermittent or permanent contact with raw or treated water

shall have two finishing coats of an approved coal tar pitch epoxy paint
such as "Epilux 5" by Berger Paints, or equivalent. The total coating shall
be minimum of 0.125 mm thick.
After the second coat of primer is hard dry, the entire surface shall be
wet rubbed cutting down to a smooth uniform surface.
surface
becomes
dry,
be
undercoat
When the
of synthetic enamel paint
conforming-to IS:2932 of optimum thickness shall be applied by brushing

with minimum of brush marks. The coat shall be allowed to hard
dry. The under coat shall then be wet rubbed cutting down to a
smooth finish, taking adequate care to ensure that at no place the
undercoat is completely removed. The surface shall then be allowed to
dry.
The
first finishing coat of paint shall be
applied
by brushing and
allowed to hard dry. The gloss from the entire surface shall then be
gently removed and the surface dusted off. The second finishing coat
shall then be applied by brushing.
At
least
24
hours
shall
elapse
between
the
application
of
successive coats. Each coat shall very slightly in shade and this shall
be got approved from Employers representative.
1.12.4 Galvanised Steelwork
Newly galvanised steelwork shall be primed with an etch primer

such as calcium plumbate. Steelwork that has been galvanised for a
long period so that the surface has oxidised adequately to allow
adhesion of under-coats, need not have an initial coat of each
primer.
After
priming,
contact
with
galvanised
raw
steelwork
in
constant
or
intermittent
or treated water shall be given two coats of an
approved coat of tar pitch epoxy paint such as "Epilux 5" by Berger
PAGE 186 OF 281
535 of 2461
MMRDA
Paints, or equivalent. The total coating shall have a minimum thickness

of 0.1 25 mm.
Protective coats for galvanised steelwork not in contact with water shall be:
1.
One coat of micaceous iron oxide paint for interior galvanised steel
work.
2.
Two coats Of micaceous iron oxide paint for external galvanized

steelwork.
Galvanised steelwork not in contact with water shall be finished with at

least one coat of gloss paint on top of an approved undercoat.
1.12.5 Bituminous Surfaces
Metalwork
items
that
have
been
given
shop
treatment
of
bituminous paint shall be painted with two coats of` an approved

anti-bleed paint before applying a coat of decorative finishing paint.
1.12.6 Aluminium Surfaces
Aluminum surfaces shall be worked clean, dried and thoroughly

degreased
before painting, by an appropriate solvent (such as one
consisting of equal parts of white spirit and
light
solvent
naptha).
Flame cleaning shall not be permitted. The clean degreased

surface
shall be
treated
to
ensure paint
adhesion
either by
mechanical roughening, chemical adhesion, or etch primers or wash

primers applied in strict conformity with the manufacturer's instructions
or by other treatment approved by the Employers representative.
The pretreated surface shall receive a priming coat with an inhibiting

pigment containing not less than 20% by weight of fine chromate or
other approved chromate in a suitable water-resisting vehicle.
PAGE 187 OF 281
536 of 2461
MMRDA
The priming coat shall not contain any copper or mercury compounds
and it shall also be free from graphite and carbonaceous materials
and shall not contain any lead. Priming coat shall consist of a tung-oil
phenolicresin which is pigmented with equal parts of zinc tetoroxy
chromate and red iron oxide.
Aluminum surfaces in contact with concrete, or resting on pads on

concrete, shall be painted with two coats bituminous paint, and the
concrete surfaces shall also receive two coats bituminous paint.
1.12.7 Woodwork
Woodwork for painting shall be carefully rubbed down, treated with

preservatives and knotted, stopped and primed in the shop. Care
shall be taken to ensure that priming is thoroughly brushed into every
part of the surface and in particular at end grains, joint and notches
where two coats are to be applied. Primers for wood shall he of
a standard equivalent to, or better than "Aluminum Wood Primer
Sealer A519-3697" by I.C.I. Paints.
After the woodwork has been fitted and all defects in the surfaces have
been made good and re primed, one coat of approved undercoat shall
be applied to internal surfaces and two coats to external surfaces. An
undercoat of quality equal to or better than "Delux Undercoat A522
line" shall be used.
'Timber work shall be decoratively finished with one coat of finishing

paint of standard equal to, or better than "Delux Gloss Finish A365 line".
1.12.8 Waterproof Cement Paint
1.12.8.1
Surface Preparation
The wall should be washed thoroughly with clean soft

water and freed of all loose particles, dust, dirt, lichen,
PAGE 188 OF 281
537 of 2461
MMRDA
moss, efflorescence and Lime wash by Scrubbing with a

wire brush. Inequality and holes shall be filled up with
cement paste, which should be allowed to set. To get
even uniform mat finish it is necessary to keep the
surface damp throughout the operation. In hot dry weather
the wall should be frequently sprinkled with water to keep it
moist.
1.12.8.2
Mixing the paint
Loosen the contents by either rolling the drum or shaking

the container before opening it. Take one measure of water
by volume in a clean pot and add two volumes of approved
quality
waterproof
cement
paint
conforming
to
IS:
5410. Stir well to make a paste of high consistency

then
add
one more
measure of
water constantly
stirring the mixture. The final composition of water and

paint is now 1:1 by volume. Keep stirring the mixture
all the time and use it up within an hour. Do not use the mix
if it is left over 'for more than two hours.
1.12.8.3
Method of Application
Wet the surface by any convenient method. A small

surface can be wetted by brush. When applying paint
surface should be damp and not wet. While applying the
first coat brush hard into the surface to cover pores
and cavities to ensure better bond. Twelve hours after
applying the first coat cure the surface by sprinkling
the
water.
Before applying the second coat damp the
surface and after the application of second coat cure it as

directed above. In hot climate repeat curing at least twice
at the interval of six hours for optimum best results.
1.12.8.4
Curing
PAGE 189 OF 281
538 of 2461
MMRDA
After sprinkling fine spray of water should cure each

application paint normally after twelve hours when paint
film is hardened satisfactorily. In summer when weather is
hot, curing may be done little earlier. Water marks may be
left over the surface if a stream of water is allowed to flow
before the paint film is hardened.
1.12.9 Silicon Paint
1.12.9.1
Preparation
A solution for application shall be prepared from Syltrit

1772
or
equivalent.
The Manufacturer's
instructions
shall be followed. This solution shall be prepared to a

concentration of about 3 % solids by mixing 1 kg. of water
dilatable solution of sodium methyl siliconate with 9 kg.
of water. Concentration higher than 3% solids are not
recommended as they may cause a white precipitate of
sodium carbonate formation.
1.12.9.2
Application
A flooding technique should be used in applying to

obtain the best penetration. When spraying, the solution
should not be atomized or misted, but flowed on in a solid
stream, with the spray gun held, at a distance just enough
to eliminate foaming on the masonry surface. If foaming is
allowed then certain visible marks might appear after
application. The run down of 150 to 300 mm should
be maintained with generous overlapping of passes.
Dipping and brushing methods are also suitable. After
application of the solution, the treated surface should be
allowed to dry at least 24 hours to develop maximum water
repellency. This interval may be shortened somewhat by
PAGE 190 OF 281
539 of 2461
MMRDA
force drying at temperatures to 30 degree C. Though this

removes the water quickly, time must still be allowed for
the curing. Reaction between the solution and the surface
being treated. Until the reaction is complete the applied film
still remains water soluble and any rain failing during this
time can wash it out. So application should be done in dry
weather or at least in absence of rain and fog.
1.12.9.3
Spraying Equipment
Spraying equipment shall be hand operated stirrup pump

with stainless steel nozzle fitted with PVC or polyethylene
delivery pipe. Components of the spraying, equipment that
are in contact with the treating solution should be of black
iron, mild
steel,
stainless steel, Teflon, PVC or
polyethylene. They should not be of aluminum or

galvanised steel.
1.12.9.4
Safety
The solution should always be applied in a liquid stream,

not by misting or fogging. If misting
occurs,
avoid
inhalation. Contact with the eyes or skin should be

treated immediately by flooding the area with large
quantities of water for at least 15 minutes.
1.12.10
Relevant IS Codes
IS:63 : Whiting for paints
IS:133 : Enamel, interior, undercoating & finishing colour as

required
IS:2395
: C.P. for painting concrete, masonry & plaster
surfaces
PAGE 191 OF 281
540 of 2461
MMRDA
IS:5410
: Cement paint, colour as required
IS:5411
: Plastic emulsion paint for interior use
1.12.11 Distempering
1.12.11.1
Type Distempering shall be of the oil or water bound type

as specified.
1.12.11.2
Material
Dry distemper or oil bound washable distemper of

approved brand and manufacture for water bound and oil
bound respectively conforming to IS:426 shall be used.
The proportions of the mix shall be as per the approved
manufacturers instructions.
The dry distemper shall be stirred slowly in clean warm

water using 8.6 liters of water per kg. of distemper or as
specified by the approved makers.
The mixture shall be
well stirred before and during use to maintain an even

consistency.
Thinner as stipulated by approved manufacturer shall be

used in case of distemper for oil bound type.
Dry distemper shall not be mixed in larger quantity than is

actually required for one day work.
1.12.11.3
Preparation of Surface and Priming Coat
The surface shall be thoroughly brushed free from

mortar
dropping
and
other
foreign matter and sand
papered smooth.
PAGE 192 OF 281
541 of 2461
MMRDA
A priming coat of whiting shall be applied over the

prepared surface in case of water bound distempering
and distemper primer or cement primer shall be applied in
the case of oil bound distemper.
The white washing
coat shall be used as priming coat for distemper.
1.12.11.4
Application
After the primer coat is dried for atleast four hours,

the entire surface shall be coated uniformly with proper
distemper brushed in horizontal strokes, immediately
followed by vertical ones which together shall constitute
one coat.
Subsequent coats shall be applied in the same way and

only after the previous coat has dried. Enough distemper
shall be mixed to finish one room at a time.
The
finished surface shall be even and uniform and shall no

brush marks. After each days work, the brushes shall be
washed in hot water and hung down to dry. Old brushes,
which are dirty or caked with distemper, shall not be used.
1.12.12 Decorative Finish Cement Paint
1.12.12.1
Surface Preparation
Plastered surface shall be thoroughly cleaned of dust, dirt,

grease, oil marks, etc. before the coat is applied.
All the
holes and depressions should be filled with gypsum prior to

application of the paint.
The surface shall be wet
with clean water before paint is applied. Application of

primer shall be as per specifications recommended by
approved manufacturer and as directed by the Employers
representative.
PAGE 193 OF 281
542 of 2461
1.12.12.2
MMRDA
Preparation of Mix and Application
Any approved cement paint shall be mixed in such

quantities as can be used up within an hour of mixing. The
solution shall be applied on the prepared surface with good
quality brushes and no brush mark shall be visible on the
finish work.
1.12.13 Painting
1.12.13.1
Painting General
Paints, oils, varnishes etc. of approved brand and

manufacture
Codes
conforming
shall
received
be
used.
to
relevant Indian
Ready
mixed
from approved manufacturer
admixture
shall
be
used.
The
Standard
paints
without
Contractor
as
any
shall
obtain permission for the make and color of the paint he

proposes to use and if required, polish for wood work shall
be tested as per IS:5807 (parts I and II).
Whenever thinning
is necessary, the brand of thinner
recommended by approved manufacturer

instructed
used.Paints,
oil, varnishes,
thinner,
etc.
or
as
shall
be
shall
be
brought to the site in the original containers in sealed

condition and shall be kept in the joint custody of
Contractor and Employers representative.
1.12.13.2
Commencing the Work
Painting except priming coat shall generally be taken

in hand after all other building work is practically
finished.
Approval of Employers representative shall
PAGE 194 OF 281
543 of 2461
MMRDA
be sought before commencing the work.
1.12.13.3
Workmanship
All the work shall be carried out wherever applicable as per

IS:1477 (Parts I & II) and IS:2338 (Part I).
1.12.13.4
The surface shall be thoroughly cleaned.

dust,
scales
and
grease
shall
All
dirt,
be removed
before
painting is started. The surface shall be perfectly dry

to permit good absorption. The prepared surface shall
receive
approval
from
for
commencing the painting work. For wood surfaces, a

priming
coat
without
coloring material
should
be
applied after which all the holes, cracks etc shall be

stopped with putty and all knots properly killed with quick
lime.
Specially for wood surface, knots if visible shall be covered

with red lead conforming to BIS:103.
Holes
and
identification on the surface shall be filled with wood

putty and rubbed smooth. Surface should be thoroughly
dry.
1.12.13.5
Application
Paint shall be thoroughly stirred in the container when

pouring into
smaller
containers for use.
It shall be
continuously stirred while applying on the surface. The

painting shall be applied evenly and smoothly in the
direction of grains of wood and perpendicular to it. Each
coat shall be allowed to dry before the next coat is applied.
PAGE 195 OF 281
544 of 2461
MMRDA
Specified number of coats shall be applied and atleast

24 hours shall elapse between application of the first
coat and the subsequent second coat. No painting shall be
carried out on exterior work in wet weather condition or on
surface which are not entirely dry. Each coat shall be lightly
rubbed down with sandpaper or fine pumice stone and
cleaned of dust before the next coat is laid. No left over
paint shall be put back into stock tins.
The finished
surface shall be free
from hair or brush
marks, strokes, clogging of paint puddles in the corners of

panels, angles of moulding, etc.
1.12.14 Painting With Synthetic Enamel/Enamel Paint
1.12.14.1
Material
Synthetic enamel/enamel paint of approved brand and

manufacture and of required shade shall be used for the
topcoat only. The paint for under coat shall be of shade to
match the topcoat, as recommended by approved
manufacturer shall be used.
1.12.14.2
The
surface
shall be
thoroughly
cleaned.
All dirt,
scales and grease shall be removed before painting

started.
The surface shall be perfectly dry to permit
good absorption. The prepared surface shall receive

approval from Employers representative for commencing
the painting work.
Specially for wood surfaces, knots if visible shall be

covered with red lead conforming to IS:103. Holes and
indentation on the surface shall be filled with good putty
PAGE 196 OF 281
545 of 2461
MMRDA
and rubbed smooth. Surface should be thoroughly dry.
1.12.14.3 Application
a)
Under Coat
One coat of the specified paint of shade matching

with the shade of the top coat shall be applied and
allowed to dry overnight. It shall be rubbed next day
with the finest grade of wet
abrasive
paper
to
ensure smooth and even surface, free from

brush marks and all loose particles dusted off.
b)
Top Coat
Top coats of specified paint in the desired shade

shall be applied after the under coat is thoroughly
dried. Additional finishing coat shall be applied if
found necessary to ensure a properly uniform glossy
surface.
1.12.15 Plastic Emulsion Paint
The paint shall be of an approved manufacturer such as Asian paints,

Nerolac, Snowcem India, ICI and shall conform to IS 5411 Part 2. Lime
gauged cement plastered surfaces shall not be painted for atleast one
month after plastering. A sample patch shall be painted to check alkali
reaction if so desired by the Employers representative. Painting shall be
strictly as per manufacturer's specifications.
Recommendations given by the paint manufacturer shall be strictly

followed for mixing and application of paint. The prepared surface shall
be treated with two coats of primer consisting of cement primer, whiting
or as per manufacturers specifications. The paint shall be applied with
brush or roller. The paint is dried, by evaporation of the water content
PAGE 197 OF 281
546 of 2461
MMRDA
and as soon as the water has evaporated, the next coat can then be
applied. The time of drying varies from 1 hour on absorbed surface and
2-3 hours for non-absorbed surfaces.
The thinning of the emulsion shall be done with water and not by
turpentine. The surface on finishing shall present a flat, velvety smooth
finish. Minimum three coats of Plastic Emulsion paint shall be applied
and the colour shade shall be uniform over the area.
1.13
Expansion Joints and Construction Joints
1.13.1 General
The item of providing expansion joints and construction joints in

concrete includes all the
material,
labour,
tools
and
plants
necessary for completing the item in best workmanlike manner.
1.13.2 Material
The Material to be used in the joints shall be ribbed PVC water stop of
specified width approved by the Employers representative, bitumen
impregnated
approved
fibre
sealant
board
as
material
filler
(In
conforming
to IS:10566
and
case of movement joint only).
In
addition, IS:12220-1987 and 1838 shall also be adhered.
1.13.3 Joints in Floor
Joints in floor shall be provided as specified on drawings. In case of PVC

water stops to be provided horizontal position flat-footed PVC water
stops shall be used. The water stops shall be provided in such a way
that half the portion of water stop (width wise) is embedded
concrete
and
half
remains
exposed
for
next
in
concrete.
the
Steel
reinforcement shall not be discontinued where construction joints in floor

are provided.
PAGE 198 OF 281
547 of 2461
MMRDA
1.13.4 Joints in Walls
1.13.4.1
Expansion Joint
Expansion joints shall be provided in the roof slab and wall

and divide wall is of R.C.C. The joints shall be so located
that in no case the slab shall be more than 45 metres long
in one stretch. The general layout of roof slab showing the
position of expansion joint is given in the accompanying
drawing. The two adjoining portions of the roof slab at the
expansion joints shall be separated by a gap of about
25 mm width which shall be bridged by means of 230
mm wide water stop. These water stops shall be fixed in
such a manner that it is equally embeded in each portion of
the slab on either side of the joint and shall be located at
mid section of the slab.
The joint shall be continuous in
length and shall be properly joined together or welded at all

junction along its length. The gap between the adjacent
slab
below
the water stops shall be filled with filler
material like thermocol or such compound which may be

This may be achieved by placing a strip of filler material in

position adjacent to the face of concreted slab panel
while concreting the adjoining panel. The space above,
water stop shall be filled with sealant material overlaid
by filler material like thermocol and polysulphide sealant
as shown in the drawing.
The expansion joints in the end wall and divide wall shall
be provided in such a manner that the joint shall divide
the structure longitudinally and transversely as shown
in the drawing. The two adjacent parts of the wall shall be
separated by a gap of about 25 mm width which shall be
bridged by 300 mm wide PVC water stop.
However, no
PAGE 199 OF 281
548 of 2461
MMRDA
gap shall be provided in the footing of the wall.
The
gap on water face shall be treated with polysulphide

sealant material as shown in the drawing.
The water
stops shall be either PVC
equivalent
approved
by
the
or
either
as
per
specifications given hereinafter.
1.13.4.2
Construction Joint
The construction joints shall be generally provided at

the end of the concreting or colcreting operation of an
element or a member of a structure, or at boundary
of the panels or segments or at pre-determined locations.
The construction joints in the R.C.C. slab shall be
characterised by the continuance of the reinforcing steel,
being a structural R.C.C. member.
The concreting of a
slab at the joint shall be done by laying the concrete

against the vertical stopping off boards, the adjoining
panels being cast butting against each other.
Construction joints in the side wall and the divide wall of

reservoir shall be of two types (I) horizontal construction
joints and (ii) vertical construction joints.
The horizontal construction joints shall be serrated type

where stones from the lower lift of the wall shall be
projecting out sufficiently and will be embedding into the
over laying lift of the wall masonry giving a well bonded,
and consequently, a water tight joint.
The vertical construction joints in the wall shall be of

tongue and groove type.
The groove of these joints
shall be 300 mm x 300 mm and it shall be provided 300

mm away from the water face of the wall. These joints
shall be provided with PVC water stop at a depth of 200
PAGE 200 OF 281
549 of 2461
MMRDA
mm from water face which shall be primarily responsible

for the water from water face which shall be primarily
responsible for the water tightness of the joints. These
joints shall have a plain finish for a depth of 300 mm from
water face by virtue of its casting against vertical face of
the centering of vertical face of the previously cast
panels
cast
butting
against
each
other while
the
remaining depth beyond300 mm shall have masonry

facing which will present a rough surface and thus provide
a good bond between the consecutive panels.
In the case of divide wall the water stop shall be located at

the centre of the key which shall be located at the centre of
divide wall. The key shall be of the same dimensions as
that in the end walls.
The construction joints in
the bottom layer of the floor
which shall be case in colcrete shall be cast against

vertical stopping off boards.
On
the water face the
vertical joints shall have a groove provided with bitumen of

12 mm x 20 mm size which shall be filled with polysulphide
sealant material.
No such special treatment need be done for the joints

provided in the roof slab, bottom layer of the floor and the
horizontal joints in the wall. The joints in roof slab and
bottom layer of the floor shall however, be staggered with
those in the overlaying layers such as brick bat coba,
I.P.S. and top R.C.C. layer of the floor to minimise
the chances of leakage by increasing its path, if any.
1.13.4.3
Complete Construction Joints
These joints are provided in the top layer of the floor

of the reservoir with a view to localise shrinkage
PAGE 201 OF 281
550 of 2461
MMRDA
cracks at these joints.
These joints are characterised
by complete discontinuity of steel without any initial

gap as in the case of expansion joints.
The joints
between the adjacent panels of the floor shall be provided

with a groove at top of dimension 12 mm x 20 mm and it
shall be filled with polysulphide sealant and they shall be
provided with water stops as specified earlier.
The joint between top layer of the floor and the walls
or between the top layer of the floor and the column
footing, shall also be provided with a groove of 12 mm x 20
mm which shall be filled with sealant material as per
specifications given below:
Joint Fillers : Joint fillers shall be of durable, compressible

and non-extruding material. It shall be non-staining, nonabsorbent and compatible with sealant material used.
Sealant Material : The joint sealing compounds should be

capable of properly ensuring water tightness in vertical and
horizontal and inclined joints in water retaining and other
structures having severe service conditions in respect
of
anticipated
movement
or exposure to weather.
Typical uses include expansion joints in the walls of water

tanks, and in roof and deck slabs exposed to the weather.
The compound should be flexible, durable and weather

proof and should have sufficient elasticity to allow joint
movements
of
the
concrete
components
wherever
The sealant shall be polysulphide rubber
sealing
necessary.
compound conforming to BS 4254 of 1967 or ASA-A 1161-1960 or any other equivalent specifications. It shall be
capable of cold pouf application for horizontal joints and
PAGE 202 OF 281
551 of 2461
cold
MMRDA
application of vertical and
inclined joints.
The
sealing compounds shall be suitable for use in the tropics

where it will be subjected to high ambient temperatures,
humidity and very strong sunlight.
It shall not degrade
under these conditions and shall be suitable for use with

raw and treated water including water dosed with chlorine.
The sealant shall be odour and taint free from lead. It shall
be available in choice of colours and shall give a
though, permanent seal, be waterproof, non-staining
and remain resilient.Sealing compounds for vertical
and horizontal joints shall be used complete with the
appropriate
quantity of primer
instruction for use.

adhesion
to
as per manufacturers
The primers should ensure good
the concrete
and
should
be
specially
developed for respective sealing compounds.

sealants
without
shall
be
applied
guns
as
specified
with
by
pressure
The
guns
or
the manufacturers.
Sealing compound shall be fully cured before water is

permitted to come in contact.
The sealant material should be formulated as to have a

storage period of one year at a temperature of 40oC.
1.14
Epoxy Coating, Bituminous, Polymer Painting
1.14.1 Epoxy Coating
1.14.1.1
General
Epoxy coating is to be applied to the internal surface of the

unit wherever specified. The thickness of epoxy film shall
be 300 microns.
1.14.1.2
Materials
PAGE 203 OF 281
552 of 2461
MMRDA
A solvent free epoxy coating like Araldite GY 255

manufactured by Hindustan CIBA Geigy Limited, Bombay
or equivalent product of FOSROC is to be used for forming
the film.
Incase of use of an equivalent it should be got
approved by the Employer placing supply orders. Materials

used and process of application to the concrete of other
surfaces should be strictly according to the instructions of
the suppliers of the epoxy. Araldite GY 255 one part by
weight is to be mixed with 1 part by weight of Hardener H Y
45. The viscosity should be such that it is convenient for
brush application.
1.14.1.3
Subsurface Preparation
The concrete surface should be cleaned thoroughly by

sand blasting. The mild steel parts also are to be cleaned
to be free of grease and thoroughly sand blasted.
The
coverage should not be more than 6 sq.m. for concrete and

5 sq.m. for mild steel per kg of epoxy respectively.
The moisture content of concrete before application of

epoxy coating shall be less than 4%.
This has to be
checked properly through a small sample. To achieve

this epoxy coating shall be done in hot season.
1.14.1.4
Curing
The curing should be done for 7 days at room temperature.

if the temperature is less than 15 c the space should be
warmed up by incandescent lamps, heaters, blowers or
infrared lamp.
manufacturer
The
of
the
instructions
product
both
of
the
as
for
supplier
use
of
materials and application take priority over the above

instructions and they should be followed very rightly.
PAGE 204 OF 281
553 of 2461
1.14.2
MMRDA
Bituminous Painting
Two coats of bituminous paint of 80/100 grade, with 1.65

kg/m2 spread will be provided on internal face of sludge
sump.
1.14.2.1
Material
The material shall be of best quality un-pigmented

bituminous
base
pain
of
such
a composition as to
satisfy the requirements of IS-9862.with total volatile matter

contained in the paint shall not exceed 55% by weight.
At least 95% of the solid materials shall be soluble, in

carbon di-sulphide or in benzene, and the closed flash
point as determined in Abel's apparatus shall not be
less than (86F)30C. The paint shall remain liquid and
retain
its
consistency
at
the
ordinary atmospheric
temperature when packed in suitable containers. The

drying time shall not he less than 2 hours and not more
than 8 hours, and after drying, paint shall not shoe any
surface cracks, tendencies to powder or discoloration
due to weathering action or expansion and contraction. It
shall also be able to resist the action of acids and alkalis. It
shall not soften under the action of mineral turpentine.
The film resulting from brushing the material on a strip of

tinned iron, 30 standard wire gauge after being allowed
to dry at room temperature not below (65F) 18.3C
for 48 hours shall not, when bent double over a (quarter
inch)6 mm dia rod, show any signs of flaking or cracking.
The time occupied for the actual bending shall not
exceed one second. When the paint has dried hard, a 4H
pencil should not be capable of scratching it. The weight of
the paint shall be firm 0.83 to 1.25 kg per liter, the
PAGE 205 OF 281
554 of 2461
MMRDA
component of the paint shall he such as not to react

with
water
chlorinated
or
otherwise
and
develop
poisonous or harmful elements thereto.
The paint shall be of' Indian manufacture of approved make

and quality
1.14.2.2
Application
All corners and junctions shall be properly rounded off to

present a uniform and smooth finish.
After complete
curing of the plaster, it will be allowed to day up.
After
drying the moisture content shall be brought to a value

less
than
4%
by using
below-lamp. The surface
should be well cleaned with smooth brush to make it dust

free. The coating shall be allowed to dry and kept in dry
condition till final setting takes place.
1.14.3 Polymer Painting
Polymer
paint
shall
be
elastomeric
thermoplastic, fire retardant, coating
(450%
elongation),
skin tensile strength 18 to 21
kg/cm2, antifungal, antibacterial anticorrosive graft polymer paint of

approved make Meta Chem or equivalent.
Fire retardant coating shall confirm BS 3119 specifications
1.15
Door, Windows, Grills, Shutters etc.
IS:1003 (I)
: Timber paneled and glazed door & ventilator shutters
IS:1003 (II)
IS:1038
shutters
: Steel doors, windows & ventilators
Timber paneled and glazed window & ventilator
PAGE 206 OF 281
555 of 2461
MMRDA
IS:1081
: Fixing & glazing of metal doors, windows & ventilators
IS:1361
: Steel windows for industrial buildings
IS:2202
: Wooden flush door shutter (solid core type)
IS:2202 (I)
: Plywood face panels
IS:2202 (II)
: Particle board and hardboard face panel
IS:4020
: Methods of test for wooden flush doors
IS:6248
: Metal rolling shutters & rolling grills
IS:7452
: Hot rolled steel sections for doors, windows & ventilators
IS:10451
IS:10521
: Steel sliding shutters

: Collapsible gates
1.15.2 General
The items under this clause cover doors, windows, grills, rolling
shutters, collapsible gates etc. normally required to be provide in a
building used whether for residential, office, laboratory or industrial
purpose.
Doors
and
windows
Shutter
shall
be
of
Teakwood
as
specified in the bill of quantities/drawings or as directed by the

Employers representative. (Latest Material may be specified for doors
and window shutters).
The
frames and
shutters
shall be
of
either
steel or wood,
Aluminium of thickness of members as shown on the drawings. The

material used shall be of good quality seasoned timber of specified wood
or rolled steel sections as the case may be.
They shall be provided with all necessary fittings like hold fasts,
hinges, locking arrangements stoppers, eyes and hooks, tower bolts,
handles, fixing lugs etc., of sizes and quality grade as specified.
They shall be provided in complete form including painting, glazing,

fixing in position true to level and plumb.
PAGE 207 OF 281
556 of 2461
MMRDA
Steel rolling shutters shall be of approved make and shall conform to

IS 6248 - 1979. Metal rolling shutters and rolling grills.
The builders hardware shall all be as per relevant Indian Standards.
1.15.3 Woodwork in Doors, Windows, Partitions, Louvers, Railings etc.
Wood used for all work shall be the best of the respective class
specified, and properly seasoned by at least 6 months air drying,
suitable for joiner's work, should be of natural growth,
uniform
in
texture, straight grained, free from sapwood, dead knots, open

shakes, boreholes, rot, decay and any and all other defects and
blemishes.
The thickness specified for joiner's wrought timbers are, unless

otherwise specified, prior to planning and 3 mm will be allowed from the
thickness stated for each wrought faces.
All joining shall be wrought on all faces and finished off by hand with
sandpaper, with slightly rounded arises.
The joints shall be pinned with hard wood pins and put together with
white lead. Jointing shall be by means of mortise and tenor or dovetailed
joints as approved.
Any joiner's work which shall split, fracture, shrink, or show flaws or
other defects due to unsoundness, inadequate seasoning or bad
workmanship, shall be removed and replaced with sound material at
the Contractor's expense.
Doors, windows and ventilator frames, transoms and mullions shall

be rebated. All dimensions shall be as per drawings. The top
framing member of doors and top and bottom framing of windows
and ventilators shall project about to mm below finished floor.
Surface coming in contact with brickwork shall be painted with
PAGE 208 OF 281
557 of 2461
MMRDA
bitumen as directed by the Employers representative. Each of the

door and window frames shall be provided with 3 Nos. M. S. 225 x 25
x 6 flat split holdfasts on each side. These holdfasts shall be embedded
in masonry of concrete work. The work shall conform to IS:4021.
The doors shall be paneled or solid flush doors as described in

the item of work. All flush doors shall be supplied with approved
fittings
such
as
hinges,
mortise
lock
of approved
make
with
handles on both sides, oxidised brass tower bolts and latch

arrangements, door stops etc. and as shown in drawings but
exclusive of door closers. Door closers, where separately specified
shall be of heavy duty hydraulic type to be approved by Employers
representative Paneled doors shall have the same fittings except in
place of union lock, an aldrop shall be provided. Each door leaf shall
have two 250 mm tower bolts, two aluminum or oxidised brass handles,
and one door stopper be made of weatherproof plywood. Flush doors
shall conform to IS:2202 (Part-I).
Doors will generally have no sills but if a few have to be provided, the
Contractor shall do so at no extra cost to the Owner.
The type of window shall be as specified. Each shutter shall have one
pair of hinges, two tower bolts (one 225 mm long and another 150 mm
long), one handle and one hook with eye and pegstay. Ventilators shall
have two M. S. hold fasts and hinges, one handle and one hook and eye
at each and one small tower bolt in the centre. Where so directed by the
Employers representative, the doors and windows shall be provided
with parliamentary type hinges at no extra cost.
The workmanship of all door and window shutters shall conform to the
requirements of IS:1003
(Part-I
&
II)
and
IS:2202
(Part-I).
If
required, flush door panels shall be got tested as per IS:4020.

Cupboards, almirahs and shelves shall be provided as per Employers
representative. The doors could be of either hinged type or sliding type
PAGE 209 OF 281
558 of 2461
MMRDA
as approved by the Employers representative. All dimensions as

furnished in the drawings shall be followed. Fixtures and fittings as
shown on drawings or as directed by Employers representative shall be
used.
Railings and architraves shall conform to the shape shown on drawings

or as approved and fixed by means of screws (counter sunk or
otherwise) or bolts.
The finish expected is of a very high order and the work shall be allinclusive weather or not all detailed specifications have been spelt
out and the work shall be free from blemish. No iron bars or grills
are proposed to be provided in the windows or ventilators. Glass louvred
ventilators where specified shall be provided.
Glazed windows, louvres, ventilators and doors shall be provided

with either clear or pinheaded glass 5.5 mm thick which shall be free
from all blemishes and shall conform to IS:1761. It should be clearly
understood that glass which does not have uniform refractive index
or which is wavy will be rejected. Woodwork shall not be painted, oiled or
otherwise treated before the Employers representative has approved it.
1.15.4 Steel Doors, Windows and Fittings (Aluminium Windows)
The steel doors, windows, ventilators shall conform or IS:4351 and

IS:1038. All steel doors windows, ventilators, louvres etc. shall be of
sizes as specified and conform to the description in the respective
item of work. Whether or not specifically mentioned, all fixtures and
fittings necessary for the satisfactory operation of the doors and
windows shall be provided. Doors, windows and ventilators shall be
obtained from an approved manufacturer. Specific approval for such
purchase shall be obtained before hand. Sample shall also be got
approved before further manufacture starts, unless this is waived in
writing by the Employers representative. All steel doors shall be of
pressed steel (18 gauge) flush type with or without removable transome.
PAGE 210 OF 281
559 of 2461
MMRDA
All doors shall be provided with a three way bolting device and locking
arrangement with duplicate keys and handles of both sides and
operable from either side. The Contractor shall obtain windows with
friction hinges in place of windows with pegstays if so directed by the
Employers representative. For centre hung and top hung ventilators
suitable spring catch/pulley and chord arrangement shall be provided for
facility of opening. Whenever fly mesh over windows have been called
for, they shall be fixed on the window and suitable lever type or
rototype arrangement shall be provided for opening or closing of the
glazed panels from inside. Prior approval of Employers representative
shall be taken before order is placed with the manufacturer.
Where specified, steel doors supplied shall be airtight. For this purpose,
the Contractor shall provide necessary padding material such as
rubber, felt or any other approved material.
1.15.5 Rolling Shutters
The rolling shutters shall conform to the size required. The rolling
slats shall be in one piece and be made of heavy gauge steel sheets
minimum 18 SWG in thickness. A cylindrical hood shall be provided on
the top to enclose the shutter when it is open. The rolling shutters shall
be provided with
suitable locking arrangements and deep
channel
guides, In case galvanised rolling shutters are specified the rolling

shutter
shall
be
made
of
hot
dip galvanised slats, hood, deep
channel guides all preferably in one piece. In case of hand operated pull
& push type rolling shutters of sizes larger than 10 sq.m. in area and in
case of very large gear operated and/or as directed by the Employers
representative, rolling shutters shall be provided with ball bearings for
smooth & efficient operation. In case of large rolling shutters &
depending upon local wind conditions, the rolling shutters should be
provided with special locking type of wider channel guides or it
shall be provided with central moveable channel supports to take up
design wind pressures in the area.
PAGE 211 OF 281
560 of 2461
1.16
MMRDA
Hand Railing
Hand railing and vertical posts shall be made from galvanised mild steel
pipes and fittings. The design of the railing shall be approved by the
manufacturer's
drawings
to
whom
showing
the Contractor
positions
of
vertical
shall
submit
posts, joints,
expansion joints and joint details and all fixing details. Fabrication shall not start
until these drawings have approved by the Employers representative .
Hand railing and vertical posts fabricated from galvanised mild steel pipes and
fittings shall conform to the following requirements.
The height of the top railing shall be 1000 mm above finished floor level
unless otherwise shown. There shall be total 3 horizontal rows. Top row shall
be of 32 mm dia and middle two rows shall be of 25 mm dia GI medium
class pipe. The lower railing shall 550 mm above finished floor and Toe plate
should be provided at the bottom of the rail of the size100mm wide x 5 mm
thick subject to the approval these and other leading dimensions may be varied
slightly to suit manufacturer's standard products.
a.
Unless otherwise shown, vertical posts shall be made of galvanised mild

steel tubes (medium class) of 40 mm nominal bore and fittings such
as Tees, Bends, Crossed etc. of heavy class conforming to IS:1239.
b.
Unless otherwise shown, top horizontal post shall be made of galvanised

mild steel tubes (medium class) of 32 mm nominal bore and fittings
such
as Tees,
Bends, Crossed etc. of heavy class conforming to
IS:1239.
c.
Unless otherwise shown, lower two horizontal post shall be made of

galvanised mild steel tubes (medium class) of 25 mm nominal bore and
fittings such as Tees, Bends, Crossed etc. of heavy class conforming to
IS:1239.
PAGE 212 OF 281
561 of 2461
d.
MMRDA
In general the vertical posts shall be spaced at 1.5 metre c/c and shall
be built into the concrete or bolted to the MS plate embedded in
concrete as shown on detailed drawing.
e.
Hand railing and vertical posts shall be painted with 2 coats of approved
paint.
1.17
Rungs
Rungs shall be provided in all manholes/inspection chambers/pumping stations

over 0.6 mm in depth and shall be of cast iron conforming to IS:5455. These
rungs shall be fixed staggered in two vertical runs, 300 mm apart horizontally
and 300 mm c/c vertically. The top rung shall be 450 mm below the
manhole/inspection chamber cover and the lowest not more than 300 mm
above the benching. The rungs shall be of 20 mm diameter with epoxy paint for
corrosion resistance or equivalent as approved by Employers representative.
1.18
Piping Work
1.18.1 Reinforced Cement Concrete Pipes (Class NP 3)
1.18.1.1
Applicable Codes
Laying of pipes and fittings/ special shall comply with all

currently applicable statues, regulation, standards and
codes. In particular, the following standards, unless
otherwise specified herein, shall be referred to. In all
cases the latest revision of the standards/ codes shall
be referred to.
a)
IS: 783
: Code of practice for laying of

concrete pipes
b)
IS 458
: Specification
for
pre-
cast
PAGE 213 OF 281
562 of 2461
MMRDA
concrete pipes (with

and without reinforcement)
c)
IS 3597 of 1966
: Method of tests for concrete pipes
I.S.458
d)
IS 5382
: Specifications
for
rubber
sealing rings for gas

mains, water mains
e)
Operational Guidelines and Code of Practice for

Stainless Steel Products in Drinking Water Supply,
British Stainless Steel Association, 2002
ISI Marked RCC NP3 Socket and Spigot pipes conforming

to IS: 458/1988 shall only be used under this contract.
Sulphate
resistance
cement
shall
be
used
in
manufacturing of the pipes. The Pipes to be used shall be

perfectly cylindrical; sound without any damage. The pipes
shall be suitable for rubber jointing. The rubber shall
be
of
good
quality conforming to relevant I.S.
Specifications and duly inspected by the approved third

party inspecting agency.
All buried piping under the sewage treatment plant process

units and used for transferring the liquid contents shall be
of Stainless Steel AISI 304 grade.
1.18.1.2
Laying of Pipes
Care shall be exercised in loading, transporting, and

unloading of concrete Pipes. Handling shall be such as
to avoid impact. Gradual unloading by inclined plane or
by chain block for higher, diameter is recommended.
Pipes
shall
be
lowered
into
the
trench
carefully,
PAGE 214 OF 281
563 of 2461
mechanical
MMRDA
appliances
may
be
used. Under
no
circumstances shall the pipes be dropped or dumped

into the trench without proper support.
All pipe sections and connections shall be inspected

carefully before being laid. Broken or defective pipes or
connections shall not be used, and if such defective
sections are found, the same shall be removed by the
Contractor at his cost and risk and shall have to be rebuilt
with good pipes and materials.
All lumps, blisters and excess coating materials shall be

removed gently from the ends of each pipes and they shall
be wiped clean and dry before the pipe is laid.
For spigot and socket pipes, with rubber jointing rings,

proper jointing shall be ensured.
Every precaution shall be taken to prevent foreign
materials from
entering in
to
pipe when it is being
placed in the trench.
Pipes shall be laid true to line and grade as specified.
Laying of pipes shall always proceed upgrade of a

slope.
However,
for
pipes
having spigot and socket
joints, the socket ends shall face upstream.
The pipe shall be secured in place with approved back fill

material or concrete tamped under it except at the joint
portions.
At times when pipe laying is not in progress the open ends

of pipe shall be closed by a water tight plug or canvas or
other means approved by the Employers representative.
PAGE 215 OF 281
564 of 2461
MMRDA
Trench shall be kept free from water until the material

in the joints has hardened. If bailing out of water is
required for excavation and laying of pipe no extra
payment for bailing out water shall be made in any form
and this shall be done by the Contractor at his own cost.
When the pipe is closed and the trench liable to be flooded

by water, care shall be taken to prevent the pipe from
floating.
Walking or working on the completed sewer shall not be

permitted until the trench has been back filled to a height of
at least 30 cm over a pipe.
The cutting of pipes for inserting fittings or closure shall be

done in a neat and workman like manner without danger to
the pipe so as to leave a smooth surface and at right
angles to the axis of the pipe.
Before connecting a pipe to a manhole, a relieving arch or

any other similar protection device shall be made in the
manhole for the safety of the pipe.
The pipe when laid shall not be subjected to super

imposed load beyond what the pipe can safely with stand
The pipe shall be laid along the side of the trench, each
pipe in its proper position for laying with an extra pipe
after every 20 nos. to allow for cutting, if necessary. Where
the trench crosses a road or place where such distribution
is inadmissible, the pipes shall be stacked in heaps at each
end, sufficient to fill in the length. As far as possible, pipe
shall be laid straight in rising gradient. It should be
possible to empty the pipe readily and completely. The
socket end of the pipe shall be facing up hill. All the pipes
PAGE 216 OF 281
565 of 2461
MMRDA
shall be used in standard length as far as possible. Cut

length may be used only where necessary, to make up to
exact length. All the pipes shall be first inspected for any
damage and cracks. No cracked or damaged pipes shall
be used.
The connection to an existing sewer shall be done through

manhole chamber. However, before connecting a pipe to a
manhole, a relieving arch or any other similar protection
device shall be made in the manhole for the safety of the
pipe.
1.18.1.3
Pipe Bedding
The pipe bedding of class A, B, C will be provided as per

requirement
and
instructions
of
The
Employers
representative according to approved design and drawings,

as per site condition.
In places where the natural foundation is inadequate, the

pipes shall be laid either in a concrete cradle, supported
on
proper
foundation
or
on
any
other
suitable
designed structure, to be approved by the department.
Pipes laid in trenches in earth shall be bedded evenly

and firmly and as for as the haunches of the pipe so as
to safely transmit the load expected from the back fill
through the pipe to the bed. This shall be done either by
excavating the bottom of the trench to fit the curve and
around the curve of the pipe to form an even bed,
necessary provision shall be made for joints, wherever
required.
When the pipe is laid in trench in rock, hard clay, shale or

other hard material, the space below the pipe shall be
PAGE 217 OF 281
566 of 2461
MMRDA
excavated and replaced with an equalising bed of

sand or compacted earth. In no case, shall the pipe be laid
directly on such hard material.
Wherever required, the encasing of pipe shall be done

with
concrete.
Suitable
nos.
of manholes
shall be
provided at proper interval or at the places where

there is change of direction of the alignment and grade
as per the direction of Employers representative.
1.18.1.4
Jointing
Each concrete pipe with the rubber ring accurately

positioned on the spigot shall be pushed well home
into the socket of the previously laid pipe by means
of uniformity applied pressure with the aid of a jack or
similar appliance.
Concrete pipes of the spigot and socket type with roll on

rubber rings shall be used, and the manufacturers
instructions shall be deemed to form a part of this
specification.
Rubber rings shall be lubricated before making the joint

and the lubricant shall only be soft soap water or an
approved lubricant supplied by the manufacture.
In case of RCC Pipe entering or leaving a manhole a

flexible joint may be provided at least within 0.60 M from
the outer end of the manhole.
The spigot and socket pipes shall be jointed with rubber

joints for which rubber gasket shall be arranged by
Contractor and such rubber gaskets / rings shall confirm to
relevant I.S. Specifications. The department shall provide
PAGE 218 OF 281
567 of 2461
MMRDA
no jointing material.
The section of the pipe shall be jointed together in such a

manner that there shall be as little unevenness as possible
along the inside of the pipe.
1.18.1.5
Testing
All pipelines shall be subjected to a test pressure of at least

2.50 m head of water, at the highest point of the section
under test.
The tolerance of two liters per centimeter of diameter

per kilometer shall be allowed during a period of ten
minutes.
Before commencing the hydraulic test the pipelines

shall be filled with water and maintained full for 24
hours by adding water, if necessary under a head of 60
cms of water.
The test shall be carried out by suitably plugging the low

end of the drains and the ends of connections, if any and
filling the system with water.
A knuckle bend shall be temporarily jointed in at the top

end and a sufficient length of vertical pipe jointed to it so as
to provide the required test head, or the top end may be
plugged with a connection to a hose ending, in funnel
which could be raised or lowered till the required head is
obtained and fixed suitably for observation.
If any leakage is found visible then the defective part of the

work should be cut out and made good. A slight amount
of sweating which is uniform may be over looked but
PAGE 219 OF 281
568 of 2461
MMRDA
excessive sweating form a particular pipe or joint shall

be watched for and taken as indicating a defect to be
made good.
Any joint found leaking or sweating shall be rectified or

embedded into 15 cm layer of cement concrete (1:2:4) 30
Cm in length and the section re-tested.
The testing of the rubber rings shall confirm to I.S 3400 of

1965 and also I.S. 5382 of 1969.However, after the
delivery of the pipes made at sites, the Contractor shall
have to arrange for visual tests for whole of the lot,
received from time to time at site.
1.18.1.6
Inspection of the Joints
After the joints of any pipes in underground work have

thoroughly set, the Employers representative
(or
any
person whom he may appoint) any inspect the joints

and if he has any doubt as to their soundness he may
required the Contractor to cut open and clean away the
cement or lead as the case may be of any joint that he may
select and to make good the same at their expense
provided that unless some defect be found, they shall not
be required to open more than one joint in 20 M of pipe
length if the defect be found the Employers representative
may direct them to open as many joints as he may deem
necessary.
1.18.1.7
Cleaning of the Pipes
As soon as a stretch of pipe whether of stoneware or Cast

iron or R.C. Pipes has been laid
manhole,
the
Contractor shall
from
manhole
to
run
through
the
pipes both backwards and forwards a double disc or solid

PAGE 220 OF 281
569 of 2461
MMRDA
or closed cylinder 75 mm less in diameter than the internal

diameter of the pipes. The open end of an incomplete
stretch of pipeline shall be securely closed as may be
directed by the Employers representative to prevent entry
of mud or silt etc.
If as a result of the removal of any obstruction the

Employers representative considers that damages may
have been caused to the pipelines, he shall be entitled to
order the length to be re tested at the expense of the
Contractor. Should such retest prove unsatisfactory the
Contractor shall at his own expenses amend the work and
carry out such further tests as are required by the
Employers representative. It shall also be ascertained by
the Contractor that each stretch from manhole to manhole
is
absolute
clear
and
without
any
obstruction
by
means of visual examination of the interior of the pipe

line suitably enlightened by projected sunlight or otherwise.
1.18.1.8
Fracture of Pipes
In the event of pipes being fractured after being laid

whether due to imperfect loads have or the material for
refilling have been improperly selected or to any other
cause,
the Contractor in every instance will be held
responsible and will be called upon to replace such

defective pipes at his own cost, if such defect appears
before the expiration of the period of maintenance.
Any pipe or length of pipes found to be defective

shall
be
Contractors
immediately
expense
removed
and
remade.The inspections and
and replaced at the
leaking
joints
shall
be
tests
shall
then
be
repeated as often as necessary until the whole line

under inspection or test is accepted by the Employers
PAGE 221 OF 281
570 of 2461
MMRDA
representative.
1.18.1.9
All works to be clear clean and perfect
The Contractors shall after completion or whenever

required by the Employers representative, prove all pipes
and fitting to be clear clean and perfect, and for this
purpose shall at their own expense and in the presence
of
the
or
his
appointee,
provide suitable instruments and appliances and pass

them through the pipes and shall, if required, throw in
water and show that it passes freely through every portion
of the work. Brick, mortar and rubbish shall not be allowed
to fall into the manholes of sewer lines while fixing or if
allowed, shall be removed by the Contractor at their own
expense.
1.18.2 Centrifugally Cast (Spun) Ductile Iron Pipe
The material of construction for the pipe line shall be Ductle Iron
(DI) with internal cement mortar lining (Class K7).
1.18.2.1
Scope of Work
Laying in trenches centrifugally cast (spun) ductile iron

pressure pipes of class K7 as per IS: 8329: 2000 (Code
of practice for use and laying of ductile iron pipes)
including jointing
(tyton
push
joint),
bends
of
all
degrees, tees, collars, tapers, crosses, flange sockets

&
spigots,
branched
pipes,
chamfering etc.
where
required. Testing of pipes should be done as per IS:

8329: 1994.
1.18.2.2
Applicable Codes
PAGE 222 OF 281
571 of 2461
MMRDA
Important IS codes applicable in case of Ductile iron

pipes, fittings, jointing & laying are:
S. No. IS Codes
1
Description
8329
Centrifugally cast (spun) ductile

iron pressure pipes for water, gas
and sewage specification
9523
Ductile iron fittings for pressure

pipes
for
water,
gas
and
sewage
3
12288
Code of practice for use and

laying of ductile iron pipes
12820
Dimensional
rubber
joints
requirements
gasket
and
for
push-on
of
mechanical
joints
for
use with cast iron pipes and

fittings for carrying water, gas and
sewage
1.18.2.3
Pipe & Pipe Joint
Ductile iron pipe of K7 class of socket & spigot end suitable

for
tyton
push
on
joints
or
mechanical
joints
is
recommended for the project wherever required.
Push-on-Joint: A flexible joint in which an elastomeric

gasket is located in the socket and the joint assembly is
effected by entering the spigot through the gasket into
the socket. Allowable angle of deflection for push on joints
are tabulated below.
Nominal Diameter,
80 to 200mm
250 to 350
400
Allowable angle of deflection

5.0 degree
4.0 degree
3.5 degree
PAGE 223 OF 281
572 of 2461
MMRDA
450 to 600
3.0 degree
700 to 900
2.5 degree
Mechanical
Joint:
flexible
joint
in
which
an
elastimeric gasket is located in the socket, sealing

being obtained by applying pressure to the gasket by
means of a gland bolted to the socket. Allowable angle
of deflection for mechanical joints is tabulated below.
Nominal
Allowable angle of deflection
80 to 300
Diameter,mm
350
400
5 degree
4 degree, 50 seconds
450
500
600
700
Ductile iron pipe having screwed on flanges and welded on

flanges shall conform to the requirement of Table 4 & 13
of IS 8329:1994. Shielded Nickel- iron electrodes is
the preferred
material
for
manual
arc
welding
of
flanges. Flange shall preferably be of ductile iron. For

screwed on flanged pipes, the method of screwing and the
exact form of thread are left to the discretion of the
manufacturer in view of the fact that flanges are
never removed after screwing on the barrels of the pipes.
1.18.2.4
Rubber Gasket
Rubber
gasket
mechanical
joints
for
use
shall
with
conform
push-on-joints
to
or
IS 12820:1989.
Rubber gasket for use with flanged joints shall conform to

IS 638: 1979.
Rubber gasket shall be compatible with the fluid to be

PAGE 224 OF 281
573 of 2461
MMRDA
conveyed for materials, pressure and temperature. While

conveying potable water the gaskets
deteriorate
should
not
the quality of water or should not impart or
odour.
1.18.2.5
Hydrostatic Test
All pipes shall be tested hydrostatically at a pressure

specified below. To perform the test, pressure shall be
applied internally and shall be steadily maintained for a
period of minimum 15 seconds during which the pipes
may be struck moderately with a 700 g hammer. The
pipes shall withstand the pressure test and shall not
show any sign of leakage, sweating or other defects of
any kind.
1.18.2.6
Nominal Diameter, mm
80 - 300
350 600
Class
K9
K9
Working Pressure
1.8 MPa
1.8 MPa
Max. works test pressure
5.0 MPa
4.0 MPa
Max. site test pressure
3.2 MPa
2.4 MPa
Pipe Lining
Lining
of
corrosion
pipes
&
resistance
fittings
&
are
recommended
for
improved hydraulic carrying
capacity.
External surface of pipe & fittings is protected with

epoxy
coating
material
having
a minimum dry film
thickness of 80 microns.
Pipe should be internally lined with sulphate resistance

cement mortar of minimum thickness as given below.
The internal lining should be done by centrifugal method.
PAGE 225 OF 281
574 of 2461
MMRDA
Dia of pipe, mm
Thickness of lining, mm
80-300
350 600
3
5
700 1200
Cement lining of the fitting is done with spray gun and then
by hand to give a smooth and uniform thickness, as it is not
practicable to utilise centrifugal methods.
1.18.2.7
Use and Laying of Ductile Iron Pipe
Excavation, backfilling, laying & jointing of pipe should

be strictly as per IS: 12288-1987 (Code of practice for
Use & laying of Ductile Iron Pipes).
The width of trench at bottom between the faces of

sheeting shall be such as to provide 300mm clearance on
either side of the pipe. Trenches may require extra width to
permit placement of timber supports, sheeting, bracing and
appurtenances if they are employed. Holes
for
pipe
socket should be provided at each joint, but should

be no longer than necessary for joint assembly and for
assurance that pipe barrels will lay flat on the trench
bottom. Pipe bottom should be true and even in order
to provide support for full length of the pipe barrel.
Special consideration should be given to the depth of the

trench. Minimum earth cover over pipeline should not be
less than 1000mm. It may be necessary to increase the
depth of pipeline to avoid land drains or in the vicinity of
heavy traffic roads, railways or other crossings.
A minimum earth cushion of 150mm depth should be

PAGE 226 OF 281
575 of 2461
MMRDA
provided below the pipe line to protect the pipe and its
coating. Earth cushion should be of sand or fine graded
excavated material.
Back Filling: For the purpose of back filling, the depth of

the trench shall be considered as divided into the following
three zones from the bottom of the trench to its top.
Zone A : From the bottom of the trench to the level

of the centre line of the pipe. Backfilling in zone A shall
be done by hand with sand, fine gravel or other fine graded
material placed in layers of 150mm and compacted by
tamping. The back filling material shall be deposited in
the trench for its full width of each side of the pipe,
fitting and appurtenances simultaneously.
Zone B : From the level of the centre line of the pipe to a

level 300mm above the top of the pipe. Backfilling in zone
B shall be done by hand or approved mechanical methods
in layers of 150mm. The type of back fill material to be
used and the method of placing and consolidating shall
be prescribed by the Employers representative keeping
in view the local condition.
Zone C : From a level 300mm above the top of the pipe to

the top of the trench. Back filling in zone C shall be done
by hand or approved mechanical methods. The types of
back fill material and method of filling shall be as
prescribed by the Employers representative.
When
pipes
are
laid
under
roads
and
pavement
subjected to heavy traffic loads, the trenches may be

covered
with
reinforced
concrete
slabs of
suitable
dimensions.
PAGE 227 OF 281
576 of 2461
MMRDA
Laying of pipe: Pipes shall be lowered into the trench with

tackle suitable for the weight of pipes. For smaller sizes, up
to 250mm nominal bore, the pipe may be lowered by the
use of ropes but for heavier pipes, either a well designed
set of shear legs or mobile crane should be used.
On gradients of 1:15 or steeper, precautions shall be taken

to ensure that the spigot of the pipe being laid does not
move into or out of the socket of the laid pipe during the
jointing operations. As soon as the joint assembly has
been completed, the pipe should be held firmly in position
while the trench is backfilled over the barrel of the pipe.
The backfill should be well compacted.
Supporting pipes above ground: It is recommended

that above ground installations of spigot and socket
pipes be provided with one support per pipe, the
supports being positioned behind the socket of each pipe.
If necessary, unsupported spans between 4 and 6 m may
be obtained by positioning the pipe supports relative
to
the
pipe
joints.
The recommended maximum
unsupported span for flanged pipe is 8m.
Pipe should be fixed to the supports with mild steel straps

so that axial movement sue to expansion or contraction
resulting from temperature fluctuation, is taken up at
individual joints in the pipe line.
Cutting of pipe for inserting valves, fittings, etc, shall

be done as per para 5.4 of IS: 12288 1987.
Pipeline Anchorage: All pipelines having unanchored
flexible joints require anchorage at the
changes
of
directions and at dead ends to resist the static thrusts

developed
required
by internal
on
steep
pressure.
slopes
to
Anchorage
resist
pipe
is
also
against
PAGE 228 OF 281
577 of 2461
MMRDA
slippage.
1.18.2.8
After a new pipeline is laid and jointed, testing shall be

done for: Mechanical soundness and leak tightness of
pipes and fittings, Leak tightness of joints, and Soundness
of any construction work, in particular that of the
anchorages.
The completed pipeline may be tested either in one length

or in sections. The length of section depends upon the
availability of suitable water, number of joints to be
inspected and difference in elevation between one part of
the pipeline and another. The maximum field hydrostatic
test pressure for ductile iron pipelines with flexible
joints as per IS 12288: 1987 is tabulated below.
Nominal Bore,mm
Maximum
field
hydrostatic test pressure,

N/mm2
1.18.2.9
Up to 300
4.5
350 to 600
3.0
700 to 1200
2.1
Restoration and cleaning up
Where any road, payment, shrubbery, fences, poles or

other
property
and
surface structures
have
been
damaged, removed or disturbed during the course of

work,
such property and surface structures shall be
replaced or repaired after completion of work.
All roads, pavements, paved footpaths, curbing, gutters,

shrubbery, fences, poles or other property and surface
PAGE 229 OF 281
578 of 2461
MMRDA
structures removed of disturbed, as a part of the work

shall be restored to a condition equal to that before the
work began.
All surplus materials, and all tools and temporary structures

shall be removed from the site as directed by the executing
authority.
1.18.3 General Specifications for CI Piping Work
1.18.3.1
Cast Iron Pipe and Specials
1.
All CI Pipes and specials supplied for this

contract
shall
confirm
to
the
following
specifications:
a.
IS 1536 - 1989 Specification for centrifugal

cast (Spun) iron pressure pipes for water, gas
and sewage.
b.
IS 1538 - 1976 (Part V) Specification for cast

iron fittings for pressure pipes.
Wherever
reference
is
made
for
Indian
Standard
Specification the latest specification is applied.
2.
All cast iron pipes supplied shall conform to class LA

of Indian Standard specifications. The work test
pressure and the hydrostatic test pressure shall be
as follows:
a.
Hydrostatic Test pressure at works 3.5 N/mm2

(35 kg/sq.cm.)
b.
Hydrostatic test pressure after installation 1.2
PAGE 230 OF 281
579 of 2461
MMRDA
N/mm2
(12 kg/sq.cm.) All pipes to be
supplied in this contract shall have SBR

quantity rubber gaskets rubber tyton joints as
per BIS 5282, 12820 with the spigot end
suitably chamfered for smooth entry of pipe in
the socket fitted with SBR quality rubber
gasket.
Care shall be taken to ensure that
fittings fit easily into this pipe.
c.
Each pipe shall be coated in accordance

to Indian Standard specification. All pipe
shall be marked as under:
Manufacturers
name
or
identification
mark
The Nominal Diameter
Class Reference
Mass of pipe
The number of this Indian Standard and
The last two digits of the year of

manufacture.
1.18.3.2
Cast Iron fittings
All cast iron fittings supplied shall confirm to heavy class of

IS:1538, Part 1 to 23.
The work of Test pressure and
Hydrostatic test pressure shall be as follow:
Test Pressure
PAGE 231 OF 281
580 of 2461
MMRDA
300 mm to 600 mm
600 mm to 1200 mm
2.5 N/sq.mm (25 kg/sq.cm)
1.0
N/sq.mm
(10
kg/sq.cm)
Where non standard fittings are required in special

locations, this shall be supplied of steel of minimum
plate thickness of 6 mm and fabricated as per drawings
and directions of Employers representative. These mild
steel
fittings
will
be
specially
protected
against
corrosion with painting.
All Standard fittings marked as under:
a.
Manufacturers name or identification mark,
b.
The Nominal Diameter,
c.
Class Reference,
d.
Mass of pipe,
e.
The Number of this Indian Standard, and
f.
The last two digits of the year of manufacturer.
1.18.4 Specification For Laying, Jointing & Testing of CI Pipe
1.18.4.1
Stacking
The pipes and specials shall be handled with sufficient

care to avoid damage to them. These shall be lined up
on one side of the alignment of the trench, socket facing
uphill or in the direction of flow of water.
PAGE 232 OF 281
581 of 2461
1.18.4.2
MMRDA
Trench For CI Pipes and Specials
The trenches for the pipes shall be excavated to lines and

levels as directed. The bed of the trench shall have to be
truly and evenly dressed throughout from one change of
grade to next. The gradient is to be set out by means of
bonning rods and the required depth is excavated at any
point. The depth of the trench shall not be less than 1
meter measured from the top of the pipe to the surface of
the ground under roads crossing and not less than 0.75m
elsewhere.
The width of the trench shall be the nominal diameter of

the pipe plus 40 cm. but it shall not be less than 60 cm. in
case of all kinds of soils excluding rock and not less than
55 cm. in case of rock. The bed of the trench, if in
soft or made up earth, shall be well watered and
rammed before laying the pipes and the depressions if any
shall be properly filled with earth and consolidated in 20
cm. layers. If the rock is met with, it shall be removed
to 15 cm. below the level of the pipe and the trench
will be refilled with excavated materials and consolidated
to the required grade.
The excavated materials shall not be placed within 1

meter or half of
the depth of the trench whichever is
greater from the edge of the trench.
The materials excavated shall be separated and stacked

so that in refilling they may be re-laid and compacted in the
same
order
to
the
satisfaction
of
the
Employers
representative. The trench shall be kept free of water.

Shoring and Timbering shall be provided wherever
required. Excavation below water table shall be done after
dewatering the trenches.
PAGE 233 OF 281
582 of 2461
After
the
MMRDA
excavation
of
the
trench
is
completed,
hollows shall be cut at the required positions to receive

the sockets of the pipes and these hollows shall be
sufficient depth to ensure that the barrels of the pipes shall
rest throughout their entire length on the solid ground and
that sufficient spaces left for jointing to underside of the
pipe joint.
These socket holes shall be refilled with sand
after jointing the pipe.
All types of pipes water mains, cables, etc. met within the
course of excavation shall be carefully protected
and
supported.
the
Care
shall be
taken
not to
disturb
electrical and communication cables.
1.18.4.3
Laying of Pipes and Specials
Before being laid the pipes shall be examined to see that

there are no cracks or defects. The
cracked
or
defective
rejected.
The
pipes
shall
be
summarily
pipes shall be thoroughly cleaned of all dust and dirt and

special care shall be taken to clean the inside of the socket
and outside of the spigots.
The pipes shall be lowered into the trench by means of

suitable pulley blocks, sheet legs, chains ropes etc. In no
case the pipes shall be rolled and dropped into the trench.
After lowering, the pipes shall be arranged so that the
spigot of one pipe shall be carefully centered into the
socket of the next pipe, and pushed to the full distance that
it can go. The pipeline shall be laid to the levels required.
Specials shall also be laid in their proper position as stated
above. For pipe bedding PCC of grade M10 shall be used.
Where so directed, the pipes and specials may be

PAGE 234 OF 281
583 of 2461
MMRDA
laid on masonry or concrete pillars. The pipe laid on

the level ground shall be laid with socket facing the
direction
of
the flow of water. In all other cases, the
sockets shall be laid facing up hill.
Any deviation either in plan or elevation less than 11

degree shall be effected by laying the straight pipes
round a flat curve, of such radius that minimum
thickness of lead at the face of the socket shall not be
reduced below 6 mm. or the opening between spigot and
socket increased beyond 12 mm at any point.
deviation of about 2 degree can be affected at each

joint in this way. At the end of each days work, the last
pipe laid shall have its open ends securely closed with a
wooden plug to prevent entry of water, soil, rats and any
other foreign matter into the pipe.
Cement concrete thrust blocks of suitable design as

approved by the Employers representative shall be
provided at 45 degree and 90 degree bands of the pipes
and also at places where there is likelihood of thrust so as
to withstand the dynamic and static forces developed due
to water in the pipe line. The thrust blocks shall be made
after the joints have been made.
1.18.4.4
Jointing
Jointing shall be carried out using approved quality rubber

rings.
1.18.4.5
Testing of Joints
After laying and jointing, the pipes and fittings shall

be inspected under working conditions of pressure and
flow.
Any joint found leaking shall be redone and all
PAGE 235 OF 281
584 of 2461
MMRDA
leaking pipes removed and replaced without extra cost. For

hydraulic tests, all pipes shall be kept under test for 15sec
at works and shall withstand hydrostatic test pressure as
specified in BIS 1536/1989. The pipes shall be slowly and
carefully charged with water allowing all air to escape and
avoiding all shock or water hammer.
The draw off takes and stopcocks shall then be closed and
specified hydraulic pressure shall be applied gradually.
Pressure gauge must be accurate and preferably should
have been recalibrate before the test. The test pump
having been stopped the test pressure should maintain
without loss for at least half an hour. The pipes and
fittings shall be tested in sections as the work of
laying
proceeds,
keeping
the
joints
exposed
for
inspection during the testing.
1.18.4.6
Backfilling
The trenches prepared for laying of pipes shall be backfilled

after testing.
1.19
Valves
1.19.1 Butterfly Valve
The specification in subsection for mechanical works be referred.
1.19.2 Sluice Valve
1.19.3 Dual Plate Check Valve

PAGE 236 OF 281
585 of 2461
MMRDA
1.19.4 Knife Gate Valves
The valve should be provided with gate made of stainless steel and the
gate should have beveled knife edge at the bottom to cut through and
easily enter in the solids settled in the bottom and ensure positive
shut-off / closure. The valve should be bonnet-less and suitable for
face
to
face
flange connection in between pipelines. It should be
suitable for uni-directional application.
The valve body should be of Cast Iron GR.FG 260.
The body
shall be designed to withstand 15 bar pressure.
The valve shall be provided with replaceable type flexible seating

seats to offer drop tight shut off. The seals should be made of EPDM
rubber and should be held in place by an easily removable type seal
retainer ring. The seal retainer ring should be designed in a manner so
that the flow of the fluid should be away from the sealing perimeter
and towards the center of the valve
The valve housing should have integral as cast tapered lugs provided for
pushing the gate towards the flexible rubber seal only at the verge of
closure with a view to avoid seal wear and achieve drop tight shut off.
The surface of the gate coming in contact with the seal should be
polished and buffed.
The valve shall be provided with sufficient ply of stuffing seals in the in
built stuffing box to seal the rear opening. The stuffing box should have
internal tappers for pushing the seals on to the gate. The seals should be
of non-asbestos PTFE to reduce the friction and
offer
higher
life.
Provision shall be made to enable tighten the stuffing seals by

means of a pusher arrangement to minimize the leakage through the
back of the valve. Replacement of stuffing seals should be done in
installed condition of the valve.
PAGE 237 OF 281
586 of 2461
MMRDA
The spindle should be double start threaded and non-rising type for
compact and safe operation.
covered by protection shields.
The gate movement area should be

Gate opening indicating arrangement
should be provided to find out the extent of gate opening / closing.
Flange drilling suitable to mount between flanges as per IS 1538-1993
Body Cast Iron FG 260 as per IS 210
Knife gate : AISI:304 Gr: ASTM A240
Retainer ring: SS:304 ASTM A351 Gr. CF:8
Inlet Seal: EPDM
Spindle: AISI:410 Gr. ASTM A276
Spindle Nut: Cast Iron Gr. FG 200 as per IS 210
Stuffing plate: Cast Steel ASTM A216 Gr. WCB
Stuffing seal: Synthetic yarn with PTFE
Factory Test:
Body Test:
The valves shall be hydrostatically pressure tested at
specified pressure without any visible leakage.
Seat test: The valve shall be hydrostatically pressure tested for seat
leakage at 10 bar for no visible leakage.
ZFT-STD-X-CI-F1-M
Body (Housing)
Cast Iron Gr. FG 260 as per IS 210
Flange Drilling
Suitable to mount between DIN PN 10/IS:1538-1993
PAGE 238 OF 281
587 of 2461
MMRDA
flanges
Knife gate
Stainless Steel ASTM A 240 AISI:304
Seal Retainer Ring Cast Stainless Steel ASTM A 351 GR. CF:8
Inlet Seal
EPDM Rubber
Gland Packing
Synthetic Yarn with PTFE
Stuffing Plate
Cast Steel Galvanized
Spindle (Stem)
Stainless Steel ASTM A276 AISI:410
Spindle Nut
Cast Iron
Supporting channels
Mild Steel Painted
Adapter plate
Cast iron / Mild steel painted
Hand Wheel
Cast iron as per IS 210 Grade 260
Fasteners
High Tensile Galvanized
Body test
10 bar (hydro-static)
Seat test
2.8 bar (Hydro-static) generally as per MSS SP-81
Painting Internal
Red Oxide
Painting External
Two coats epoxy paint RAL 5022
1.19.5 Reflux Valves
1.19.5.1
Cast Iron Reflux Valves
60 mm to 350 mm diameter valves shall be swing checkvalves, flanged, and shall have cast iron body and
renewable bronze seat, bronze hinge, stainless steel
hinge shaft. The valve shall conform to IS 5312 and,
where any of the requirements specified are not covered
therein, to U.S. Federal Specification WW-V-51 D, Type IV,
Class A.
Cast Iron shall conform to ASTM A-126-66 and flanges

to ANSI B 16.1. The valves shall be designed for low
head loss, shall be adjustable for non-slamming closure
and shall be seat-tight. An arrow showing direction of flow
shall be prominently cast on body of valve. The water
working pressure shall be 10 kg/cm square except that the
PAGE 239 OF 281
588 of 2461
MMRDA
valve shall have pressure rating same as the piping where

the pipe class is higher.
Valves shall be from approved
manufacturer only.
1.19.5.2
Pump Check Valves larger than 400 mm Diameter
All check valves larger than 400-mm diameter installed on

the pump discharge shall be flanged ductile iron body,
cover disc. The seat shall be of renewable bronze
ASTM B 148. The disc shall be hinged on a stainless steel
shaft. The gate pins shall also be of stainless steel. The
valves shall be designed for a working, pressure of 10kg/cm
square. Valve operation shall be of the oil cushioned type
such that the valve swing to 90 percent closed immediately
upon stoppage of flow and cushioning cylinders shall
control
the
slamming,
final
within
closure,
an
to
prevent
mechanical
adjustable timing of one to three
seconds. The valves shall be from approved manufacturers

only.
1.20
Single Faced Sluice Gates
Please refer standard specification for mechanical works.
1.21
Water Supply and Sanitary Works
1.21.1 Applicable Codes
The
following
standards
and
codes
are
made
part
of
this
All standards, codes of practice referred to
herein shall be the latest editions including all official amendments and
revisions.
IS : 210
Specification for grey iron castings
PAGE 240 OF 281
589 of 2461
MMRDA
IS : 269
Specification for ordinary and low heat Portland cement
IS : 383
: Specification for coarse and fine aggregates from natural

sources for concrete
IS : 432
: Specification for mild steel and medium tensile steel bars and
hard drawn steel wire for concrete reinforcement
IS : 456
Code of Practice for plain and reinforced concrete
IS : 458
Concrete Pipes (with and without reinforcement)
IS : 516
Methods of tests for strength of concrete
IS : 554
Dimensions for pipe threads where pressure tight joints are

required on the threads
IS : 651
Salt glazed stoneware pipes and fittings
IS : 774
: Flushing Cisterns for water closets and urinals (valveless

siphonic type)
IS : 775
: Cast iron brackets and supports for wash basins and sinks
IS : 781
Sand-cast brass
screw-down bib
taps and
stop
taps
for water services
IS : 783
IS : 1068
Code of practice for laying of concrete pipes
Electroplated coatings of nickel and chromium of iron and
steel
IS : 1077
: Specification for common burnt clay building bricks
IS : 1172
Code of practice for basic requirements for water supply,
PAGE 241 OF 281
590 of 2461
MMRDA
drainage and sanitation
IS : 1786
Specification for high strength deformed steel bars and

wires for concrete reinforcement
IS : 1239
Mild steel tubes (Part I) and mild steel tubulars and other
wrought steel pipe fittings (Part II)
IS : 1536
Centrifugually cast (spun) iron pressure pipes for water,
gas and
sewage
IS : 1626
Asbestos cement building pipes, gutters and fittings

(spigot and socket types)
IS : 1703
Copper Alloy float valves (horizontal plunger
type) for
water supply purposes
IS : 1726
Cast iron manhole covers and frames
IS : 1729
Sand cast iron spigot and socket soil, waste and ventilating
pipes, fittings and accessories
IS : 1742
Code of practice for buildings drainage
IS : 2065
Code of practice for water supply in Buildings
IS : 2116
Specification for sand for masonry mortars
IS : 2212
Code of practice for brickwork
IS : 2250
Code of practice for preparation and use of masonry mortars
IS : 2326
Automatic flushing cisterns for urinals
PAGE 242 OF 281
591 of 2461
IS : 2470
MMRDA
Code of practice for design and construction of
IS : 2556
septic tanks (Parts I& II)

Vitreous sanitary appliances (Part I to Part XV)
IS : 2963
IS : 3306
IS : 3025
IS : 3311
Method for sampling and test (Physical and chemical) for

waste water (Parts 1 to 44)
water and
Waste plug and its accessories for sinks and wash
IS : 5455
basins
Specification
for cast iron steps for manholes
IS : 4127
Code of Practice for laying of glazed stoneware pipes
IS : 3495
Methods of tests of burnt clay building bricks
IS : 4111
IS : 5382
IS : 5329
Code of practice for ancillary structures in

manholes
sewerage system
Specification for rubber sealing rings for gas mains,
and sewers
water mains
Code of practice for sanitary pipe work above ground for
IS : 5434
Non-ferrous
alloy bottle traps for marine use
buildings
Specification for copper alloy waste fittings for wash

Sinks
basins and
Specification
for
chemically
resistant
glazed
Fittings
stoneware pipes and
1.21.2 Sanitary Installation
The work shall be carried out complying in all respects with any specific
requirements of the local body in whose jurisdiction the work is
situated, and as approved by the Employers representative.
Any damage caused to the building, or to installations therein, either due to

negligence on the part of the Contractor, or due to actual requirements of
the work, shall be made good and the building or the installation shall be
restored to its original condition by the Contractor.
Licensed plumbers shall carry out all sanitary and plumbing work.
All
sanitary
appliance
including
sanitary
fittings,
fixtures,
toilet
requisites shall be of size, and design as approved by the Employers

representative.
PAGE 243 OF 281
592 of 2461
MMRDA
All white glazed porcelain fixtures, such as wash basin, sink drain
board, water closet pan, urinal, `P trap etc. shall have hard durable white
glazed finish.
They shall be free from cracks and other glazing defects.
No chipped porcelain fixtures shall be used.
Joints between iron and earthenware pipes shall be made perfectly air and
watertight by caulking with neat cement mortar.
1.21.3 Indian Type Water Closet
Water closets shall be white porcelain Orissa type Indian soil pans,
690mm long conforming to IS:2556 of approved make and pattern.
Flushing cistern of standard capacity with accessories such as chain,
handle, stop tap, brass unions, jamb nuts, overflow pipe and bends, etc.
shall be provided.
1.21.4 Urinals
Urinals shall be white glazed flat back type of approved make and of size
430 mm x 260 mm x 350 mm conforming to IS 2556. High level automatic
CI flushing cistern of 10 litre capacity as per IS 2326 with necessary CI
brackets, GI pipes for water connection from cistern to urinals, stop tap,
waste pipe upto CI waste shaft etc. shall be provided.
1.21.5 Wash Basin
Wash basin shall be of white glazed earthenware conforming to IS

2556 of approved make and of size 560mm x 410mm.
The wash
basins shall be provided with water supply GI pipe, chromium plated tap,
stopcock, CP bottle trap, GI waste water pipe and all necessary
accessories and fittings.
1.21.6 Sinks
Sinks shall be of white glazed earthenware conforming to IS 2556 of

PAGE 244 OF 281
593 of 2461
MMRDA
approved make and of size 450mm x 300mm x 150mm.
The sink
shall be provided with CP tap, water supply GI pipe, non-ferrous

waste fitting, waste plug and necessary accessories and fittings.
1.21.7 Cast Iron Soil Waste And Vent Pipes and Fittings
All cast iron pipes and fittings shall be of uniform thickness with
strong and deep sockets, free from flaws, air holes, cracks, sand holes
and other defects and conform to IS:1536. The diameter approved shall be
internal diameter of pipe. The pipe and fittings shall be true to shape,
smooth and cylindrical and shall ring clearly when struck over with a
light hand hammer. All popes and fittings shall be properly cleaned of all
foreign materials before being fixed.
All plug bends of drainage pipes shall be provided with inspection

and cleaning caps, covers, which shall be fixed with nuts and screws.
Pipes shall be fixed to the wall by W.I or MS holder bat clamps unless
projecting ears with fixing holes are provided at socket end of pipe.
The pipes shall be installed, truly vertical or to the lines and slopes as
indicated. The clamps shall be fixed to the walls by embedding their hooks
in cement concrete blocks (1:2:4) 10 cm x 10 cm making necessary
holes in the walls at proper places.
All holes and breakage shall be
made good. The clamps shall be kept 25 mm clear of the finished face of
the walls to facilitate cleaning and painting of pipes.
The annular space between the socket and spigot shall be filled with a
gasket of hemp or spun yarn soaked in neat cement slurry. The joint shall
then be filled with stiff cement mortar 1:2 (1 cement : 2 fine sand) well
pressed with caulking tool and finished smooth on top at an angle of 45
The joint shall be kept wet for not less than 7 days by tying a piece of gunny
bag kept moist. Joints shall be perfectly air tight as well as water tight.
C.I pipes and fittings which are exposed shall be first cleaned and then
painted with a coat of red lead primer. Two coats of zinc paint with white
base and mixed with pigment of required colour to get the approved shade
PAGE 245 OF 281
594 of 2461
MMRDA
shall be given over the base primer coat.
The thickness of fittings and their socket and spigot dimensions shall
conform to the thickness and dimension approved for the corresponding
sizes of straight pipes.
The connection between the main pipe and branch pipes shall be made by
using branches and bends with access for cleaning. Floor traps shall be
provided with 25 mm Dia. Puff pipe where the length of the waste is more
than 1800mm or the floor trap is connected to a waste stack through bends.
All cast iron pipes and fittings including joints shall be tested by a
smoke test to the satisfaction of the Employers representative and left
in working condition after completion. The smoke test shall be carried out
as stated under:
Smoke shall be pumped into the pipe at the lowest and from a smoke
machine, which consists of a bellow and a burner.
The material
usually burnt is greasy cotton waste, which gives out a clear pungent
smoke which is easily detectable by sight as well as by smell if there is a
leak at any point of the pipeline.
Water test and air test shall be conducted as stipulated in IS:5329
1.21.8 Galvanised Mild Steel (GI) Pipes
The pipes shall be galvanised mild steel welded pipes and seamless
screwed and sockets tubes conforming to the requirements of IS.1239, for
medium grade. These shall be of the diameter (nominal bore) approved.
The sockets shall be designated by the respective nominal bores of the
pipes for which they are intended. The pipes and sockets shall be finished
neatly, well galvanised on both inner and outer surfaces, and shall be free
from cracks, surface flaws, laminations and other defects.
All screws,
threads shall be clean and well cut. The ends shall be cut cleanly and
square with the axis of the tube.
PAGE 246 OF 281
595 of 2461
MMRDA
All screwed tubes and sockets shall have pipe threads conforming to the
requirements of IS.554.
Screwed tubes shall have taper threads while
the sockets shall have parallel threads.
The fittings shall be of malleable cast iron or mild steel tubes

complying with all the appropriate requirements as approved for pipes.
The fittings shall be designated by the respective nominal bores of the
pipes for which they are intended.
The fittings shall have screw
threads at the ends conforming to the requirements of IS.554.

Female threads on fittings shall be parallel and male threads (except
on running nipples and collars of unions) shall be tapered.
The pipes and fittings shall be inspected at site before use to ascertain that
they conform to the specification.
The defective pipes shall be rejected.
Where the pipes have to be cut or re-threaded, the ends shall be carefully
filled out so that no obstruction to bore is offered. The ends of the pipes
shall then be threaded conforming to the requirements of IS.554 with pipe
dies and taps carefully in such a manner as will not result in slackness of
joints when the two piece are screwed together. The taps and dies shall be
used only for straightening bent and damaged screw threads and shall not
be used for turning of the threads so as the make them slack, water
tight joint. The screw thread of pipes and fitting shall be protected from
damage until they are fitted.
The pipes shall be cleaned and cleared of all foreign matter before being
laid. In jointing the pipes, the inside of the socket and the screwed end of
the pipes shall be oiled and rubbed over with white lead and few turns of
spun yarn wrapped around the screwed end of the pipe. The end shall then
be screwed in the socket, tee, etc, with the pipe wrench. Care should be
taken that all pipes and fittings are properly jointed so as to make the
joints completely water tight and pies are kept at all times free from dust
and dirt during fixing. Burrs from the joint shall be removed after screwing.
After laying, the open ends of the pipes shall be temporarily plugged to
prevent access of soil or any other foreign matter.
PAGE 247 OF 281
596 of 2461
MMRDA
Any threads exposed after jointing shall be painted or in the case of

underground piping thickly coated with approved anticorrosive paint to
prevent corrosion.
For internal work the galvanised iron pipes and fittings shall run on the
surface of the walls or ceiling (not in chase) unless otherwise specified.
The fixing shall be done by means of standard pattern holder bat clamps.
Keeping the pipe about 1.5 cm clear of the wall. Pipes and fittings shall
be fixed truly vertical/horizontal. When it is found necessary to conceal
the pipes, chasing may be adopted or pipes fixed in the ducts of
recesses etc, provided there is sufficient space to work on the pipes with
the usual tools. The pipes shall not ordinarily be buried in walls or solids
floors.
Where unavoidable, pipes may be buried for short distances
provided adequate protection is given against damage, but the joints

in pipes shall not be buried MS pipe sleeve shall be fixed at a place
where a pipe is passing through a wall of floor for reception of the
pipe and to allow freedom for expansion/contraction and other movements
maintenance. In case the pipe is embedded in walls or floors it should be
painted with anti-corrosive bitumastic paint of approved quality. The pipe
should not come in contract with lime mortar or lime concrete as the pipe is
affected by lime. Under the floors the pipes shall be laid in layer of sand
filling or as approved by the Employers representative.
GI pipes with socket and spigot ends shall be provided with lead caulked
joints wherever specified and the joints shall conform to the requirements of
IS:3114.
The work of excavation and backfilling shall be done true to line and
gradient
in accordance
with
general
Employers
requirements
for
earthworks in trenches for pipes laid underground.
The pipes shall be laid on a layer of 10.0 cm sand and sand filled upto 15
cm above the pipes.
shall also be provided.
A sand cushion of 15 cm on either side of the pipe

The remaining portion of the trench shall then
PAGE 248 OF 281
597 of 2461
MMRDA
be filled with excavated earth. The surplus earth shall be got rid of as
directed. When excavation is done in rock the bottom shall be cut deep
enough to permit the pipes to be laid on a cushion of sand 75 mm
minimum.
The pipes and fittings after they are laid and jointed shall be
subjected
to hydrostatic pressure test as approved by the Employers
representative and shall satisfactorily pass the test. Pipeline system shall
be tested in sections as the work proceeds, keeping the joints
exposed for inspection. Pipes shall be slowly and carefully charged with
water allowing all air to escape. All draw-off taps shall then be closed
and water pressure gradually raised to test pressure. Care shall be taken
to ensure that pressure gauge is accurate and preferably should have been
recalibrated before the test. Pump used having been stopped the section of
the pipeline shall maintain the test pressure for at least half an hour.
Any
joints or pipes found leaking should be removed and replaced by the

Contractor.
The GI pipeline shall be cut to the required length at the position where the
meter and stopcock are required to be fixed.
be threaded.
The ends of the pipes shall
The meter and stopcock shall be fixed in position by means
of connecting pipe, G.I nuts, sockets, etc.

near the inlet of the water meter.
The stopcock shall be fixed
The paper disc inserted in the
ripples of the meter shall be removed and meter installed exactly

horizontally or vertically and with the arrow cast on the body of the meter
pointing in the direction of flow. Care shall be taken that the factory seal of
the meter is not disturbed. Whenever the meter is to be fixed to a newly
fitted pipeline, the pipeline will have to be completely washed before fixing
the meter. For the purpose, a connecting piece of pipe equal to the length
of the meter is to be fixed on the new pipeline. The water shall be allowed
to flow completely to wash the pipeline and then the meter installed as
described above by replacing the connecting piece.
1.21.9 Not Used
PAGE 249 OF 281
598 of 2461
1.21.10
MMRDA
Stoneware Pipe and Fittings
All pipes with spigot and socket ends shall conform to

IS.651/3006 and shall be of grade À. These shall be sound,
free from visible defects such as fine cracks or hair cracks.
The glaze of the pipes shall be free from crazing. The pipes
shall give a sharp clear note when struck with a light hammer.
The following information shall be clearly marked on each

pipe and fitting:
a.
Internal diameter
b.
Grade
c.
Date of manufacture;
d.
Name of manufacture or his registered trade-mark or

both
All pipes and fittings shall have ISI mark jointing of

GSW pipes
and
fittings
shall
be done as per the
requirements of the following Employers Requirements and

the relevant IS.
After jointing, extraneous material if any,
shall be removed from the inside of the pipes and fittings and
the newly made joints shall be thoroughly cured. In cased,
rubber sealing rings are used for jointing, these shall conform
to IS:5382.
1.21.10.1
Spigot and Socket Joint (Cement Joint)
The Spigot of each pipe shall be slipped home well into the
socket of the pipe previously laid and adjusted in the correct
position.
In each joint, spun yarn soaked in neat cement
slurry or tarred gasket shall be passed around the joint

PAGE 250 OF 281
599 of 2461
MMRDA
and inserted in it by means of caulking tool. More skeins

of yarn or gasket shall be added if necessary and shall be
well caulked.
Yarn or gasket so rammed shall not occupy
more than one fourth of the depth or socket.
Cement mortar (1:1) shall be slightly moistened and carefully

inserted by hand into the remaining space of the joint after
caulking of yarn or gasket. The mortar shall then be caulked
into the joint with a caulking tool. More cement mortar shall
be added until the space of joint has been completely filled
with tightly caulked mortar. The joint shall then be finished
off neatly outside the socket at an angle of 45 degrees.
The cement mortar joints shall be cured at least for seven

days before testing.
The approximate quantities of cement required for each joint

for certain common sizes of pipes are given below for
guidance:
Nominal diameter of pipe (mm)
1.21.10.2
Cement (kg)
150
1.5
200
2.0
250
2.5
300
3.25
350
4.5
400
5.5
450
6.5
Spigot and Socket Joint (Rubber Ring Joint)
The pipe with the rubber ring accurately positioned on the

spigot shall be pushed
well home into the socket of the
previously laid pipe by means of uniformly applied pressure

with the aid of a jack or similar appliance. The rubber rings
PAGE 251 OF 281
600 of 2461
MMRDA
conforming to IS: 5382 shall be
used
and
the
manufacturers instructions shall be deemed to form a

part of this Employers Requirements.
The rubber rings
shall be lubricated before making the joint and the lubricant

shall
be
soft
soap
water
or
an
approved
lubricant
supplied by the manufacturer.
1.21.10.3
Cleaning of Pipes
As soon as a stretch of GSW pipes has been laid complete

from manhole to manhole or for a length as approved by the
Employers representative, the Contractor shall run through
the pipes both backward and forward a double disc or solid or
closed cylinder 50 mm less in diameter than the internal
diameter of pipes. The open end of an incomplete stretch of
pipeline shall be securely closed as approved by the
Employers representative to prevent entry of mud or silt etc.
If as a result of the removal of any obstruction the

Employers representative considers that damage may have
been caused to the pipelines, he shall be entitled to order the
length to be tested immediately.
prove
unsatisfactory
the
Should such a test
Contractor
shall repair
the
pipeline and carry out such further tests as are required

It shall also be ascertained by the Contractor that each length

from manhole to manhole or the length as approved by the
Employers representative is absolutely clear and without any
obstruction by means of visual examination of the interior
of the pipeline suitably illuminated by projected sunlight or
otherwise.
1.21.10.4
Testing at Work Site
PAGE 252 OF 281
601 of 2461
MMRDA
After laying and jointing of GSW pipes is completed the

pipeline shall be tested as per the following Employers
Requirements
and
as
approved
by
the
Employers
representative. All equipment for testing at work site shall

be supplied and erected by the Contractor. Potable water
for testing of pipeline shall be arranged by him.
Damage
during testing shall be the Contractors responsibility and

shall be rectified by him to
the full satisfaction of the
Water used for test shall be
removed from pipes and not released to the excavated

trenches.
After the joints have thoroughly set and have been checked
by the Employers representative and before backfilling the
trenches, the entire section of the sewer or storm water drain
shall be proved by the Contractor to be water tight.
Before
commencing the hydraulic test, the pipelines shall be filled

with water and maintained full for 24 hours by adding water. If
necessary, under a head of 0.6 m of water.
The test
shall be carried out by suitably plugging the low end of the

drain and the ends of connections, if any, and filling the
system with water.
A knuckle bend shall be temporarily
jointed at the top end and a sufficient length of vertical pipe

jointed to it so as to provide the required test head, or the top
end may be plugged with a connection to a hose ending in a
funnel which could be raised or lowered till the required head
is obtained and fixed suitably for observation. The pipeline
shall be subjected to a test pressure of at least 2.5 m head of
water at the highest point of the section under test. The
leakage tolerance of two litres per centimeter of diameter per
kilometer may be allowed during a period of 10 minutes. Any
leakage including excessive sweating which causes a drop in
the test water level will be visible and the defective part of the
work should be removed and made good.
PAGE 253 OF 281
602 of 2461
MMRDA
If any damage is caused to the pipeline during the

execution of work or while cleaning/testing the pipeline as
specified, the Contractor shall be held responsible for the
same and shall replace the damaged pipeline and re-test the
same to the full satisfaction of the Employers representative.
Water for testing of pipeline shall be arranged by the

Contractor.
1.21.11 Stop Cock And Bib Cock
Stopcocks and Bibcocks shall be of brass heavy class, chromium plated

and of approved manufacture and pattern complying with IS: 781. They
shall be of specified size and of the screw down type.
The cocks shall
open in anti-clockwise direction and chromium plating shall be done in

accordance with IS: 1068.
1.21.12 Not Used
1.21.13 Manholes / Inspection Chambers
1.21.13.1
Location
Manholes / Inspection chambers shall be constructed at

places approved by the Employers representative.
1.21.13.2
Excavation
Excavation,
manholes
shoring,
/
dewatering
Inspection
etc.
for
the
pits
of
chambers, laying of pipes and
fittings/specials shall be done in accordance with Employers

representative requirements described elsewhere in the
document.
1.21.13.3
Bed Concrete
PAGE 254 OF 281
603 of 2461
MMRDA
The bed concrete (min grade M15) for manholes/Inspection

Chambers shall be done in accordance
representative
requirements
with
described
Employers
elsewhere
in
the document.
1.21.13.4
Bricks
Bricks used for construction of manholes / Inspection

chambers shall conform to the relevant Indian Standards.
They shall be sound, hard, homogeneous in texture, well
burnt in kiln without being vitrified, table moulded, deep red,
cherry or copper coloured, of regular shape and size and shall
have sharp and square and parallel faces. The bricks shall be
free from pores, chips, flaws or humps of any kind. Bricks
containing unground particles and/or which absorb water
more than 1/6th of their weight when soaked in water for
twenty-four hours shall be rejected. Overburnt or underburnt
bricks shall be liable to rejection.
clear
ringing
sound
minimum
crushing
otherwise
noted
when
strength
in
The bricks shall give a
struck
of
drawings.
and
50
shall
kg/sq.cm,
have
unless
The class and quality
requirements of bricks shall be as laid down in IS: 1077.
The size of the brick shall be 23.0 x 11.5 x 7.5 cm

unless otherwise specified; but tolerance upto + 3 mm in
each direction shall be permitted. Only full size brick shall be
used for masonry work. Brickbats shall be used only with the
permission of Employers representative to
make
up
required wall length or for bonding. Sample bricks shall

be submitted to the Employers representative for approval
and bricks supplied shall conform to approved samples.
If
required by the Employers representative, brick samples shall

be tested as per IS:3495 by Contractor.Bricks rejected by
the Employers representative shall be removed from the
PAGE 255 OF 281
604 of 2461
MMRDA
site within 24 hours.
1.21.13.5
Cement Mortar
Mortar for brick masonry shall be prepared as per

IS:2250,
Manholes
Inspection chambers
shall
be
constructed in brick masonry with cement mortar (1:3)

unless otherwise specified.
Gauge boxes for sand shall
be of such dimensions that one bag containing 50 kg of

cement forms one unit.
The sand shall be free from
clay, shale, loam, alkali and organic matter and shall be of

sound, hard, clean and durable particles. Sand shall be as
the
If required by
Employers representative and shall be thoroughly
washed till it is free of any contamination.
For preparing cement mortar, the ingredients shall first

be mixed thoroughly in dry condition. Water shall then be
added and mixing continued to give a uniform mix of
required consistency. Cement mortar shall be used within 25
minutes of mixing. Mortar left unused in the specified period
shall be rejected.
The Contractor shall arrange for tests on mortar samples if so

required by Employers representative.
Retempering of
mortar shall not be permitted.
1.21.13.6
Brick Masonry
All bricks shall be thoroughly soaked in clean water for at

least one hour immediately before being laid.
Brick work
230 mm thick and over shall be laid in English Bond

unless otherwise specified. 115 mm thick brick work shall be
laid with stretchers.
For laying bricks, a layer of mortar shall
be spread over the full width of suitable length of the lower

PAGE 256 OF 281
605 of 2461
course.
MMRDA
Each brick shall be pressed into the mortar and
shoved into final position so as to embed the brick fully

in mortar.
Bricks shall be laid with frogs
uppermost.
All brickwork shall be plumb and square unless otherwise

shown on drawing and true to dimensions shown.
Vertical
joints in alternate courses shall come directly one over the

other and be in line.
Horizontal courses shall be leveled.
The thickness of brick course shall be kept uniform. For walls

of thickness greater than 230 mm both faces shall be kept in
vertical planes unless otherwise specified. All interconnected
brickwork shall be carried out at nearly one level (so that
there is uniform distribution of pressure on the supporting
structure) and no portion of the work shall be left more than
one course lower than the adjacent work.
Where this is
not possible, the work shall be raked back according to

bond (and not saw-toothed) at an angle not exceeding 45
degrees.
But in no case
the
level
adjoining walls shall exceed 1.25 m.
difference
between
Workmanship shall
conform to IS:2212.
Brick shall be so laid that all joints are well filled with mortar.
The thickness of joints shall not be less than 6 mm and not
more than 10 mm.
The face joints shall be raked to a
minimum depth of 12 mm by raking tools daily during the

progress of work when the mortar is still green, so as to
provide a proper key for the plastering to be done.
When
plastering is not required to be done, the joints shall be

uniform in thickness and be struck flush and finished at the
time of laying. The face of brickwork shall be cleaned of all
dirt before another course is laid on top. If mortar in the lower
course has begun to set, the joints shall be raked out to a
depth of 12 mm before another course is laid.
PAGE 257 OF 281
606 of 2461
1.21.13.7
MMRDA
Cement Plaster
All joints in masonry shall be raked to a depth of 12 mm with

hooked took made for the purpose when the mortar is still
green and in any case within 48 hours of its laying.
The
surface to be rendered shall be washed with fresh clean

water free from all dirt, loose material, grease etc. and
thoroughly wetter for 6 hours before plastering work is
commenced.
Concrete surfaces to be rendered will
however be kept dry.
The wall should not be too wet but
only damp at the time of plastering. The damping shall be

uniform to get uniform bond between the plaster and the wall.
Cement shall be mixed thoroughly in dry condition and then

just enough water added to obtain a workable consistency.
The quality of water, sand and cement shall be as per
relevant IS.
The mortar thus mixed shall be used
immediately and in no case shall the mortar be allowed to

remain for more than 25 minutes after mixing with water.
Curing of plaster shall be started as soon as the applied

plaster has hardened enough so as not to be damaged.
Curing shall be done by continuously applying water in a
fine spray and shall be carried out for at least 7 days.
Plastering shall be done on both faces of brick masonry in

cement mortar (1:2) and 20 mm thick unless otherwise
specified.
Plastering work shall be carried out in two layers, the first

layer being 14 mm thick and the second layer being 6 mm
thick.
The first layer shall be dashed against the prepared
surface with a trowel to obtain an even surface. The second

layer shall then be applied and finished leaving an even
and uniform surface, trowel finished unless otherwise
PAGE 258 OF 281
607 of 2461
MMRDA
1.21.13.8
Cement Concrete Channel
The channel for the manhole shall be constructed in

cement concrete of M15 grade. Both sides of the channel
shall be taken up to the level of the crown of the
outgoing sewer. They shall be benched up in concrete and
rendered in cement mortar (1:1) of 20 mm thickness and
formed to a slope of 1 in 12 towards the channel.
1.21.13.9
Pipe Entering or Leaving Manhole / Inspection Chamber
Whenever a pipe enters or leaves a manhole / inspection

chamber, bricks on edge must be cut to a proper form and laid
around the upper end of the pipe so as to form an arch. All
around the pipes, there shall be a joint of cement mortar (1:2)
13 mm thick between it and the bricks.
1.21.13.10
Cast Iron Steps
Cast iron steps shall be as per IS:5455. The steps shall be of

grey cast iron of grade 15 as per IS:210. The steps shall be
clean, well cast and they shall be free from air and sand
holes, cold shuts and wrappings.
The portion of the step
which projects from the wall of the manhole / inspection

chamber
shall
have
raised
chequered
design
to
provide an adequate non-slip grip CI steps shall weigh not

less than 4.5 kg each and shall be of 150 mm x 375 mm
overall dimensions. These steps shall be coated with a black
bituminous composition.
The coating shall be smooth and
tenacious. It shall not flow when exposed to a temperature of

63 degrees C and shall not be brittle as a chip of at
temperature of 0 degree C.
PAGE 259 OF 281
608 of 2461
MMRDA
Where the depth of invert of manhole exceeds 800 mm,

cast iron steps of approved pattern shall be fixed in the
brick work at the interval of 300 mm vertically and staggered
at 380 mm horizontally centre to centre.
In case of pipe
diameter greater than 600 mm, box type CI steps weighing 19

kg each shall be provided at 300 mm vertically in channel of
manhole / inspection chamber.
1.21.13.11
Frame and Covers
Frame and covers for manholes shall be of required type

and dimensions as per the relevant drawings prepared by
the Contractor.
Following information shall be clearly
marked on each cover.
Year of manufacture,
Identification mark of the purchaser
SEWERS/SWD
Arrow showing direction of flow
Approved Makes
KK Manholes and Gratings

S.S. Manholes
Bharat Pipes and Covers
a)
Cast Iron Frame and Cover
The cast iron frame and cover shall be of gray cast

iron as per IS: 1726.
The general requirements for
casting and coating of CI frame and cover shall be as

specified for CI steps in Clause 15.15.10. The covers
shall have a raised chequered design to provide an
adequate non-slip grip. The rise of the chequer shall
PAGE 260 OF 281
609 of 2461
MMRDA
be not less than 4 mm.
The locking device for the
cover shall be provided as approved by the Employers

representative. The CI covers for the load test shall be
selected at one for every lot of fifty or part thereof for
each type and size manufactured and as approved by
The frame shall be
fixed in cement concrete of M15 grade all round and

finished with neat cement. The manhole frame shall
have 560 mm diameter clear opening and shall weigh
not less than 208 kg. Including cover.
In case of
rectangular CI frame and cover of 900 mm x 600 mm

clear opening, the total weight shall not be less than
275 kg. In case of scraper manhole the frame shall
have clear opening of 1200 mm x 900 mm and shall
weigh not less than 900 kg including cover.
The
manhole / inspection cover and frame shall be

painted with three coats of anti-corrosive paint after
fixing in position.
b)
Fibre Reinforced Concrete Frame and Cover
Fibre reinforced concrete frame and cover shall be

capable of withstanding load of 35 tonnes.
The
frame shall be fixed in cement concrete of M15

grade all around and finished with neat cement. The
fibre-reinforced frame shall have clear opening of 560
mm diameter and weighing 103 kg.
The cover shall
have a minimum thickness of 100 mm and weighing 78

kg. The fibres shall constitute 1% of the weight of the
concrete in the form of 50 mm to 100 mm long high
tensile steel wires.
For the cover, MS sheet lapping
of 18 gauge shall be provided to avoid damage to the

edges. Similarly for frame, MS angle/flat shall be
provided along the edge.
Both MS sheet and
angle shall be painted with black bituminous paint.

PAGE 261 OF 281
610 of 2461
MMRDA
The cover should have suitable lifting arrangement.

The fibre reinforced frame and cover shall be
manufactured as approved.
c)
Reinforced Cement Concrete Frame and Cover
Reinforced
for
cement
manholes
shall
concrete
be
frame
of
and
cover
required dimensions
and shape as shown on the drawing prepared by the

Contractor
and
approved
by
the
Employers
representative. The frame and cover shall be cast in

cement concrete of M20 grades.
Minimum cover to
the reinforcement shall be 40 mm.
The edges of
frame and covers shall be provided with mild steel

angles to avoid damages to the corners.
angles
shall
be
painted
paint.
The
covers
with
should
black
have
These
bituminous
suitable lifting
arrangement.
1.21.13.12
Drop Manhole
When a sewer connects a main sewer, and where the

difference in level between water line (peak flow levels) or
main line and the invert level of branch lines is more than 600
mm or a drop of more than 600 mm is required to be given in
the same sewer line and it is uneconomical or impractical to
arrange the connection within 600 mm, a drop connection
shall be
provided
for which
manhole
shall
be
constructed as per relevant drawing, incorporating a vertical

drop pipe from the higher sewer to the lower one. This pipe
shall be provided outside the shaft and encased in concrete.
A continuation of the branch sewer should be built through the
shaft wall to form a rodding and inspection eye, which should
be provided with a half blank flange.
The diameter of
the black drop should be at least as large as that of the

PAGE 262 OF 281
611 of 2461
MMRDA
incoming pipe.
The drop pipe should terminate at its lower
end with a plain or duck-foot bend turned so as to discharge

its flow at 45 degrees or less to the direction of the flow in the
main sewer.
The pipe unless of cast iron should be
surrounded with 150 mm thick concrete.
In the case of sewers over 450 mm in diameter the drop in

level may be accomplished by one of the following approved
methods.
1.21.13.13
a.
A cascade,
b.
A ramp,
c.
By drops in previous manholes.
RCC Manhole
M20 grade of concrete used for construction of RCC

manhole shall have min cement content of 390kg/cum of
concrete. Min cover to the reinforcement shall be 50mm.
1.21.14 Vent Shafts
1.21.14.1
General
Vent shafts shall be erected at such places as approved by

1.21.14.2
GI Pipe Vent Shaft

GI pipe vent shall be of 100 mm diameter of C class as per
IS: 1239 and 6 metre height from ground level with slotted
cap.
The vent shaft shall be embedded in concrete of
M10 grade and anchored with a 6mm thick MS base plate of

200 mm x 200 mm. The vent shaft shall be painted with one
coat of silver paint over one coat of red lead oxide paint.The
PAGE 263 OF 281
612 of 2461
MMRDA
vent shaft shall be connected to manhole by 150 mm

diameter glazed stoneware pipe encased by M10 concrete of
150 mm thickness all around as approved by the Employers
representative.
1.21.14.3
RCC Vent Shaft
Reinforced cement concrete vent shaft shall be of M20 grade

concrete, 200 mm diameter at bottom and tapered to 100 mm
diameter at top (both inside clear openings) and 6 m height
from ground level.
The vent shaft shall be embedded in
concrete of M10 grade and anchored by 2 nos. of 16 mm

diameter and 600 mm long MS bars. The vent shaft shall be
connected to manhole as specified in (b) above through
a brick masonry flue chamber.
1.21.15 Septic Tank
R.C.C. Hume pipe septic tanks shall be made of high quality and rich
cement concrete of M35 grade to assure a maintenance-free and troublefree functioning. The tanks shall be made to withstand all normal loads and
vibrations.
The tanks shall be moulded by using centrifugal force in a
specially designed machine to ensure homogenous packing of concrete

without honeycombing, without any holes or air gaps and a compact and
smooth leak proof surface. The septic tank of length about 2.5 m and
suitably designed diameter, shall be provided with two manholes, 100 mm
dia vent pipe with a cowl, lifting and lowering hooks. A drain valve and
disposal pipe, 20 m long, 100 mm dia and made of SGSW shall be provided
to drain out the supernatant from the tank.
The tank shall be cleaned once in three months and the silt shall be
removed and disposed.
1.21.16 Miscellaneous
PAGE 264 OF 281
613 of 2461
MMRDA
If any damage is caused to the other services such as water supply

pipeline, sewer, cable, etc. during the construction of manholes and
erection of vent shafts, the Contractor shall be held responsible for the
same and shall replace the damaged services to the full satisfaction of
the Employers representative. The interior of manholes shall be cleared
of all debris
after
construction
and
before
testing
the
same
for
water tightness by the Contractor.
1.22
Road Side Drains
1.22.1 Applicable Codes and Specifications
The following specifications, standards and codes are referred to in this

part.
All earthwork shall be according to Employers representative specified
under Section n Earthwork.
1.22.2 Slab Culvert
Slab culverts shall be

existing
cross
constructed at specified locations of the
drainage works
as
directed
by
the
Employers
representative. The Concrete works specifications for construction of RC

slab and the rubble masonry specifications for the supporting rubble walls
shall be followed as per Employers Requirements.
1.22.2.1
Bitumen at Location of Contact
The bitumen to be used on the top of the bed concrete at the

location of contact of RCC slab above in two coats shall be
straight run bitumen of specified grade.
1.22.2.2
Graded Gravel Free Draining Backfill
On each side of the uncoarsed rubble walls supporting

PAGE 265 OF 281
614 of 2461
MMRDA
the slab culvert a free draining backfill of thickness 200 mm

shall be provided.
The material for this backfill shall be
granular consisting of sound, tough, durable particles of

crushed or uncrushed gravel, crushed stone or brickbats
which will not become powdery under loads and in contact
with water.
The material shall be free from soft, thin,
enlongated or laminated pieces and vegetable or other

deleterious substances.
It shall be graded and shall
meet the grading requirements given in hereunder.
Sieve Designation
1.22.2.3
Percent Passing by Weight
10 mm
100
4.75 mm
30-65
425 microns
5-30
150 microns
0-10
Weep Holes
Weep holes as shown on the drawings or as directed by the

Employers representative shall be provided in the masonry
to drain water from the backfilling. Weep holes shall be
of asbestos cement pipes conforming to IS: 6908 in
rubber walls with necessary M10 concrete cushioning 75
mm thick.
They shall extend through the full width of
the masonry at a spacing of 1.5 m c/c and with slope of

about 1 vertical to 20 horizontal towards the drainage face.
1.22.3 Pipe Drains
Wherever required, pipe drains shall be provided for cross drainage

purposes.The sequence of construction shall be as follows:
i)
laying of sand/shingle bedding on the original ground
ii)
laying of PCC of M10 grade
PAGE 266 OF 281
615 of 2461
MMRDA
iii)
laying of concrete pipes of NP3 class as per IS:458
iv)
Constructing embankment above in compacted murum, laying of

the sub-base and Water bound Macadam as specified hereinabove.
The details of above works as directed by Employers representative shall

be followed.
1.22.3.1
Materials for Pipe Drains
All materials used in the construction of pipe drains shall

conform Employers representative. RCC pipes class NP3
shall conform to IS: 458.
Each consignment of cement concrete pipes shall be

inspected, tested if necessary, and approved by Employers
representative at the place of manufacture or at site
before their incorporation in the Works.
1.22.3.2
Excavation for pipes
The foundation bed for pipe drain shall be executed true to the
lines and grades shown on the drawings or as directed by
the Employers representative. The pipes shall be placed
in shallow excavation of the natural ground in open
trenches
cut
in
the
existing embankment, taken down
to levels as shown in the drawings. Where trenching is

involved, its width on either side of pipe shall not be less than
150 mm nor more than one-third the diameter of pipe. The
sides
of
the
trench
shall be
as
nearly
vertical
as
possible.
When during excavation, the material encountered is soft,

spongy
or
other
unstable
soil,
unless
other
special
PAGE 267 OF 281
616 of 2461
MMRDA
construction methods are called for such unsuitable material

shall be removed upto a depth of 600 mm or as
Before placing
any backfill material, exposed surface of the soft soil shall

be lightly compacted with one pass of 0.5 T roller.
On the
lightly compacted surface, coarse sand and shingle shall be

spread in two successive layers of 300 mm and each layer
shall be compacted by rolling with a min 0.5 T roller and with a
minimum of 10 passes each, both in longitudinal and
transverse directions.
When bed rock or boulder strata are encountered, excavation

shall be taken down at least 200 mm below bottom level of
pipe as directed by Employers representative and space filled
with approved sand and shingle and thoroughly compacted to
provide adequate support for the pipes. Trenches shall be
kept free from water until the pipes are installed and the joints
have been hardened.
1.22.3.3
Bedding for pipe
The bedding surface shall provide a firm foundation of uniform

density throughout the length of the pipe drain and shall
conform to the specified level and grade. The pipe shall be
bedded in a cradle of concrete having a mix not leaner than
M-10. The pipe shall be laid on the concrete bedding before
the concrete has set.
1.22.3.4
Laying of pipes
No pipes shall be placed in position until the foundations

have been approved by Employers representative.
When
pipes are to be laid adjacent to each other, they shall

be separated by a distance at least equal to or greater than
half the diameter of pipe subject to a minimum of 450 mm.
PAGE 268 OF 281
617 of 2461
MMRDA
BLANK PAGE
PAGE 269 OF 281
618 of 2461
MMRDA
The laying of pipes on the prepared concrete foundation shall

start from the outlet and proceed towards the inlet and be
completed to the specified lines and grades. The pipes shall
be fitted and matched so that when laid they form a drain with
a smooth uniform invert. Any pipe found defective or
damaged during laying shall be removed at the cost of the
Contractor.
1.22.3.5
Jointing
All the joints shall be made with care so that their interior face
is smooth and consistent with the interior surface of the pipes.
The ends of the pipes should be so shaped as to form a selfcentering joint with jointing space 13 mm wide.
The jointing
space shall be filled with cement mortar (1 cement to 2

sand) mixed sufficiently dry to remain in position when
forced with a trowel or rammer. Care shall be taken to fill all
voids and excess mortar shall be removed. After finishing
the joints shall be kept covered and damp for at least four
days.
1.22.3.6
Back filling
Trenches shall be backfilled with selected materials as

per
Employers
Requirements given
in
this
part.
Backfilling upto 0.3 metre above the top of pipe shall be

carefully done and murum shall be thoroughly consolidated
under the haunches of the pipe.
1.22.3.7
Concrete Encasement
Concrete encasement shall be provided at places wherever

directed by the Employers representative. Concrete shall be
of M 20 grade.
PAGE 269 OF 281
619 of 2461
1.23
MMRDA
Bored Cast in Situ Piles for Foundations
1.23.1 Scope of Work
The scope of work comprises finishing of all materials, plant, labour,

equipment, services for complete and proper installation of cast in situ
concrete bored piles, both vertical and battered, for foundations and pile
caps and beams as shown in the drawings or specified including all
surveying and setting out necessary for forming correct location of piles,
furnishing everything necessary for forming working piles, test piles and
anchor piles (if necessary) excavation for pile upto cut off to true elevation
breaking of all piles upto cut off level specified load tests of single piles
and/or group of piles and cleaning up of the work area. For checking the
quality of the pile shaft, Contractor shall provide everything necessary for
examining the piles as instructed.
The information given in the bore logs and soil investigation report, is given
in good faith and the Employer will not be responsible for any discrepancy
or inaccuracies therein and shall not entertain any claim whatsoever for the
Contractor on this account. Nothing contained in this Contract document or
these specifications shall relieve the Contractor from obtaining the approval
from the Employers representative for the pile installation and testing
procedure to be followed by him. During the execution of works, should any
error or ambiguity appear in any of the Contract documents, the Contractor
shall not proceed with the work before obtaining the instructions /
clarifications from the Employers representative.
1.23.2 Related Specifications and Codes
Following related specifications and Codes shall be referred in conjunction

with this specification.
i)
IS 2911 (Part 1, Section 2)
ii)
IS 2911 (Part 4)
PAGE 270 OF 281
620 of 2461
MMRDA
iii)
Other relevant IS Codes
iv)
Technical Specifications for General Civil Works of buildings are

enclosed along with this document.
v)
Reference to any code shall always mean reference to the latest

revised edition of the code including all amendment and addendum
upto date.
In the event of any variation or conflict between the requirement of this

specification and those of the above referred related specifications and
codes, the former shall govern.
The cast in situ bored piles shall be formed by boring to specified depths as
shown or called for in the drawings or as directed by the Employers
representative at site and filling the same with reinforced concrete as
specified therein. The full depth of bore hole will be lined with permanent
mild steel liners of 6 mm thickness.
1.23.3 Diameter of the Piles
In general the measurement of the diameter of the pile shall be as

follows:
For cast in situ bored piles employing temporary casing withdrawn

during the placing of the concrete, the nominal diameter shall be the
outside diameter of the temporary casing
For cast in situ bored piles with permanent liners, the nominal
diameter shall be inside diameter of the permanent left in place.
For partly lined bored cast in situ piles using drilling and the nominal
diameter shall be the inside diameter of the guide liners, (temporary
or permanent). The Contractor may however be required to
PAGE 271 OF 281
621 of 2461
MMRDA
demonstrate to the Employers representative, if so called for by him,

that the diameter of the bore hole for its full length is not less than the
nominal diameter specified and this may be done by lowering a guide
ring having a diameter equal to the nominal diameter of the pile into
the bore hole before concreting the pile or lowering the reinforcement
cage
The temporary casing / boring shall be filled with concrete, after

placing the reinforcement cage concrete compacted (in the case of
pressure piles) and the casing extracted (in the case of unlined piles).
1.23.4 Materials
Concrete (Piling Work):
a.
Unless otherwise stated herein all aspects of the concrete work

including
materials,
specifications,
preliminary
mix
designs,
workmanship and inspection testing stipulated in specifications of

plain and reinforced concrete shall apply.
b.
Cement:
Cement shall be used any of the following and type selected shall be
appropriate for internal use.
1)
Portland slag cement (PSC): Chemical requirements as per IS

455-1989 and physical requirement as per IS 8112-1989 as
directed by Employers representative.
2)
GGBS: GGBS conforming to IS 12089 will be permitted to mix

in appropriate proportion in OPC 43, provided the concrete is
produced in batching plant as directed by Employers
representative.
3)
43 Grade ordinary Portland Cement conforming to IS 8112-
PAGE 272 OF 281
622 of 2461
MMRDA
1989 is generally acceptable.
4)
Portland Pozzolano Cement (PPC): PPC Cement shall be

permitted conforming to IS 1489 & applicability as per relevant
IS codes / as directed by Employers representative.
c.
Maximum size of aggregates shall be 20mm.
d.
Unless otherwise called for on the drawings or in the bills of

quantities, the concrete shall be of Grade M35 by trimie. Concrete for
pile in aggressive environment like alkali soiles / alkaline water shall
have minimum cement content as 420 Kg / cu. m.
e.
Concrete, for piles cast in situ shall have sufficient slump (125 to 175
mm) to give it a self compacting consistency. The water cement ratio
including the water contained in the aggregates shall be limited to
0.45 unless otherwise stipulated. Plasticizing agents may be used by
the Contractor to improve the workability but the Employers
representative shall be furnished with proof that the proposed
plasticizing agent has no adverse effects on the hardened concrete
or reinforcement.
f.
At least one load test shall be made for every 100 piles cast and not
less than six cubes shall be cast on each day concreting of piles.
Three of the six cubes constituting one test shall be tested on the 7th
day from casting the cubes and the remaining cubes shall be tested
on the 28th day after casting. Records of all cube tests shall be
communicated to the Employers representative.
g.
The Employers representative reserves the right to reject any pile of

deficient concrete strength. Such rejected piles shall be replaced by
the Contractor at his own cost who shall also bear the additional
costs of widening pile caps resulting from the grouping of the piles as
a result of replacement of piles.
PAGE 273 OF 281
623 of 2461
h.
MMRDA
Employers representative also reserves the right to order change in

the mix design and/or water cement ratio to obtain the specified
strength or workability.
i.
All reinforcement for use in the piles shafts shall be as per drawings
and be assembled and tied and/or welded together and made up into
cages sufficiently rigid to withstand handling without damage and
distortion.
j.
Joints in longitudinal reinforcement bars, if unavoidable shall be

made by lapping and the laps shall be tack-welded to prevent
distortions of the reinforcement cage.
k.
The projecting length of longitudinal bars beyond the pile cut off level
shall be equal to 40 times the diameter or such other length as
shown on the drawings.
l.
As specified in the drawings, the lateral reinforcement shall consist of

helix made as shown on the drawings.
m.
The minimum of longitudinal bars shall be six (6).
n.
Concrete cover over all reinforcement including lateral helical

reinforcement shall be 50 mm, unless otherwise specified or shown
on the drawings. Care shall be taken to preserve the correct cover
and alignment of reinforcement free from any twist, throughout the
whole operation of placing the reinforcement in the bore hole and
placing the concrete, the inside diameter of the reinforcement cage
shall be adequate for the operation of the tremie pipe when used.
1.23.5 Drilling Mud (Bentonite)
The drilling mud shall have such properties as to permit the formation of
filter cake on the sides of the bore holes, the thickness of which would
depend on the nature of the subsoil deposit. Sodium based benetonites
PAGE 274 OF 281
624 of 2461
MMRDA
have ideal properties suitable for use as drilling mud.
During the boring operation the fresh suspension gets contaminated with
bored spoil and gradually becomes heavy. This contaminated benetonite
may be reused depending upon the manner of boring, type of strata
encountered and the specific gravity of the contaminated benetonite. It is
essential to check the specific gravity of the benetonite in the borehole
before concreting. The contaminated benetonite may be collected in a
suitable receptacle and allow the heavier particles to settle and the slurry
washed out before reuse. The drilling muds shall be suitably disposed off
without causing any nuisance to the surrounding area in a manner approved
1.23.6 Boring Operations
Boring for lined bored piles or pressure piles:
a)
Boring shall be done to the minimum elevation specified on the

drawings or as modified in writing by the Employers representative
during the progress of boring.
b)
Temporary steel casing shall be used to line the bore hole as the
depth increase to prevent the sides of bore hole from collapsing. If
firm strata are not met with, such as stiff clay or soft rock, the casing
shall be tapped down into these strata to prevent the ingress of the
ground water and the boring may then proceed without casing, if
c)
The bottom of the lining shall be kept for enough in advance of the
boring to prevent the entry of soil into the lining and formation of
cavities and settlement of soil surrounding the lining.
d)
Bailing out of muck from the borehole shall be done by a flap value
bailer
or
any
other
method
approved
by
the
Employers
representative.
PAGE 275 OF 281
625 of 2461
e)
MMRDA
After the bore hole has gone down to the final depth, clean water
should be pumped through a pipe resting at the base of the bore
hole, to remove completely all muck and other loose material from
the bottom of the bore hole. Sufficient pressure of the water shall be
maintained during these flushing operations, which shall normally
continue for 10 to 15 minutes.
f)
Boring may be done by direct mud circulation, reverse mud

circulation or by bailer using drilling mud to stabilize the borehole
from collapsing.
g)
A protective steel casing of suitable length both above the ground

and below it shall be installed for protection of personnel and to
prevent caving and displacement of the earth and for retention of the
surface water
1.23.7 Inspection of Bored Piles:
The boring, immediately before placing the reinforcement and depositing the
concrete, shall be thoroughly inspected visually by means of an electric
lamp attached to a drop of chord of sufficient length to reach the bottom of
the boring.
The diameter of the hole may be checked in the case of benetonite slurry
bored piles by lowering a guide ring through the depth of the hole. The
depth of the bore hole shall be measured by means of a chain to which a
plump bob weighing not less than 250 gm is attached. The Contractor shall
provide all the equipments required for the above inspection and he shall
co-ordinate this work with the Employers representative.
1.23.8 Concreting
a)
The concrete shall be freshly mixed and in sufficient quantities in the

casing to examine that during the withdrawal, a sufficient head of
PAGE 276 OF 281
626 of 2461
MMRDA
concrete is maintained to prevent the inflow of soil and subsoil water.
b)
The entire depth of the pile shall be concreted in one operation

without stoppage.
c)
All concreting operation for piles shall be carried out during day
time only.
d)
Exposed proportion of piles shall be cured for at least 10 days from

the date of casing.
e)
When installing the piles in groups, sufficient time shall be allowed for
freshly poured concrete in pile to set before installing adjacent piles.
The Employers representative in consultation with the Contractor
shall determine the installation sequence and time schedule to ensure
that freshly concreted piles are not damaged due to installation of
adjacent piles. Consecutive piles in a group with in 0.5 m of each
other shall however not be constructed before a lapse of 2 days after
the installation of previous pile.
f)
All care shall be taken to prevent formation of voids in the piles by

pockets of air trapped within. Particular attention shall be paid to this
during the withdrawal of casing. The Volume of concrete placed in the
pile shall be checked with the theoretical Volume of the pile, and any
shortfall in the actual Volume concreted shall be reported to the
g)
After the boring has been flushed and approved and with the
reinforcement in place, the pile shaft shall be concreted by tremie
process, as described above for lined bored piles. Before concreting,
the bore shall be flushed once again with benetonite slurry through
the tremie pipe to ensure that the bottom is cleaned after placing the
reinforcement. The tremie pipe shall always be maintained a minimum
2 to 2.5 m inside the concrete.
PAGE 277 OF 281
627 of 2461
MMRDA
1.23.9 Testing of Piles
A.
1.5% of the total number or minimum two piles shall be subjected to

non destructive load tests to 1.50 times to design load. (i.e.
Estimated load carrying capacity of pile).
The test shall be carried out by applying a series of load on a pile

unaided by any other support. The load shall preferably be applied by
means of hydraulic jack reacting against a loaded platform, which
shall be preloaded to not less than 2 times the estimated safe
load-bearing capacity of the pile.
The test load shall be applied in equal increments of one fifth of the
estimated safe load or as directed by Employers representative.
Alternate loading and unloading at each load increment shall be
performed and the elastic and plastic settlements recorded.
Each stage of loading or unloading shall be maintained till the rate of

movement of the pile top is not more than 0.02 mm per hour.
B.
Acceptance Criteria:
Piles shall satisfy the following requirements:
i)
The total settlement for the test load shall not exceed 12
mm.
ii)
The net (residual) settlement after the test load is removed

shall not exceed 6 mm.
iii)
The general behaviour of the pile during the test shall be

proper and uniform.
The pile which fails to satisfy the above requirements shall be

rejected and another pile tested in lieu. The rejected pile shall be
PAGE 278 OF 281
628 of 2461
MMRDA
replaced or rectified with prior approval of Employers representative

at the Contractors risk and cost.
If the second pile tested also fails, the rejection of part or the entire
lot and rectification measures to be done at Contractors risk and
cost, shall be at the discretion of the Employers representative.
Any pile / piles to be installed in replacement of the rejected piles as

directed by the Employers representative shall be done by the
Contractor at this own cost. The Contractor shall also not be paid for
expenses incurred by him in extracting the rejected piles / casings
provisions of extra piles, enlargement of pile caps necessitated as a
result of defective or workmanship of the Contractor.
1.23.10
Replacement of Rejected Piles
Piles / boring / casing that are defective or exceed the tolerances as

specified above shall be left in place or pulled out as directed by the
Employers representative without adversely affecting the performance of
the adjacent piles. In case the piles / casing cannot be removed, they shall
be cut out as directed by the Employers representative. Voids resulting
from rejected borings or extraction of the piles or casings shall be filled with
gravel or sand unless other piles are installed in such voids.
1.23.11 General
i)
Pumping and bailing out of water, shoring, shuttering etc. if found

necessary for successful and speedy operation of work, shall be
carried out by the Contractor and cost of such works shall be
included in his rates. No extra claims whatsoever on all subsidiary
works pertaining to piling work will be entertained.
ii)
All the excavated materials including debris, loose earth etc. shall be
carted
away
and
disposed
off
as
directed
by
Employers
representative.
PAGE 279 OF 281
629 of 2461
iii)
MMRDA
The Contractor shall provide all the equipments, tools and plants
required for the works and the rates shall include the cost of bringing
the equipments etc. to site proper maintenance and removal of the
same after completion of work.
iv)
The piles shall be driven as accurately as possible to the vertical or to

the specified batter. The permissible positioned deviation for piles
shall not be greater than 7.5 cm and shall not exceed 2% (about 1
deg.) from the specified inclination. Piles not conforming to above
requirements may be rejected. The Contractor at his own cost shall
rectify any remedial measures required due to errors in piling. Prior to
carrying out the rectification work, approval for such remedial
measures should be obtained by the Contractor from Employers
representative.
v)
Piles that are defective shall be pulled out or left in places as directed
by Employers representative and additional piles shall be driven to
replace them.
vi)
The piles should penetrate into hard, load bearing strata. Founding
stratum of each pile shall be approved by Employers representative.
The pile should penetrate a minimum of 15 cm into founding strata.
The founding strata shall be as follows:
a)
For piles up to and including 45 cm dia that the strata in which

penetration by chiselling with Tonne chisel continuously for
half an hour does not exceed 15 cm.
b)
For piles above 45 cm dia Same as above but with 2

Tonne chisel.
vii)
Samples of the hard strata be taken and appropriately marked. SPT

tests shall be performed on pile to determine founding strata (clay
stone) with N > 50.
PAGE 280 OF 281
630 of 2461
viii)
MMRDA
Chipping of concrete piles above given cut-off level or building up

piles up to given cut-off levels, if any, for casting pile caps and plinth
beams with specified concrete mix and as per drawings shall be
included in the cost of piling and no extra payment shall be
considered on this account.
ix)
Adequate length of bars to be left over the cut-off level of the pile to
develop anchorage in the pile caps and also dowels to be kept of
adequate lengths.
x)
Built up portion of piles / pile caps and beams shall be thoroughly

cured as per instructions of Employers representative for a period of
two weeks at least or as directed.
xi)
Sample of the hard strata shall be taken appropriately marked and

preserved. All openings etc. if required in beams walls shall be
provided by the Contractor, free of cost, if intimated to the Contractor
before pouring concrete.
xii)
Rig register and weekly report as per the format, approved by the
Employers representative shall be submitted to Employer.
xiii)
During the period of establishing mix design, no nominal mix for piling
work will be followed. In no case, Contractor will be allowed to cast
pile with nominal mix.
xiv)
The length of pile shall be measured from the tip of the pile to the
bottom of the pile cap. The eight cm. length of the pile tip projecting
into the cap shall not be measured for the payment and also shall
not be deducted from the quantity of pile cap concrete. Empty boring
will not be considered for any type of payments.
PAGE 281 OF 281
631 of 2461
MMRDA
Table of Contents
SUB-SECTION 6B.2: MS PIPELINE ........................................................................................................... 1
2.1
General Scope ............................................................................................................................. 1
2.2
Applicable Codes and Specifications ......................................................................................... 4
2.3
Design of Pipeline ....................................................................................................................... 6
2.3.1
General ................................................................................................................................ 6
2.3.2
Detailed L-Section ............................................................................................................... 8
2.3.3
Detailed Design ................................................................................................................... 8
2.3.4
Design Criteria for Appurtenances...................................................................................... 9
2.3.5
Structural Design Criteria .................................................................................................. 10
2.4
Material Specifications............................................................................................................. 15
2.4.1
Steel Plates and Coils ........................................................................................................ 16
2.4.2
Chemical Composition and Requirements........................................................................ 16
2.4.3
Mechanical Properties and Requirements........................................................................ 17
2.4.4
Tolerances for Plates ......................................................................................................... 19
2.4.5
Inspection.......................................................................................................................... 19
2.4.6
Procurement ..................................................................................................................... 20
2.4.7
Replacement of Unsatisfactory Material .......................................................................... 21
2.4.8
Packing and Identification ................................................................................................. 22
2.4.9
Electrodes.......................................................................................................................... 22
2.5
Factory ...................................................................................................................................... 23
2.6
Manufacturing of MS Pipe and Specials .................................................................................. 23
2.6.1
Spirally Welded Pipes ........................................................................................................ 23
2.6.2
Specials / Fittings .............................................................................................................. 24
2.6.3
Other Specials ................................................................................................................... 30
2.7
Welding ..................................................................................................................................... 31
2.7.1
Testing Of Weld Coupons.................................................................................................. 33
2.7.2
Re-Tests ............................................................................................................................. 35
2.7.3
Testing of Welded Joints .................................................................................................. 35
2.7.3.1
Radiography of Joints ........................................................................................................ 35
2.7.3.1.1
Radiographic Inspection of Welded Joints .................................................................... 37
2.7.3.2
Ultrasonic Testing of Welded Joints.................................................................................. 38
2.7.4
Pipe Testing in Fabrication Shop (Factory Test) ................................................................ 39
2.7.5
Marking ............................................................................................................................. 40
632 of 2461
MMRDA
2.7.6
Stress Relieving ................................................................................................................. 41
2.7.7
Joints ................................................................................................................................. 41
2.7.8
Storage .............................................................................................................................. 43
2.7.9
Transportation and Handling ............................................................................................ 44
2.8
Pipeline Construction ............................................................................................................... 45
2.8.1
General .............................................................................................................................. 45
2.8.2
Contractor to Resurvey the Pipeline Route ...................................................................... 46
2.8.3
Bench Mark ....................................................................................................................... 52
2.9
Pipe Laying ................................................................................................................................ 52
2.9.1
Level Control ..................................................................................................................... 54
2.9.2
Laying to Curves ................................................................................................................ 54
2.9.3
Lowering and Jointing ....................................................................................................... 54
2.9.4
Floatation .......................................................................................................................... 55
2.9.5
Steel Props ........................................................................................................................ 56
2.9.6
Above Ground Pipelines.................................................................................................... 56
2.9.7
Buried Pipelines ................................................................................................................ 61
2.9.8
Encasement for Road Crossing/Nallah Crossing/Alignment falling in road ...................... 69
2.10
Hydraulic Testing of Pipeline ................................................................................................... 69
2.11
Cement Mortar Lining .............................................................................................................. 69
2.12
External Coating for WS Pipe Line below Ground (Buried) .................................................... 95
2.12.1
General Stipulations .......................................................................................................... 95
2.12.2
Plant, Scale and Installation .............................................................................................. 96
2.12.3
Tape Coating for MS Pipe ................................................................................................. 97
2.12.4
Field Procedures ............................................................................................................. 112
2.12.4.1
Protection during Field Welding of Joints ................................................................. 113
2.12.4.2
Hoisting ....................................................................................................................... 113
2.12.5
Inspection and Testing ................................................................................................... 113
2.12.5.1
Material Acceptance .................................................................................................. 113
2.12.5.2
Inspection and Testing by the Employer ................................................................... 114
2.12.5.3
Coating Application Inspection: ................................................................................. 114
2.12.5.4
Access of Employer..................................................................................................... 114
2.12.5.5
Facilities for Employer ................................................................................................ 115
2.12.6
Coated Pipe Tests ........................................................................................................... 115
2.12.6.1
2.12.6.1.1
General ....................................................................................................................... 115

Visual Inspection .................................................................................................... 115
633 of 2461
MMRDA
2.12.6.1.2
Width Deviation ..................................................................................................... 116
2.12.6.1.3
Thickness................................................................................................................. 116
2.12.6.1.4
Holiday Detection ................................................................................................... 117
2.12.6.1.5
Adhesion ................................................................................................................. 118
2.12.6.1.6
Water Absorption ................................................................................................... 118
2.12.6.1.7
Water-vapor Transmission:.................................................................................... 119
2.12.6.1.8
Dielectric Strength .................................................................................................. 119
2.12.6.1.9
Insulation Resistance.............................................................................................. 119
2.12.6.1.10
Cathodic Disbondment Test ................................................................................... 119
2.12.6.1.11
Tensile Strength ...................................................................................................... 120
2.12.6.1.12
Elongation ............................................................................................................... 120
2.12.6.1.13
Impact Resistance................................................................................................... 120
2.12.6.1.14
Penetration / Deformation Resistance .................................................................. 121
2.12.6.1.15
Nonpolyolefinic Material Content ......................................................................... 121
2.12.7
Rejection ......................................................................................................................... 122
2.12.8
Delivery ........................................................................................................................... 123
2.12.8.1
Marking ....................................................................................................................... 123
2.12.8.2
Packaging .................................................................................................................... 124
2.12.8.3
Handling, Transportation and Storage ...................................................................... 124
2.12.9
Coating of Welded Joints for MS Pipeline ..................................................................... 127
2.12.9.1
General ....................................................................................................................... 127
2.12.9.2
Quality ........................................................................................................................ 127
2.12.9.3
Coating System ........................................................................................................... 128
2.12.9.3.1
Sleeve Requirements.............................................................................................. 128
2.12.9.3.2
Material .................................................................................................................. 128
2.12.9.3.3
Form ........................................................................................................................ 129
2.12.9.3.4
Dimensions ............................................................................................................. 129
2.12.10
Field Coating Application ........................................................................................... 130
2.12.10.1
Equipment .................................................................................................................. 131
2.12.10.2
Surface Preparation.................................................................................................... 131
2.12.10.2.1
Bare Surface............................................................................................................ 131
2.12.10.2.2
Blast Cleaning ......................................................................................................... 131
2.12.10.2.3
Protection from Moisture ...................................................................................... 132
2.12.10.2.4
Wire Brush Cleaning ............................................................................................... 132
2.12.10.3
Coating and Wrapping................................................................................................ 132
634 of 2461
MMRDA
2.12.10.3.1
Coating Repair ........................................................................................................ 133
2.12.10.3.2
Outdoor Storage ..................................................................................................... 133
2.12.11
Other Requirement .................................................................................................... 134
2.12.11.1
Coating Width ............................................................................................................. 134
2.12.11.2
Impact Resistance: ..................................................................................................... 134
2.12.11.3
Coating Thickness ....................................................................................................... 134
2.12.11.4
Water-vapor Transmission ......................................................................................... 135
2.12.11.5
Dielectric Strength ...................................................................................................... 135
2.12.11.6
Volume Resistivity ...................................................................................................... 135
2.12.11.7
Adhesion ..................................................................................................................... 135
2.12.11.8
Heat Shock .................................................................................................................. 135
2.12.11.9
Tensile Strength .......................................................................................................... 136
2.12.11.10
Elongation ............................................................................................................... 136
2.12.12
Electrical Inspection for Continuity ........................................................................... 136
2.12.13
Delivery ....................................................................................................................... 138
2.12.13.1
Packaging .................................................................................................................... 138
2.12.13.2
Marking ....................................................................................................................... 138
2.12.13.3
Shipping, Handling and Storing .................................................................................. 139
2.12.14
Coatings for Exterior of Special Sections, Connections and Fittings ........................ 139
2.12.14.1
General ....................................................................................................................... 139
2.12.14.2
Materials and Workmanship ..................................................................................... 139
2.12.14.3
Material Requirements .............................................................................................. 139
2.12.14.3.1
Liquid Adhesive ...................................................................................................... 140
2.12.14.3.2
Prefabricated Tape ................................................................................................. 140
2.12.14.3.2.1
Materials ............................................................................................................. 140
2.12.14.3.2.2
Form .................................................................................................................... 142
2.12.14.3.2.3
Dimensions ......................................................................................................... 142
2.12.14.3.2.4
Thickness............................................................................................................. 142
2.12.14.4
Coating Application (Field and Shop) ........................................................................ 143
2.12.14.4.1
Equipment, Surface Preparation............................................................................ 143
2.12.14.4.2
Visual Comparative Standards, Protection from Moisture................................... 143
2.12.14.4.3
Priming .................................................................................................................... 144
2.12.14.4.4
Coating and Wrapping............................................................................................ 144
2.12.14.4.5
Coating Repair ........................................................................................................ 145
2.12.14.5
Field Procedures ......................................................................................................... 145
635 of 2461
MMRDA
2.12.14.6
Inspection ................................................................................................................... 146
2.12.14.7
Electrical Inspection for Continuity ........................................................................... 146
2.12.14.8
Testing......................................................................................................................... 146
2.12.14.8.1
Tape and Coating System Tests ............................................................................. 146
2.12.14.8.1.1
Tape Width ......................................................................................................... 146
2.12.14.8.1.2
Tape Thickness.................................................................................................... 147
2.12.14.8.1.3
Water Vapor Transmission................................................................................. 147
2.12.14.8.1.4
Dielectric Breakdown ......................................................................................... 148
2.12.14.8.1.5
Insulation Resistance.......................................................................................... 148
2.12.14.8.1.6
Adhesion to Primed Steel................................................................................... 148
2.12.15
Rejection ..................................................................................................................... 148
2.12.16
Delivery ....................................................................................................................... 149
2.12.16.1
Marking ....................................................................................................................... 149
2.12.16.2
Packaging and Shipping .............................................................................................. 149
2.12.16.2.1
Packaging ................................................................................................................ 149
2.12.16.2.2
Shipping, Handling and Storage ............................................................................. 150
2.13
External coating on MS pipe above ground ...................................................................... 150
2.13.1
Coating and Lining Systems............................................................................................. 150
2.13.1.1
Liquid-Epoxy Coatings ................................................................................................. 150
2.13.1.2
Coating Thickness........................................................................................................ 151
2.13.1.3
Coating Application ..................................................................................................... 151
2.13.2
Pipe Preparation ............................................................................................................. 151
2.13.2.1
Cleaning....................................................................................................................... 151
2.13.2.2
Abrasive Blast Cleaning ............................................................................................... 151
2.13.2.3
Surface Inspection....................................................................................................... 152
2.13.2.4
Interior Cleaning ......................................................................................................... 152
2.13.2.5
Application Temperature ............................................................................................ 152
2.13.2.6
Application of Epoxy Coating System.......................................................................... 152
2.13.3
Cure ................................................................................................................................. 153
2.13.4
Electrical Inspection for Continuity ................................................................................. 153
2.13.5
Coating Repair ................................................................................................................. 153
2.13.6
Welded Field Joints ........................................................................................................ 153
2.13.6.1
Preparation ................................................................................................................. 153
2.13.6.2
Electrical Inspection .................................................................................................... 154
2.13.6.3
Bedding and Trench Backfill ........................................................................................ 154
636 of 2461
2.14
MMRDA
Civil Works .............................................................................................................................. 154
2.14.1
Supports .......................................................................................................................... 154
2.14.2
Valve Chambers .............................................................................................................. 155
2.14.2.1
Flow Meter Chambers and Room .............................................................................. 155
2.14.3
Safety Foot Rests ............................................................................................................ 156
2.14.4
Thrust Blocks/Anchor Block ........................................................................................... 156
2.15
Pipelines under Existing Roads .......................................................................................... 158
2.16
Reinstatement of Roads/Pavements/Fences/Compound Walls Etc. ............................... 158
2.17
Internal Cleaning of Pipeline .............................................................................................. 158
2.18
Pipeline Disinfection .......................................................................................................... 159
2.19
Markings ............................................................................................................................. 160
2.20
Fencing, Watching and Lighting ......................................................................................... 160
2.21
Damage to Public Utilities .................................................................................................. 161
2.22
Clearing the Site ................................................................................................................. 161
2.23
Valves .................................................................................................................................. 161
637 of 2461
MMRDA
SUB-SECTION 6B.2: MS PIPELINE
2.1
General Scope
The scope covers the manufacturing, supply, delivery, lowering, laying,

jointing, internal lining, outer coating, testing and commissioning of mild steel
welded
pipes
including
associated
civil,
electromechanical
and
instrumentation works.
The proposed pipes shall be spirally welded. The pipe line shall be generally
laid below ground, but some portion will be laid above ground as per the site
conditions. All the pipes shall be lined with 12 mm thick cement mortar lining.
Pipes laid below ground shall be coated with pre-fabricated Polyolefin tapes.
All lining and coating shall be done in strict accordance with the specifications
provided in this section in order to provide best quality, durable and long
lasting protection for the water transmission system.
The contractor shall carry out all works related to pipeline wholly in
accordance with the terms and conditions of the project to fulfill the
requirements. All materials used and equipment installed shall be as per the
specifications described in the contract and all work shall be executed in
accordance with good Engineering practices.
The details of the alignment, substrate and the various requirements have
been provided in the document and system have been worked out and
provided for in the document. However the contractor is required to recheck
all the details and submit the details of the design for all the components of
the system. Generally the following activities shall be carried out for the
pipeline works shall not be limited to:
Carrying out detailed topographical survey for the raw and clear water
main alignment in the limits of the Contract in consultation with the
Employer
SECTION 6B.2: MS PIPE
PAGE 1 OF 161
638 of 2461
MMRDA
Carrying out subsoil investigations for design of foundations including

the tests for determination of safe load. Carrying out various other
subsoil investigations such as the type of soil, the strata and the sub
soil ground water level, optimum moisture content, soil resistivity and
chemical composition, bearing capacity, etc., as may be required
Planning, design and preparation of the drawings for pipeline and allied
works
Submission of the L-sections, layout plans and cross sections and

conceptual drawings etc. and all other drawings at appropriate scale
and details for planning of all components of the project conforming to
specification for minimum and maximum soil cover, limits of gradients
for ascending descending sections, position of air valves, line valves,
washouts, thrust blocks, anchor blocks, expansion joint etc.
Submission of the design, drawings, specifications, catalogs and the

technical data sheets of all the equipment, taking into account the
interfaces to the other project components /packages
Getting approval of all design, calculations for shell thickness and

drawings, material to be used, equipment specifications and the
samples, prior to starting the work on site, from Employer
Preparation and submission of all detailed working drawings on the

basis of conceptual designs and plans for approval of the Employer
Preparation
of
the
structural
design
and
drawings
(including
reinforcement detailing) for all the works such as thrust/anchor blocks,

road and nallah crossings, pipe supports, valve chambers, etc., taking
into consideration the structural safety
Establishment of the pipe manufacturing factories with all necessary

machinery, equipment, testing facilities, etc., for MS pipes and fittings,
including manufacturing, testing, coating, lining, etc. and proper
PAGE 2 OF 161
639 of 2461
MMRDA
storage
Manufacturing, shop testing, inspection as per approved QCP / QAP

transportation to site, laying and testing, commissioning of the MS
pipelines including, fittings, specials, ancillary works, internal lining and
external coatings
Supply, installation, inspection, testing, etc., for air valves, sluice

valves, butterfly valves, expansion joints etc.
Designing and providing Cathodic Protection system for raw water and
clear water pipeline
Manufacturing, shop testing, pre-dispatch inspection, transportation to

site, storage, handling at site, installation, sectional testing, precommissioning testing, commissioning and trial runs for all components
of the system including the hydraulic, mechanical, electrical, electromechanical and instrumentation equipment
Final site clearance and leveling, excavation of the working spaces for
all structures, trench excavation for pipes and other ancillary works in
all sorts of soil adopting trench protection measures, lowering laying
and jointing MS pipes, hand lining at welded joints of two pipes and
external protection of joints, refilling and disposal of surplus earth at
suitable site as directed by the Employer
Following all the safety provisions as per various stipulations
Hydraulic testing of pipeline sectional testing and complete

transmission system as per Employers requirements
Implementation of all the environmental and relevant social mitigation

measures as required
The initial geo-technical investigations, subsoil investigations, soil

PAGE 3 OF 161
640 of 2461
MMRDA
resistivity survey, topographic survey and L-section and plan for the
pipelines have been carried out by Employer is given in
Drawings
section. The Bidder shall be responsible to confirm its validity,

correctness and completeness before submitting its bid and, if
necessary, carry out all investigations again. In any case the
responsibility for these investigations will lie with the Contractor.
2.2
Applicable Codes and Specifications
The following specifications, standards and codes, or equivalent International

specifications, standards and codes, as presented in Table 2.1, are made a
part of the specification. All standards, specifications, codes of practice
referred to herein shall be the latest editions including all applicable
amendments.
Table 2.1: List of Applicable IS Codes

Code
Title of the Code
IS 456
Code for Practice for Plain and Reinforced Concrete
IS 814
Specifications for Covered Electrodes for Metal Arc

Welding for Mild Steel.
IS 816
Code of Practice for Use of Metal Arc Welding for

General Construction
IS 817
Code of Practice for Training and Testing of Metal Arc

Welders
IS 1182
Recommended Practice for Radiographic Examination

of Fusion-Welded Butt Joints in Steel Plants.
IS 1599
Method for Bend Test.
IS 1608
Method for Tensile Testing of Steel Products.
IS 1730
Dimensions for Steel Plates, Sheets, Strips and Fiats

for General Engineering Purpose
IS 1757
Method for Charpy Impact Test (V - Notch) on Metallic

Method.
IS 1974
Bare Wire Electrodes for Submerged Arc Welding.
IS 2062
Steel for General Structural Purpose and Specifications
PAGE 4 OF 161
641 of 2461
MMRDA
Code
Title of the Code
IS 2595
Code of Practice for Radio-Graphic Testing.
IS 2598
Safety Code for industrial Radiographic Practice.
IS 2720
Methods of Test for Soils.
IS 3025
Method of sampling & Test for Water & Waste water
IS 3589
Specification for Steel Pipes for Water and Sewage

(168.3 to 2540mm Nominal Size).
IS 3600
Code of Procedure for Testing of Fusion Welded Joints

and Weld-Metal in Steel.
IS 3613
Acceptance Tests for Wire Flux Combinations for

Submerged Arc Welding.
IS 3658
Code of Practice for Liquid Penetrant Flaw Detection.
IS 4353
Recommendation for Submerged Arc Welding of Mild

Steel and Low Alloy Steels
IS 4853
Recommended Practice for Radiographic Examination

of Fusion Welded Circumferential Joints in Steel Pipes.
IS 5334
Code of Practice for Magnetic Particle Flaw Detection

of Welding
IS 5504
Specifications for Spirally Welded Pipes.
IS 5822
Code of Practice for Laying of Welded Steel Pipes for

Water Supply.
IS 6419
Welding Rods and Bare Electrodes for Glass Shielded

Arc Welding of Structural Steel.
IS 7280
Bare Wire Electrodes for submerged arc welding of

Structural Steel
IS 6631
Steel Pipes for Hydraulic Purposes.
IS 7307
Approval Tests for Welding Procedures.
IS 7310
Approval Tests for Welders Working To Approved

Welding Procedures.
IS 7343
Code of Practice for Ultrasonic Testing of Ferrous

Welded Pipes and Tubular Products.
IS 8112
Specification for 43 Grade Ordinary Rapid Portland

Cement.
IS 8910
General Technical Delivery requirement for Steel
PAGE 5 OF 161
642 of 2461
Code
MMRDA
Title of the Code

Products
IS 10221
Code of Practice for Coating and Wrapping of

Underground Mild Steel Pipeline.
IS 10748
Hot -Rolled Steel Strips for Welded Tubes and Pipes
IS 11906
Recommendation for Cement Mortar Lining for Cast

Iron, Mild
Steel and Ductile Iron Pipes and Fittings for
Transportation of Water.
IS 12330
Specification for Sulphate Resisting Portland Cement
IS 14846
Specification for Sluice Valves for Water Work

Purposes
AWWA M 11
Steel Pipes -Guide for Design and Installation
CIRIA-R-128
Guide to Design of Thrust Block on Buried Pressure

Pipeline by A.R.D Thorley
2.3
Design of Pipeline
2.3.1 General
The hydraulic and structural design of the pipe line has been made and
need not be reviewed by the contractor. The considerations for the
design are however are as below and the contractor may check the
design for his own satisfaction:
The proposed standards with regards to pipe diameters, lining, coating

and type/ class of bedding, as described in the Employer's concept
design presented in this Section, shall be regarded as being the
minimum permissible standards for this Contract.
The design of pipes to be laid in a particular stretch shall be based on:
i.
The alignment, depth of laying and type/class of bedding
ii.
The structural design of the pipes under hydraulic operation,

design load and field test conditions as well as under
PAGE 6 OF 161
643 of 2461
MMRDA
overburden and traffic load.
iii.
The location of air valves, washouts, line valves
iv.
The bends and thrust blocks.
v.
The corrosion protection of the pipes and the fitting.
vi.
Seismic requirements for civil structures on the pipeline.
The Contractor shall adopt suitable diameter within permissible

variation and offer suitable shell thickness to satisfy the requirements
in particular specifications. The grade of pipe material, diameter and
shell thickness shall be as per approval of the Employer. The minimum
requirements for the internal lining and external coating have also been
finalized by the Employer and the specifications for the same are
presented particular specifications.
The underground pipeline shall be laid with a minimum soil cover of

1500/2000 mm below the finished ground or road level/ highway as
specified and maximum cover of 3500 mm. In case soil cover exceeds
the allowable maximum cover, the Contractor shall provide required
higher thickness or suitable encasement or any other supporting
system as approved by Employer. The maximum unsupported span for
above ground pipeline shall not exceed 10.0 m, and support spacing
shall be established based on structural design of MS pipe for each
section.
All the pipes, valves, MS specials and other pipe appurtenances shall
be designed to withstand the maximum pressures to which they may
be subjected, including surge pressure under operation for pumping
main and 1.5 times maximum static head corresponding to maximum
HGL at C=120 for gravity main. Corossion allowance as specified shall
be considered.
PAGE 7 OF 161
644 of 2461
MMRDA
2.3.2 Detailed L-Section
After approval of survey details, geo-technical investigations and other

requirement of the site, the Contractor shall prepare and submit the
detailed plan and working L-section drawings showing the proposed
placement of pipes along the alignment and also salient levels (invert,
top, etc.), exact locations of all appurtenances, allied works, etc., to the
Employer for approval. The proposals must consider the requirement
as stated in the bid document particularly minimum and maximum soil
cover, minimum ascending and descending gradients and all major and
minor crossings.
2.3.3 Detailed Design
After the approval of L-section of the pipeline by Employer, the

Contractor shall be responsible to prepare and submit the following
designs for approval by Employer:
i.
Structural design of pipeline with HGL of entire section (The type

and material of pipe are not subject to any changes).
ii.
Design and Drawings of pipe support structures.
iii.
Design and Drawings of thrust and anchor blocks
iv.
Design and Drawings of expansion joints.
v.
Design and drawings for pipeline on bridge including saddles /

ring girder and thrust block.
vi.
Design and Drawings of air valve, line valve, washout and valve
chambers.
vii.
Design and Drawings of air valve tee, washout tee, manholes

and all allied works.
PAGE 8 OF 161
645 of 2461
MMRDA
viii.
Design and Drawings of fittings.
ix.
Design and Drawing of pipe trenching with suitable location of

road and trench for further pipe laying and trench section at
welding joint.
x.
Design and Drawings of discontinuity joints.
xi.
Design and drawings for cathodic protection.
2.3.4 Design Criteria for Appurtenances
The Contractor shall provide all necessary appurtenances on the

pipelines such as air valves, washout / scour valves, butterfly valves,
expansion
joints,
manholes,
etc.,
as
may
be
required.
The
appurtenances shall be provided as per the relevant IS code unless

otherwise specified below.
2.3.4.1
Air Valves
The air valves shall be provided at every summit of the

pipeline, at every peak where HGL changes, upstream of
any dip or sag necessitated for crossings below bed level
and at maximum intervals of 500 to 600m for straight
pipelines. A sluice valve shall be provided on the air valve
tee for isolation of air valve.
The valve shall be provided with valve chamber as per

specifications and as shown in the drawing. The air valve
size shall be fixed to allow adequate air exists during
operation and admission of air and exit during emptying
and filling of the pipeline. The minimum size of valve shall
be 200 mm. The air valves shall be provided liberally.
PAGE 9 OF 161
646 of 2461
2.3.4.2
MMRDA
Scour Valves
Scour valves shall be provided at valley of the pipeline to

drain out the water. The valve shall be provided at such a
distance and of such a size that the pipeline section can
be emptied within 2 to 4 hours. The valves shall be
manually operated sluice valve of size 300 mm and 400
mm as per the gradient.
The valves shall be provided with valve chambers as per

specifications. A separate sump shall be provided to
pump water to the nearest nallah/drain as shown in the
drawing.
2.3.4.3
Line Valves
The line valves in the form of manually operated butterfly

valves shall be provided on the gravity main at a spacing
of about 5 km. The valves shall be provided with
eccentric reducer, eccentric enlarger, flange adapter and
valve chambers as per specifications and as shown in
drawing
2.3.4.4
Off take Tees
Off take Tees for water supply on the clear water main for
on route consumers, at locations as directed by the
Employer, shall be provided. The off take tee shall be
extended to have a sluice valve of the same size and
blind flange at end. Sluice valve chambers shall be
provided as per specifications and drawing.
2.3.5 Structural Design Criteria
The general requirement for design of the MS pipelines shall be as per

PAGE 10 OF 161
647 of 2461
MMRDA
IS 5822, IS 3589 and AWWA-M11 manual.
2.3.5.1
For Buried Pipes / Exposed Pipes
The shell thickness shall be designed to withstand:
a)
Design pressure and field test pressure
i)
Pumping Mains
Design pressure for pumping mains

shall be higher of following two sums.
No reduction in water hammer head
due
to
control
device
shall
be
accounted for determining design

pressure
Maximum working head over

profile
+
Water hammer head without
protection
OR
Maximum static head over

profile
+
Water hammer head without
protection
Field test pressure for hydraulic

testing of pumping main shall not be
less than the design pressure
ii)
Gravity Pipeline
PAGE 11 OF 161
648 of 2461
MMRDA
Design pressure for stretches of

gravity
mains
be
separately
determined
Design pressure for the respective

gravity pipeline shall be 1.5 times
maximum static head over lowest
invert level over entire length of
pipeline in that stretch
Field test pressure for hydraulic

testing of pipeline shall not be less
than above design pressure
b)
Shell thickness proposed meets following criteria
Includes
minimum
1.0
mm
corrosion
allowance
Shell thickness after deducting corrosion

allowance is suitable for design pressure
determined as per system design criteria
specified and as per IS 5822 Code of
practice for laying electrically welded steel
pipes for water supply
c)
The shell thickness without any reduction for

corrosion allowance shall be suitable to withstand
collapsing pressure under vacuum as stated
below.
The collapsing pressure Pc in psi is based on

Stewarts formula given in AWWA manual M-11
Pc
3
502 105 (
)
PAGE 12 OF 161
649 of 2461
MMRDA
Where
t
shell thickness, inches
dn
(Outside diameter t), inches
Vacuum
level
inside
the
pipeline
with
due
consideration of vapour pressure shall be as under:
Gravity main (1/3 of atmospheric pressure)
4.85 psi
Pumping main (full vacuum)
13.85 psi
d)
The shell thickness shall be suitable for handling

as per AWWA M-11
The combination of pipe diameter and shell

thickness
shall
meet
following
requirements
depending on internal coating / lining and external

protection wrapping / taping
Deflection under soil over entire range cover

from 1.5 m to 3.5 m and live load HS 20 as
per AWWA M-11 is less than allowable pipe
deflection:
Mortar lined and coated
= 2% of pipe diameter
Mortar lined and flexible coated=
3% of pipe
diameter
Flexible lined and coated
= 5% of pipe diameter
Summation of external water load, dead load

under buoyancy and external pressure due
PAGE 13 OF 161
650 of 2461
MMRDA
to inside vacuum shall not exceed allowable

buckling pressure.
Summation of external water load, dead load

under buoyancy and live load shall not
exceed allowable buckling pressure.
The calculation for deflection and buckling

shall be based on formula given in Chapter
6: External load AWWA M11 (4th edition).
The values for variable shall be as under.
DL = Deflexion lag factor
1.0
Density of soil load
114.5
1b / ft3
= 18 KN/m3
E = modulus of soil reaction in psi as

under for range of depth of cover
Depth of Cover
E (psi)
2-5 ft
700
5-10 ft
1000
10-15 ft
1200
hw
height of water surface
above top of pipe
= soil cover
FS
= Factor of safety for buckling
PAGE 14 OF 161
651 of 2461
MMRDA
= 2.0
2.4
Live load HS-20 shall be as follow
Depth of Cover
Load
4 ft
400 psf
5 ft
250 psf
6 ft
200 psf
7 ft
176 psf
8 ft
100 psf
Above 8 ft
NIL
Material Specifications
a)
Steel plates/ coils - The pipe shall be fabricated out of Fe 410

grade strips of fresh mild steel coils (HR coils) conforming to IS2062, and having minimum specified tensile strength of 410
MPa. The steel plates for fittings, specials and stiffeners shall be
of mild steel conforming to IS: 2062.
b)
Welding consumables - such as electrodes, filler rods and wires

shall conform to IS: 814, IS: 3613, IS: 6419 and IS: 7280.
c)
Cement - The cement used shall be of one of the following
i.
Ordinary Portland Cement conforming to IS: 8112
ii.
Sulphate Resisting Portland Cement Conforming to IS:

12330
d)
Water - The water used in preparation of concrete mix shall

conform to the
requirements of mixing water given in IS: 456
and IS 3025.
Before fabrication of pipes and specials / fittings is commenced,

PAGE 15 OF 161
652 of 2461
MMRDA
the copies of the mill sheets and the manufacturer's test

certificates for plates/ coils and other materials for the fabrication
shall be submitted by the Contractor to the Employer for his
approval.
2.4.1 Steel Plates and Coils
The coils used for manufacture of the pipe shall be trimmed to the
proper width and given special edge treatment required for the welding
process.
2.4.2 Chemical Composition and Requirements
The supplied steel shall conform to the chemical composition

presented in Table 3.2, as per IS 3589 for Fe 410. The ladle analysis
of steel should be carried out by the method specified in relevant parts
of IS 228 (IS 228 - Method of chemical analysis of steel). However,
where the method is not given in IS 228 and its relevant parts, a
suitable method shall be adopted as agreed between the Employer and
the Contractor. The product analysis shall be carried out on the
finished coil / plates. The chemical requirements for steel coils / plates
are indicated in Table 2.2.
Table 2.2- Chemical Composition for MS Pipe Material

Element
Ladle Analysis
Permissible Variations for
(% max.)
Product
Analysis Over the Specified
Limit
(% max.)
Carbon (C)
0.20
0.02
Manganese (Mn)
1.30
0.04
Sulphur (S)
0.04
0.005
PAGE 16 OF 161
653 of 2461
Element
MMRDA
Ladle Analysis
Permissible Variations for
(% max.)
Product
Analysis Over the Specified
Limit
(% max.)
Phosphorus (P)
0.04
0.005
Notes:
Carbon Equivalent (CE) = C + Mn/6 + (Cr+Mo+V)/5 + (Ni+Cu)/15
CE based on ladle analysis should be 0.45 as per IS 3589
The minimum Si in silicon killed steel shall not be less than 0.10%.
When the steel is Al/Al-Si killed, the requirement regarding minimum
silicon content need not apply.
When micro-alloying elements like Nb,V and Ti are used individually or

in combination the total content shall not exceed 0.20%.
Copper may be present between 0.20 to 0.35 percent as mutually

agreed between the Employer and the Contractor. The copper bearing
quality shall be designated with a suffix Cu, for example Fe 410
Cu+WA. Nitrogen content of the steel should not exceed 0.012%,
which shall be ensured by the Manufacturer/contractor by check
analysis.
2.4.3 Mechanical Properties and Requirements
As the plate/coil sizes ordered are as per the actual sizes required for
the project, separate test piece of required sizes shall be sent along
with each lot.
2.4.3.1
Tensile Tests
PAGE 17 OF 161
654 of 2461
MMRDA
The tensile strength, yield strength and percentage

elongation of steel shall be determined from standard test
pieces cut either lengthwise or crosswise from plates.
The test shall be carried out on the standard test piece
prepared in accordance with test edition of IS 1608 or its
international equivalent standard.
The tensile strength, yield strength and percentage

elongation of steel should not be less than the specified
values in Table 3.3. Only proportional test piece
complying with the requirement Lo = 5.65/So should be
used for the tensile test, .where Lo is the gauge length
and So is the cross-sectional area of the test piece.
Number of Tensile Tests: For every 500 tons of finished

steel, one tensile test shall be conducted.
2.4.3.2
Bend Test
Bend test shall be carried out as IS 3589 / IS 5504.
Table 2.3 - Mechanical Requirements FOR Grade Fe

410
S. No.
Mechanical Property
Value
Tensile strength, Min, MPa
410
Yield Stress, Min, MPa
235
Bend Test (Internal dia.), as

per clause 9.3 of IS 3589
2.4.3.3
Ultrasonic Test
All coils shall be tested by ultrasonic equipment to check

for manufacturing defects such as voids, layers, etc. The
Contractor shall supply test certificates to this effect from
PAGE 18 OF 161
655 of 2461
MMRDA
manufacturer.
2.4.3.4
Retest
If any one test piece first selected fails to pass any of the
tests, two further samples shall be selected for testing in
respect to each failure. If the test pieces from both these
additional samples pass, the material represented by the
test samples shall be deemed to comply with the
requirements of that particular test.
If a test piece from either of these additional samples

fails, the material represented by the test samples shall
be rejected.
2.4.4 Tolerances for Plates
The tolerances for the thickness of steel plates shall be as specified

below.
Table 2.4 Tolerances for the Thickness of Steel Plates
Description
Negative
Positive
Tolerance
Tolerance
Tolerance on plate thickness
Nil
+ 20%
(No negative
tolerance)
2.4.5 Inspection
All works and material under specification will be inspected during all
phases of manufacture and testing and such inspection shall not
relieve the Contractor of his responsibility to furnish materials and
perform work in accordance with this specification.
The Contractor shall notify the Employer in advance the production of

PAGE 19 OF 161
656 of 2461
MMRDA
materials and fabrication thereof, in order that the Employer may

arrange for mill and shop inspection.
The Employer may reject any or all materials or works that do not meet
with any of the requirements of the specifications. The Contractor shall
rectify or replace such rejected material / performed work at his own
cost, to the satisfaction of the Employer.
The Employer shall have free access to those parts of all plants or any
other premises and sites that are concerned with the furnishing of
materials or the performance of work under this specification.
The Contractor shall furnish to the Employer's inspector reasonable

facilities and space for inspection, testing and obtaining of any
information he desires in respect of the character of material used and
the progress and manner of the work.
The Contractor shall supply free of cost required specimens of

materials for testing by the Employer at any time during the progress of
work and shall bear the cost of all such tests or re-tests to his
satisfaction.
The Contractor shall submit, with the material, results of inspection and
testing as per standards specified on the material supplied to indicate
its conformity in respect of chemical and physical properties per heat.
All the tests shall be carried out at the manufacturer's works. The
Employer has the right to have the material tested independently to
confirm the quality of the steel, particularly if there is no co-relation
between various test results or if ultrasonic tests certificates are not
provided.
2.4.6 Procurement
Steel, materials such as MS plates/ coils of required size and

thickness, and other structural steel such as channels, angles, nut
PAGE 20 OF 161
657 of 2461
MMRDA
bolts, etc., shall be procured by the Contractor as per specifications.

General requirements relating to supply of steel plates shall conform to
IS 8910 or any equivalent international standard. All these materials
should be procured from the reputed manufacturers.
The Contractor shall submit the original test certificates from the
manufacturer for the grade of the material and ultimate strength yield
stress. One sample from each lot as per IS specifications shall be
tested in the approved laboratory and approved from the agency
appointed by the Employer. If the test reports are not satisfactory the
entire lot will be rejected. The Contractor will not start fabrication of
pipes and specials before the test certificates from the approved
laboratory are submitted to the Employer.
The Contractor shall provide sufficient separate stacking yard for the
steel materials, fabricated pipes and specials, scrap, etc., in their
factory/factories as per the requirement. No steel plates other than
required for this project shall be stored in the factory premises.
The Contractor shall procure MS plates/coils and other structural steel

required
for
fabricating
pipes
and
specials
considering
the
wastage/scrap, etc. The Contractor should note that no claim,

whatsoever it may be, will be considered on account of wastage and/or
scrap, etc.
The Contractor shall intimate to the Employer one day in advance the
programme of transporting and stacking MS plates/coils and other
structural steel, etc., at the Contractor's factory to enable the Employer
to make necessary arrangement for inspection and sampling for
independent tests.
2.4.7 Replacement of Unsatisfactory Material
If the test results in the above referred clauses are not in conformity
with relevant IS or international specifications, the Employer may reject
PAGE 21 OF 161
658 of 2461
MMRDA
the material.
The Contractor shall make good, within one month of notification of

unsatisfactory material by the Employer, by supply of new material at
his cost to the satisfaction of the Employer.
2.4.8 Packing and Identification
The Supplier/ Contractor shall, after proper rust preventing coating

wherever necessary, pack all the material in a manner suitable for
transport to a tropical humid climatic region in accordance with
internationally accepted practices and in such a manner so as to
protect it from damage and deterioration in transit by road, rail and/ or
sea and during storage at Site till the time of use. The Contractor shall
be held responsible for all damages due to improper packing.
Each plate/coil shall carry an attached label giving the following details:
a.
Number and appropriate section of complying standard.
b.
Grade and size.
c.
Specific tensile strength / yield stress.
d.
Number of lot.
e.
Numbers of related test certificates.
2.4.9 Electrodes
The Contractor shall use appropriate type and size of electrodes with
suitable flux covering depending on the thickness of plate and the type
of joint. They shall also use standard current and voltage required for
the machine in use as per manufacturer's directions. Welding
electrodes shall conform to IS 814 and IS 4353. Electrodes from
PAGE 22 OF 161
659 of 2461
MMRDA
reputed manufacturers such as Ador/Oerlikon or equivalent shall be

used with the approval of Employer. The Contractor shall provide
suitable equipment and ovens to keep the electrodes dry at the desired
baking temperature.
2.5
Factory
The Contractor for fabrication work shall have an authorized and duly licensed
factory/factories for the fabrication of pipes and specials, etc., equipped with
all necessary mechanical and electrical equipment in sound working order for
carrying out the various operations involved in the work under the Contract
such as rolling, automatic welding, cutting, testing, machining, lining, etc., as
well as coating, painting, necessary quality control and assurance equipment
and procedures. The factory or factories shall be equipped for minimum two
production lines for this contract.
For completing the work within the Contract period, each production line of the
factory shall be equipped with adequate number of various equipment and
plant suitable for the pipe sizes, material and thickness specified/required
under the Contract.
2.6
Manufacturing of MS Pipe and Specials
2.6.1 Spirally Welded Pipes
General requirements relating to supply of spiral welded pipes shall

conform to IS 3589 and IS 5504.
All spiral welded pipes shall be
manufactured as per IS 5504. The requirements for weldable hot-rolled

carbon steel strip in coils should conform to IS 3589.
Whenever any dent, i.e., a significant alteration of the curvature of the

pipe shell, is noticed the depth of the dent shall be measured between
the lowest point of the dent and the pipe shell curvature line. All dents
exceeding 2 percent of the outer diameter of the pipe shall be removed
by cutting out a cylindrical portion of the pipe and replacing the same
PAGE 23 OF 161
660 of 2461
MMRDA
by an undamaged piece of the pipe. The Employer may permit insert

patching if the diameter of the patch is less than 25 percent of the
nominal diameter of the pipe. Repairs by hammering with or without
heating shall not be permitted. Any damage to the coating shall also be
carefully examined and rectified.
2.6.2 Specials / Fittings
Unless and otherwise mentioned in the para below, the dimensions of

all MS specials and fittings (such as tees, Y-pieces, bends, tapers,
scour tee, reducers, enlargers, etc.) shall in general conform to the
principals of IS: 7322, BS 534/AWWA C208 and MS plate/sheet
conforming to IS: 2062 and tested and laid in the same manner as the
pipes. The thickness shall be adequate to sustain field test pressure
but shall not be less than the thickness of the pipe at that point.
The Contractor shall submit the detailed drawing for each special to be
used in the pipeline. On approval by the Employer, the Contractor will
take up the manufacturing. All specials shall be manufactured under
controlled conditions at the Contractor's factory/ workshop. In
exceptional circumstances, when welding in trench is unavoidable and
approved by the Employer, a flanged opening shall be provided to
provide access inside the special for welding. The Contractor has to
ensure the timely manufacturing of the MS specials so that they can be
laid along with the pipe laying. The joints of adjacent pipe stretches
shall be made with gap pieces approved by the Employer. On
completion of the manufacturing, the material shall be inspected by the
Employer at the manufacturer's works. All welding for MS specials and
fitting shall be tested by radiography.
On approval of the Employer, the coating and lining for the specials
shall be done by the Contractor as per the specifications for coatings
and lining.
Standard fittings shall be used wherever possible in preference to

PAGE 24 OF 161
661 of 2461
MMRDA
fabricated fittings. Where fabricated fittings are supplied, with approval

of Employer they shall be fully workshop fabricated and tested in
accordance with standards.
Steel specials shall have the same chemical and mechanical properties
and shall be compatible in all respects with the pipes with which they
are to be used. The marking of pipes and fittings shall be as specified.
2.6.2.1
Flanged Branches
Flanged branches shall be fabricated in accordance with

the general specification. Flanged branches for air and
scour valves shall be welded into pipe in the required
position. The branch for an air valve shall be vertical and
at right angle to the longitudinal axis of pipe. The invert of
the branch for a scour valve shall be horizontal and at
right angles to the axis of pipe and shall align with the
invert of the barrel of the main pipe.
All the flanges shall be machined to standard thickness,

square to the axis of the pipe.
2.6.2.2
Bends
Bends to provide change of alignment in pipe laying shall

be manufactured to suit the site conditions from
manufactured and tested pipes by angle cutting of the
barrel or by such other standard procedure and rewelding. Bends shall be lined internally and coated
externally, as specified for the pipes.
a)
Bends shall be fabricated taking into account the

vertical and horizontal angles for each case.
b)
The bends shall have welded joints and the
PAGE 25 OF 161
662 of 2461
MMRDA
upstream and downstream ends of each bend

shall have a straight piece of variable lengths as
required.
c)
Bends shall be designed with deflection angle not

more than 10 degrees between two segments.
d)
When the point of intersection of a horizontal angle

coincides with that of a vertical angle, or when
these points can be made to coincide, a single
combined or compound bend shall be used.
e)
Details of thrust collars, anchor bolts, holding down

straps, saddle plates, etc., should be furnished
together with full specifications in the Contractor's
fabrication drawing.
2.6.2.3
Tapers Enlarger and Reducer
Tapers shall be manufactured out of steel plates and

lined internally and coated externally as specified for
pipes. The tapers shall be suitable for connections to the
sluice/ butterfly valves or flanged tailpiece on one side
and to MS pipe on the other side. Stiffener rings shall be
provided to afford rigidity to pipe.
2.6.2.4
Flanges
Welding neck flanges confirming to ISO 7005-1 or IS

6392 for nominal pressure rating PN 1.6 or PN 1.0 must
be used in accordance to the design pressure at the
place of installations. Nominal size of flange shall be in
conformity to the equipment or pipe appurtenance with
which they are to be used. The flange thickness and
drilling shall conform to ISO 7005 -1 or IS 6392.
PAGE 26 OF 161
663 of 2461
MMRDA
Flanges shall be provided at the end of pipes or special

where flanged valves, blank flanges, tapers, etc., have to
be introduced. The Contractor shall assemble the flanges
in the exact position by marginal cutting, if necessary, so
as to get the desired position of the sluice/ butterfly
valves, etc., either vertical or horizontal and shall then
fully weld the flanges from both sides in such a way that
no part of the welding protrudes beyond the face of the
flanges. In case the welding protrudes beyond the flanges
and if the Employer instructs that such protrusions shall
be removed, the Contractor shall file or chip them off. If
required and when instructed by the Employer, the
Contractor shall provide and weld gusset stiffeners, as
directed
2.6.2.5
Blind Flanges
Blank flanges shall be provided at all ends left unattended

for the temporary closure of work and also for
commissioning a section of the pipeline or for testing the
pipeline laid. For temporary closures, non-pressure blank
flanges consisting of mild steel plates, tack welded at the
pipe ends may be used. For pipes subjected to pressure,
the blank flanges or domes suitably designed as per
Employer's requirements shall be provided. The thickness
and drilling of the blank flanges shall be as defined in ISO
7005-1 / IS 6392.
2.6.2.6
Stiffener Rings
The Contractor shall provide stiffener rings wherever

required by the design or directed by the Employer. The
Contractor shall weld the same to the pipes with one
circumferential run on each side.
PAGE 27 OF 161
664 of 2461
2.6.2.7
MMRDA
Straps
In general the use of straps shall not be made. Whenever

its use is unavoidable, approval of Employer shall be
taken. Wherever pipe laying work is done from two faces
and/or has to be done in broken stretches due to any
difficulty met with at the Site, the final connection has to
be made by introducing straps to cover gaps up to 300
mm length. Straps shall also be provided as per the
procedure of fixing expansion joints by the method
described. Such straps shall be fabricated in the field by
cutting pipes, slitting them longitudinally and slipping
them over the ends to be connected in the form of a
collar. The collar shall be in two halves and shall have its
inside diameter equal to the outside diameter of the pipe
to be connected. A minimum lap of 80 mm on either end
of the pipe shall be kept and fillet welds shall be run both
internally and externally for circumferential joint. The
longitudinal joints of the collar shall be butt-welded.
All fillet welds shall have a throat thickness of not less

than 0.7 times the width of welding.
2.6.2.8
Manholes
Manholes shall be placed on upstream side of the

butterfly valves and at additional locations as directed by
the Employer. Manholes in the pipeline shall be placed in
suitable position in the top quadrant.
For manhole installation, a fabricated tee with one side

flanged must be used. The size of manhole shall not be
less than 500 mm and it shall project at least 300 mm
above the pipe crown. The flanged end must be provided
PAGE 28 OF 161
665 of 2461
MMRDA
with blind flanges with dished end wherever necessary to

withstand field test pressure.
AWWA M11 shall be
referred for typical details of manhole. Flanges/ Blind

Flanges/Dished ends fabricated as per IS 2062 are
acceptable.
2.6.2.9
Closing or Make-up Sections
Closing or make-up sections shall be furnished at

appropriate
locations
on
the
line
to
permit field
adjustments in pipeline length to compensate for

shrinkage in field welded joints, differences between
actual and theoretical lengths, and discrepancies in
measurements.
2.6.2.10
Test Heads
Test heads may be ellipsoidal, standard dished as per

ASME code or hemispherical. They shall be welded in the
shop and removed after the test. Allowance shall be
made in the length of the pipe section receiving the test
head for the welding and removal of the head and
preparation of the plate edges for the final weld after
testing.
2.6.2.11
Walkways, Stairs, Ladders, Hand Rails, etc.
Walkways, stairs, rungs, ladders, hand rails, etc., shall be

provided wherever necessary or as per the directions of
Employer. These shall conform to well established and
good Engineering practices.
2.6.2.12
Flange Adapters
All butterfly valves, scour valves, bulk water meters or

PAGE 29 OF 161
666 of 2461
MMRDA
any other online valves, etc., shall be installed between

flanges with a flexible MS flange adapter at one side. The
joint must allow dismantling of the valve, meters, etc.,
without causing stress to the joints of the attached pipes.
The clearance of the flanged adapter shall be 15 mm.
The pressure class of the flanged adapter shall be the
same as that of the pipe. Detailed drawings of the flanged
adapter shall be submitted to the Employer or approval.
The nuts and bolts of the adapter shall be stainless steel.
The adapters shall be painted/ coated as per specification
given for exposed pipes.
2.6.3 Other Specials
Steel material required for the fabrication of other specials shall be

procured by the Contractor as per codes specified for specials above.
The composite bends shall consist of two or more pieces jointed

together, to give the required curvature. Detailed drawings in regard to
the composite bends required on works shall be given during the
execution of the work. Before cutting the plates for fabrication of
specials the development of the shape shall be first computed and
accurate templates made wherever possible. If the templates cannot
be made the shape shall be first drawn on the plate before a cut is
taken. Wye' branches and tapers shall also be fabricated in one or
more pieces as may be necessary according to the lengths and sizes
of plates available. They shall have stiffening or labyrinth rings fixed on
them as per design requirements, and as approved by the Employer
during fabrication.
Plug plates shall be manufactured as per approved drawing. The size

of plug shall vary from 25 mm to 40 mm as may be directed by the
Employer. A hole for the plug shall be cut, drilled and threaded to exact
size and shall be provided with a suitable stainless steel plug.
PAGE 30 OF 161
667 of 2461
MMRDA
Ladders shall be manufactured from MS plates, flats and bars, as

approved by the Employer, and shall have a curvature to suit the size
of the pipeline on which they are to be fixed.
Loose flange rings shall be cut out of one plate of suitable thickness
varying from 10 mm to 100 mm. However, the Contractor will be
allowed to cut plates in segments and welded together to form a
complete ring. The protruding portion of the welded joint will have to be
chipped off and ground smooth flush with the plate. Wherever possible,
a complete ring shall be cut out of one plate. The flange rings shall be
drilled to provide bolt holes of the required size at the exact center to
center distance as may be directed. They will be mounted and tack
welded on pipes, specials, etc., and welded circumferentially as
directed.
MS stiffener ring channels shall be provided on the pipe strake as

required.
2.7
Welding
Upon receipt of the order and prior to the start of fabrication, the Contractor
shall obtain approval from the Employer of the 'Welding Procedure Method
Statement' that he intends to use in the shop work. At the same time, approval
for the field welding procedures shall also be obtained from the Employer.
All components of pipe shell either straight or bent, etc., shall be welded by
use of automatic arc welding machine by submerged arc process with
alternating current. The strength of the joint shall be at least equal to that of
the parent material. Manual welding shall be adopted only when machine
welding is not possible.
The Contractor shall use electrodes of approved make and size, the size
depending on the thickness of plate and the type of joint. Standard current
and arc voltage required for the machine shall be used with necessary
modifications as may be found necessary after experimental welding. For this
PAGE 31 OF 161
668 of 2461
MMRDA
purpose, samples of welded joints shall be prepared and tested in the

presence of the Employer for approval of the Welding Procedure Method
Statement. Only approved welding procedures shall be used throughout the
work and if any modifications are to be made, the written permission of the
Employer shall be obtained.
All the shop and field welding shall conform to IS 4353, IS 9595 and IS 816.
All longitudinal and circumferential joints shall be as per clause no.7 of IS

4353(Joint Preparation i.e., V cutting and beveling of the edge) .After
completing the welding joints of pipes or plates from one side, and before the
welding on the other side, the joints shall be back chipped/ gouged and
ground to remove irregular penetration till the even surface is exposed.
Gouging shall be resorted to when the plate thickness is above 6 mm.
All circumferential welds involving plates of unequal thickness shall be so kept

that the inside surface of plates match to provide stream-lined joints without
alteration to the internal diameter. The welding shall be of the best quality
workmanship, free from weld defects. In order to maintain a good standard in
welding, welders shall be tested by the Contractor before they are entrusted
with the job. Qualification standard for welding procedures, welders and
welding operators shall conform to IS: 7307 and IS: 7310. Only those who
pass the test shall be allowed to work on the job. Periodic competence tests
shall also be conducted at suitable intervals and those found incompetent
shall be removed from the job. If an incompetent welder has already welded
some pipes, all welding done by him previously shall be fully checked by Xray in addition to the regular X-ray inspections. The defects, if any, shall be
rectified to the satisfaction of the Employer. All such check tests and
rectification of defects shall be entirely at the cost of the Contractor. No pipes
or steel sections shall be erected unless the work of the welder concerned
has been proved to be satisfactory and qualified. Site welds shall be done by
welders qualified for the various welding positions as per applicable IS codes
and standards.
A record shall be maintained showing the names of welders and operators

PAGE 32 OF 161
669 of 2461
MMRDA
who have worked on each individual joint. Manual arc welding shall preferably
be carried out by a pair of welders so that, by observing proper sequence,
distortion can be avoided. A joint entrusted to a particular individual or a pair
shall be, as far as possible, completed by them in all respects, including
sealing run. No helper or other unauthorized person shall be permitted to do
any welding whatsoever.
The weld should not become brittle or sensitive to blows and there should be
no loss of toughness due to welding or heat treatment. The material after
welding and heat treatment shall match with the base metal properties
including original ductility. The weld should at no point be less than the
nominal thickness of plate and a slight reinforcement, as per IS codes, shall
be maintained on all weld joints. Final welding of closure gaps should be
carried out within a temperature range of average air temperature +/- 8C.
If the Contractor's working methods require that the pipes shall have cable
holes / entries installed in the fabrication shop, a hole shall be provided in the
pipe which is large enough to allow the passage of cables and other
paraphernalia necessary for welding the pipes, and a reinforcing plate shall be
welded to the pipe with a tapped hole in it. A screwed stainless steel plug
shall be provided to close the hole.
The welding shall be checked by ultrasonic testing for all length, i.e. 100 %
testing at the factory. Additionally, 10% of the joints shall be tested by
radiography. All specials shall be tested 100% by radiography.
2.7.1 Testing Of Weld Coupons
Test pieces shall be provided by the Contractor for both longitudinal

and circumferential welded joints at the positions pointed out by the
Employer. The sample so taken out shall then be cut to the exact
shape and dimensions and machined as described in relevant
PAGE 33 OF 161
670 of 2461
MMRDA
standards before testing for chemical and mechanical properties.
The entire cost of the tests including provision of test samples,

machining the test pieces, transport to and from the laboratory and
testing them in a laboratory, payment of all testing fees, cleaning and
painting shall be borne by the Contractor. The tests shall be carried out
in an Institute approved by Employer. This shall be arranged by the
Contractor with the approval of Employer. The testing laboratory shall
have instruments/equipment, which are having calibration requirements
traceable to National or International standards.
The following tests shall be carried out:
2.7.1.1
Mechanical Tests
The test plates shall be subjected to all mechanical tests

as per the approved Method Statement, or as otherwise
reasonably directed by the Employer. Tests shall be
carried out in accordance with relevant standards. The
tests shall include determination of yield strength, tensile
strength, elongation and bend tests. Tensile tests shall be
carried out in accordance with IS 1894. One test plate
shall be provided for from each lot of 100 lengths.
If a test specimen shows defective machining or develops

flaws not associated with welding, it may be discarded
and another specimen submitted. The welded joint shall
exhibit mechanical and chemical properties not lower
than those specified for IS 2062 Grade B.
Guided Bend test shall be in accordance with IS 3589 / IS

3600. One bend test shall be carried out from each lot of
50 lengths.
2.7.1.2
Field Joints
PAGE 34 OF 161
671 of 2461
MMRDA
The field welded joints shall be tested in accordance with

the procedure laid down in IS 3600. One test plate shall
be taken for every 1 km and shall be subjected to
mechanical and chemical tests as specified above.
2.7.2 Re-Tests
If the results of tests of any lot do not conform to the requirements

specified, retests of two additional specimens from the same lot shall
be made, each of which shall conform to the required specifications. In
case of a failure of one or both, gouging and repairing shall be carried
out to the particular lot of joints from which the samples have been
taken as directed by the Employer before the lot can be accepted. The
rectification process also shall have adequate test plates and they shall
be tested for compliance with the IS codes/standards.
In case both the samples yield satisfactory results in the re-test

described above, gouging and repairing will be required to be carried
out on the joint which has failed in the initial test only.
2.7.3 Testing of Welded Joints
2.7.3.1
Radiography of Joints
As soon as practicable after welding is done, selected

longitudinal and circumferential weld lengths shall be
radio-graphed to detect welding defects as per the
requirement of IS 4853 and as directed by Employer. If
the results of such radiography fail to conform to the
requirements, the Contractor shall carry out radiography
test for the pipe welding at the factory as well as the Site
as directed to the satisfaction of the Employer. All welding
up to 30 cm from edge of the pipe shall be subject to
check by radiography.
PAGE 35 OF 161
672 of 2461
MMRDA
Weld ripples or weld surface irregularities and slag, etc.,

on both inside and outside shall be removed by any
suitable mechanical process to a degree such that the
resulting radiographic contact due to any remaining
irregularities cannot mask or be confused with that of any
objectionable defect. The radiograph shall be made in
strict accordance with the latest requirements and as per
the latest and most efficient technique, either with X-ray
or gamma ray equipment. The safety requirements during
radiography shall be in accordance with IS 2598.
The radiographs are to be marked in such a way that the

corresponding portion of the welded seam and the welder
can be readily identified. All radiographs will be reviewed
by the Employer to identify the defects and determine
those which requires rectification. Defects that are not
acceptable shall be removed by chipping, grinding or
flame gouging to sound metal and the resulting cavities
shall be welded. After rectification, the joint is to be radiographed again to prove the quality of the repair. The
radiographs will be judged as acceptable or unacceptable
by the Employer based on the latest standards prescribed
by the relevant Indian standard specification.
All X-rays shall be taken with equipment and by

personnel of the Contractor. Films shall be developed
within 24 hours of exposure and be readily accessible at
all times for inspection by the Employer. The Contractor
shall provide, for the use of the Employer, suitable X-ray
viewing
equipment.
X-ray
films
shall
be
properly
maintained by the Contractor. A complete set of

radiographs and records as described in IS: 2595, for
each job shall be retained by the Contractor and shall be
handed over to the Employer on completion of the
PAGE 36 OF 161
673 of 2461
MMRDA
Contract. All films shall be identified by the number and

chart prepared indicating location of any work associated
with the pipe erection and such inspection shall be
performed by the Radiographer at the discretion of the
Employer.
2.7.3.1.1
Radiographic Inspection of Welded Joints
All welded joints to be radio graphed shall be examined in

accordance with
IS 2595 -Code of Practice for Radiographic Testing
IS 4853-
Recommended Practice for Radiographic
Examination of Fusion Welded Butt-Joints in Steel Pipes
IS 1182-
Recommended Practice for Radiographic
Examination of Fusion Welded Butt- Joints in Steel

Plates.
IS 2598 -Safety Code for Industrial Radiographic

Practice.
Sections of welds that are shown by radiography to have

any of the following types of imperfections shall be judged
unacceptable and shall be repaired.
(i)
Any type of crack or zone of incomplete fusion or

penetration.
(ii)
Any elongated slag inclusion which has length

greater than 6 mm ,any group of slag inclusion in
line that have an aggregate length greater than 12
times the thickness, except when the distance
between the successive imperfections exceeds 6 L
PAGE 37 OF 161
674 of 2461
MMRDA
where L is the length of the longest imperfection in

the group.
2.7.3.2
Ultrasonic Testing of Welded Joints
All welded joints shall be tested by Ultrasonic Testing

method and it should be in accordance with:
IS 7343
Code of practice for ultrasonic testing of

ferrous welded pipes and tubular products
IS 3664
Code of practice for ultrasonic pulse echo

testing by contact and immersion methods
IS: 2417
Glossary of terms relating to ultrasonic

testing (First revision)
IS: 4904
Specification
for
reference
blocks
for
calibration of ultrasonic flaw detectors (first

revision)
IS: 9346
Code of practice for qualification and

certification of NDT personnel for ultrasonic
examination
Prior to testing of the actual job, the performance

characteristics of the ultrasonic equipment and the search
units shall be assessed by using the calibration block as
per IS: 4904. Testing shall be done in an area reasonably
free from mechanical vibrations or electrical disturbances
that may interfere with the proper functioning of the
equipment. The equipment should not be unduly exposed
to hostile environments like hot and dusty atmosphere.
The couplant shall not run too fast and should not be
corrosive or toxic. It should be homogeneous, free from
air bubbles and solid particles.
All the essential details of the test data recorded including

test results and the test set up required for duplicating the
PAGE 38 OF 161
675 of 2461
MMRDA
test shall be included in the report.
2.7.4 Pipe Testing in Fabrication Shop (Factory Test)
A hydraulic test shall be carried out at the fabrication shop for each
pipe length fabricated, in the presence of and to the satisfaction of the
Employer. All pipes and specials shall be subjected to hydraulic test at
the fabrication yard after fabrication, but before application of protective
coatings.
Prior to testing, the pipe shall be inspected thoroughly and all the
apparent defects in welding such as slag, porosity, etc., shall be
repaired by gouging and re-welding. Each pipe shall be filled with water
slowly and the pressure increased uniformly until the required test
pressure is reached. The test pressure shall be as stipulated in IS
5504.
Each pipe to be tested shall be given a unique serial number, and shall
be painted with details such as the pipe number, shell thickness,
diameter, length, date of fabrication, etc., as directed by Employer. It
shall be entered in the register to be maintained by the Contractor. The
register shall be maintained in suitable format giving the following
information for each shell tested:
Serial No.
Pipe No.
Date of test
Specification and thickness of steel
Weight of pipe shell tested
Maximum test pressure
Details of test performance
Details of radiographic examination of welds
Name of Employer witnessing tests
A copy of these details shall be furnished to the Employer.

PAGE 39 OF 161
676 of 2461
MMRDA
For indicating the pressure inside the pipe an accurate pressure gauge
of approved make duly tested and calibrated for the accuracy of
readings shall be mounted on one of the closures, which close the pipe
ends.
The pressure shall be applied gradually by approved means and shall

be maintained for at least 2 minutes or till the inspection of all welded
joints is done during which time the pipe shall be hammered throughout
its length with sharp blows by means of a 1 kg hand hammer.
The pipe shall withstand the test without showing any sign of
weakness, leakage, oozing or sweating. If any leak or sweating is
observed in the welded joints, the same shall be repaired by gouging
and re-welding after dewatering the pipe. The repaired pipe shall be retested to conform to the specified pressure.
If any leak or sweating is observed in pipe shell the pipe under test
shall be rejected temporarily. The Contractor shall stack such rejected
pipes separately in his yard. The Employer shall inspect the same,
shall determine the nature of repairs to be carried out, and shall be
supplied with two copies of the results of all the tests carried out. The
repaired pipe shall be re-tested to conform to the specified pressure.
The external coating of pipes to be done in factory shall be done after

the successful hydraulic testing.
2.7.5 Marking
The marking shall be done after internal and external coating of the
pipeline.
All pipes and specials shall bear the following markings. The marking
shall be on the side which will be the inside of the pipe. On the specials
the direction of flow shall be stamped in a prominent manner.
PAGE 40 OF 161
677 of 2461
MMRDA
Outside diameter (mm)
Length of pipe/angle of the bend (m/degrees)
Plate thickness (mm)
Approximate weight of the pipe/special (Tons)
Internal lining: Material and thickness
External coating: Material and thickness
2.7.6 Stress Relieving
Stresses developed during fabrication of flange rings of above 40 mm

thickness due to gas cutting and welding in segments shall have to be
relieved for smooth functioning of the same after installing in the pipe
laying works.
Stress relieving shall be done as per IS 2825 Clause 6.12.3 and ASME
sec VIII, by resorting to the following process and the chart shall be
submitted in proof of this process.
The flange rings shall be put into the furnace and gradually heated up
to the temperature of 600 C at the rate of 100 C per hour. This
temperature of 600 C shall be maintained for a period in hours
obtained by dividing the thickness of flange ring in mm by 25.
The temperature shall be cooled down at the rate of 100 C per hour till
it reaches 300 C. After this the flange rings shall be taken out from the
furnace and allowed to cool down to the room temperature under
atmospheric temperature. No water or any liquid shall be poured on the
flange rings during the entire process.
2.7.7 Joints
2.7.7.1
General
Unless detailed otherwise, all pipes and fittings shall have

PAGE 41 OF 161
678 of 2461
MMRDA
welded joints. However, as necessary flanged joints or

collar sleeve joints shall be provided.
2.7.7.2
Welded Joints
The use of butt welded joints for joining pipes and end
preparation shall be in accordance with IS 3589.
2.7.7.3
Sleeve Collar Joints
The use of sleeve collars shall generally be limited to the

jointing of pipes at tie-ins. The thickness of the external
steel sleeve collar shall be not less than that of the pipe
itself and the length a minimum of 300 mm. The sleeve
shall be joined to the pipe with an internal full depth
structural weld and external sealing welds to allow the
joint to be gas tested. A gas testing hole shall be made at
each end of the sleeve and for the purpose of gas testing
the joints.
2.7.7.4
Flanged Joints
The nominal pressure rating shall be at least equal to the

highest pressure rating of the pipes or fittings to which
they are attached. The Contractor shall fabricate flanges
meeting the requirements of pipe sizes under this
Contract or otherwise to suit the abutting valves or other
connections, if they are not readily available. Flanges
shall be provided with all necessary nuts, bolts, washers
and gaskets, as specified herein. The Contractor shall
also apply graphite grease to the bolt threads when joints
are made.
2.7.7.5
Expansion Joints
PAGE 42 OF 161
679 of 2461
MMRDA
Expansion joints shall be provided for "all pipe lengths laid

above m shall be limited to the distance between two
consecutive bends or 300 meters, whichever is less. These
joints shall be equal to the internal diameter of the pipeline.
2.7.8 Storage
Before sending the pipes to the Contractor's storage yard, the exposed
portion of the pipe (i.e., internal surface and portion where coating is
not done) shall be cleaned with wire brush.
Pipes and fittings shall be stored raised off the ground and shall be
carefully supported, cushioned and wedged. Special care shall be
taken to ensure that steel pipes are cradled and supported in a manner
that prevents any distortion of the pipes and coatings.
The pipes shall be kept protected from the direct sunrays in factory. All
pipes shall be laid within 6 weeks of the shifting them to the laying Site.
All gaskets, nuts and bolts flange adapters and other similar items shall
be stored in dry conditions, raised off the ground in sheds or covered
areas.
Until required for incorporation in the Works, each rubber ring or gasket
shall be stored away from direct sunrays, electrical equipment and
other materials like oil and chemicals and also from heat and cold.
Where items require special storage requirements, the method of

storage shall be to the approval of Employer and in accordance with
manufacturer's requirements.
Storage areas shall be set out to facilitate unloading, loading and

checking of materials.
All pipe materials shall be inspected when deposited in the storage

PAGE 43 OF 161
680 of 2461
MMRDA
area and any defects or damage shall be noted and reported to the
Employer. The pipe material shall only be repaired with the Employers
approval.
End covers and other protection shall not be removed until the pipes or
fittings are incorporated into the Works.
2.7.9 Transportation and Handling
All pipes and specials fabricated in the yard and temporarily stacked in
the factory shall be transported carefully to the site of laying after
internal cleaning.
Any vehicles on which pipes are transported shall have a body of such
length that the pipes do not overhang. Large pipes shall be placed on
cradles and the loads properly secured during transit.
Additional precautions shall be taken to avoid deformation of flexible

pipes lining and coating. To maintain their circular cross-section
fraternal struts shall be fitted in the pipes. Details of the proposed
strutting system shall be submitted to the Employer for approval and, if
required by the Employer, the method of strutting shall be
demonstrated and tested on site.
The pipes and specials shall be handled in such a manner so as not to

distort their circularity or cause any damage to their coating. Wide nonabrasive or other approved slings shall be used and all hooks other
metal devices shall be well padded. Hooks engaged on the corner wall
surface at pipe ends shall not be used. Steadying ropes shall be
employed. The positions of lifting slings shall ensure that stresses and
tendency towards deformation in the pipes are kept to a minimum.
Pipes shall be unloaded on timber skids with steadying ropes or by any
other means. Padding shall be provided between coated pipes, fittings/
specials and timber skids to avoid damage to the coating. As far as
possible, pipes shall be unloaded on one side of the trench only.
PAGE 44 OF 161
681 of 2461
MMRDA
Pipe handling equipment shall be maintained in good condition and any

equipment, which in the opinion of the Employer may cause damage to
the pipes, shall be discarded.
Under no circumstances shall pipes be dropped, be allowed to strike

one another, be rolled freely or dragged along the ground.
No valves shall be lifted by the spindle.
Fabricated materials such as man-hole covers, appurtenances, bolts,

nuts, flanges, saddles, collars, bypass arrangements, etc., shall be
transported to the site of laying from the fabrication yard according to
needs of the laying operations only.
2.8
Pipeline Construction
2.8.1 General
Laying / erection of fabricated pipe lengths shall be carried out by the

Contractor who shall equip himself with all necessary tools, machinery,
labor, etc., required for the purpose. The pipeline shall be constructed
in lengths with a separate full-time gang working on each length.
Except for routine welding of joints, no other work shall be done in the
absence of the Employers Field Engineer.
The components of the exposed sections of the pipeline such as plates

and pedestals have been so designed that the centers of the plates
and pedestals shall coincide at the mean temperature of the locality.
For this reason, all works such as fixing flanges, plates, etc., in true
alignment and in correct position and tack welding of the pipes shall be
done at the mean temperature. For ascertaining the temperature, the
Contractor shall provide mercury cups and fix them to the pipe shell
from outside and shall also provide thermometers of the required type
and range.
PAGE 45 OF 161
682 of 2461
MMRDA
The Contractor shall also provide pressure gauge off takes at important
locations such as immediately after pumps, at summits, at valleys etc.,
as approved by Employer.
2.8.2 Contractor to Resurvey the Pipeline Route
While setting up the site the Contractor shall conduct a survey of the
entire pipeline route with total station and compare this with the survey
data supplied at the time of tender. Contractor shall be responsible for
checking the correctness of the data supplied and all further
Engineering and construction will be based on this data. Levels are to
be taken at 30 m intervals and at any sharp changes in level and,
where practical, the chainage points shall coincide with the original
surveys. The Contractor shall supply two hard copies and one
computer disc copy of the survey to the Employer at least 28 days
before commencing pipe laying. The Contractor shall also identify any
discrepancy that requires attention not less than 28 days before
commencement of work on the affected section, and inform the
Employer accordingly.
2.8.2.1
Topographical Surveys
The Contractor shall finalize the correct alignment of the

proposed pipeline and road and fix the location and type
of CD works, pipe crossing structures, thrust blocks,
anchor blocks, air valves, sluice valves, butterfly valves,
scour valves, etc. In addition to these, surveys are also
required for construction of required structures and other
works such as realignment and grading of existing roads
to be crossed, restoration of existing canals likely to be
damaged during laying, determination of the scour depth
of river/ nallah, etc.
The surveys to be done must be able to determine the

PAGE 46 OF 161
683 of 2461
MMRDA
following but shall not be limited to:
Provide detailed plan and L-sections of the

proposed pipeline
Provide
detailed
plan,
L-section
and
cross
sectional details of the proposed road
The design parameters for design of all CD

structures, e.g. scour depth, slope of river/nallah,
high flood level discharge, etc.
To design the structures and to make working

drawings of all cross drainage and pipe crossing
structures along the alignment
The L-section and the alignment plan must be given in a

width of at least 40 meters with cross sections at every 30
meters. The Contractor shall follow the same pipeline
alignment, as far possible, as given in the tender drawing
unless there is any specific site condition which requires
modifying the alignment, as approved by the Employer.
The alignment survey as carried out by the Contractor
has to be got approved from the Employer, before
implementation. The following features and details are to
be shown on the alignment plan.
(i)
Important land marks along / across the alignment,

km stones with indications, existing and new
benchmarks, RD, line of L Section, L-section of
center
line
of
proposed
road,
sketch
of
benchmarks, the two edges of land acquired or

proposed to be acquired at every cross section,
the location of proposed and existing cross
drainage structures, location of thrust/anchor
PAGE 47 OF 161
684 of 2461
MMRDA
blocks, location of sluice/air/scour valves, etc.
(ii)
Type of existing roads (metalled, unmetalled),

borders of the road, side roads.
(iii)
Orientation (names and directions to towns,

villages).
(iv)
River / nalla / canal /creek/ tank crossing, quarry

zones, kilns.
(v)
Zones of water logging, high groundwater level.
(vi)
Forest areas, wild life sanctuaries, zones under

agriculture.
(vii)
Any
solid
structures,
buildings,
important
administrative buildings.
(viii)
Villages / hamlets / settlements en route.
(ix)
Posts
of
electrical
transmission
lines
and
telephone lines, water supply pipes.
(x)
The final location of the proposed pumping

stations and off-take points.
The survey for this alignment, with reference to

permanent
G.T.S.
benchmarks,
has
to
be
made
according to the following:
Detailed leveling with levels at closer intervals in

case
of
sections
of
particular
interest
and
importance for the hydraulic and technical design

(depressions, peaks, villages, and irregular terrain)
PAGE 48 OF 161
685 of 2461
MMRDA
Establishing temporary benchmarks of concrete

with a steel bolt on top along the alignment at
every 1 km or at important points
The alignment survey to be carried out with double

traverse with closing fly back leveling
2.8.2.2
Submissions
The Contractor shall prepare and submit the following:
Longitudinal
sections
(L
Sections)and
the
alignment plans in 3 copies along with a softcopy

in CD
For the comprehensive overview of the stretch, at

a scale of 1:25,000, on A0 size drawing
Working L-sections to be used on the site, at a

scale so that a maximum 1.0 km stretch is covered
on one drawing. The drawing shall be of A1 size
Survey field books and notebooks
The comprehensive L-section has to be available for the

detailed design of the pipeline. The following general
criteria must be adhered while preparing the plan and Lsection of the pipeline:
The alignment shall be kept within the acquired

strip of land
Wherever feasible, the pipeline shall be kept below

ground or, if laid partly above ground, must be
PAGE 49 OF 161
686 of 2461
MMRDA
covered with soil. The pipes laid below ground or

with soil cover must have a minimum cover of 1.50
m on ZP route and 2.0m on Highway route
Wherever the pipeline is to cross existing pipelines, the

Contractor shall take necessary permissions of the
required authorities and lay the pipeline accordingly with
all required structures. The Employer shall provide
assistance to the extent possible to obtain such
permission.
The laying of pipes must not obstruct the flow of water in

the natural drains. The pipe must cross the drains either
from below the scour level or above the high flood level. If
crossed above the bed level, appropriate structures at
support and in between the nallah/ drain/ nallah/ river
must be provided with MS pipe in the exposed section.
The structure must be protected by suitably planned river
training works. If laid below ground, it must have sufficient
cover without changing the existing grade of the nallah/
river/ canal. The pipeline shall also have concrete cover
or anchors in this portion. In areas where the pipeline is
laid below canal bed levels, the damaged portions of the
embankment and the bed must be restored with proper
compaction and the canal bed and sides must be lined
with CC of approved thickness in at least a length of 60
meters along the U/S and D/S portions.
Wherever the pipeline is laid with an embankment, the

embankment must not create ponding of water. If the
conditions are unavoidable, suitable CD works must be
provided.
The drawings shall show the GL, invert level of pipe,

depth of cutting / filling, H.G.L., design working pressure
PAGE 50 OF 161
687 of 2461
MMRDA
in pipes, pipe rating and thickness, type of structures for

crossing rivers/canals/ nallah, etc. and be submitted for
approval by the Employer. They also have to show the
proposed locations of butterfly valves, air valves, scour
valves, flow meters and specials and the proposed
locations and types of the water hammer control devices.
2.8.2.3
Soil Investigations and Geo-technical Investigations
The Contractor has to determine at each proposed, thrust

block/anchor block/pipe support structure/cross drainage
structure, etc., the soil characteristics (angle of friction,
cohesion) in order to design them. It is important to
assess the potential of erosion and the stability of the soil
with a view to the lateral resistance to be taken into
account
The Contractor has to check the correctness of data

given in the tender document and carry out all necessary
technical investigations such as:
The ground water levels along the alignment
The type of soil
The depth of rock
Soil corrosiveness
Chemical properties
Bearing capacity where essential
Soil Resistivity
PAGE 51 OF 161
688 of 2461
MMRDA
Any other investigations as may be necessary
The results of the investigations and the calculations

have to be presented in a report in three copies to the
Employer for approval. The execution of the civil
construction shall be started only after approval of the
construction, design and drawings by the Employer.
2.8.3 Bench Mark
Permanent bench marks, at least one per kilometer, and temporary

bench marks for at least four in every kilometer, shall be fixed before
any work is started by the Contractor in any section. These
benchmarks shall be established away from the field of work so as not
to be disturbed during the execution and shall be securely fixed in
concrete.
2.9
Pipe Laying
Pipes shall be laid in accordance with IS 5822 unless otherwise specified

herein.
The pipeline shall be constructed in lengths with separate full-time gangs

working on each length. The work on lengths may proceed concurrently.
Excavation for the pipeline in any one length shall not at any time proceed
more than 2 km beyond the end of a hydraulically tested, completed and
backfilled length of pipe, unless otherwise approved by the Employer. The
exposed joints between tested sections shall be disregarded in the above
definition.
No metal tools or heavy objects shall be permitted to come into contact with
the pipes or fittings. External coated pipe shall be handled at all times with
wide non-abrasive canvas, rubber or leather straps or other equipment to
prevent damage to the coating. The use of chains, wire slings, or any other
handling equipment found to be injurious to the coating shall not be permitted.
PAGE 52 OF 161
689 of 2461
MMRDA
The timber or skids used to support the coated pipe prior to lowering into the
trench shall be properly padded with sufficient bags stuffed with sand or straw
for the purpose of protecting the coating. Alternatively, the pipe may be
supported alongside the trench on mounds of sand. Any injury to the
protective coating from any cause must be repaired before the pipes or fittings
are placed in the trench. During laying operations, no debris, tools cloth or
other material shall be placed in the pipe. Pipes and fittings shall be lowered
into the trench with equipment suitable for the weight of the pipes and fittings,
and they shall be carefully cleaned before jointing.
Pipes shall be laid accurately to the lines and levels shown on the approved
drawings, within a tolerance of +/-30mm.
Pipe alignments shall be straight between bends or curves. Length laid to

curves shall only be allowed where shown on the drawings or in accordance
with detailed proposals approved by the Employer.
The leveling instruments shall be used for fixing and maintaining the proper
pipe alignment and grade.
The joining of pipes shall be made in accordance with the requirements of

these Specifications. The Contractor shall obtain, from manufacturers, all
special information regarding the handling of the pipes, joints and other fittings
and he will be deemed to have made himself thoroughly conversant with all
phases of pipe laying before commencing the works.
A "badger" or "bung" about 10 mm smaller than the internal diameter of the

pipe shall be kept in the pipe at all times, pulled forward as the work
progresses. When pipe laying is not in progress, including overnight, the open
ends of the pipeline shall be blanked off with a temporary watertight fitting
approved by the Employer. The pipe shall be suitably held down so that the
pipe does not become buoyant in the event of the trench becoming flooded.
To restrict the flow of rain runoff along the trench the Contractor shall plug the
trench with backfill material at distances not exceeding 250 m until the
PAGE 53 OF 161
690 of 2461
MMRDA
pipeline can be filled in. The plugs shall be removed when trench filling is
taking place. In granular bedding areas the plugs shall be of clay and shall be
left in.
2.9.1 Level Control
The criterion for the level to which the transmission main shall be laid
shall be such that the clear cover above the crown of the pipe to
ground level shall be as specified, but in no case shall be less than 1.5
m unless otherwise approved by Employer.
2.9.2 Laying to Curves
Specially fabricated bends shall be provided for all curves, designed in

such a manner so that the curves can be negotiated as gradually as
possible, considering the conditions at the Site.
2.9.3 Lowering and Jointing
While assembling the pipes, the ends shall have to be brought close
enough to leave a uniform gap not exceeding 4 mm. There shall be no
lateral displacement between the pipe faces to be joined. If necessary,
spiders from inside and tightening rings from outside or other suitable
equipment shall be used to bring the two ends in perfect contact and
alignment. In no case shall hammering or longitudinal slitting be
permitted. Jacking may be permitted for this purpose in particular
circumstances, with prior approval of the Employer.
When the pipe is properly assembled and firmly supported on wooden

beams and wedges or by other approved means it shall be checked for
correct line and level and tack welded. The tack welded circumferential
joints shall then be welded fully.
On completion of the pipe jointing the external portion shall be coated

and the trench and the welding pits shall be cleaned. The welding pit
PAGE 54 OF 161
691 of 2461
MMRDA
shall be filled with approved bedding material and compacted in 150

mm layers.
The welding of pipes in the field should comply with IS 816 and
electrode used should comply with IS 814.Welded joints shall be tested
in accordance with procedures laid down in IS 3600 and one test
specimen shall be taken from at least one field joint out of 10.
2.9.4 Floatation
When pipeline laid underground or above ground in a long narrow

cutting gets submerged in water collected in the trench or cutting, it is
subjected to an uplift pressure due to buoyancy and is likely to float, if
completely or partly empty. In the design of pipelines, provision is to be
made to safeguard against flotation by providing sufficient overburden
or by providing sufficient dead weight/anchors.
The Contractor shall take proper precautions against the risks of

floatation and of flooding of the excavated works and shall make due
allowance in his program for any closure he considers necessary on
account of monsoon.
Should any section of the pipeline be affected by floatation in the

course of works the entire work shall be removed and then reinstalled
to the satisfaction of Employer. The entire cost of laying it again to the
correct line and level shall be to the Contractor's account.
The pipes laid are to be tested hydraulically and will therefore have to
be filled with water. Ensuring that the pipes laid are kept full of water as
far as possible after laying is one of the best safety measure against
uplift. The contractor should therefore make all efforts to do the
hydraulic testing immediately after laying of the pipe. In any case the
contractor should ensure that the lines laid in depressions are filled
with water also apart from proper cover.
PAGE 55 OF 161
692 of 2461
MMRDA
2.9.5 Steel Props
It is necessary that the roundness of the pipes is maintained circular till

the lining work is taken up. To achieve this, steel adjustable screw type
props or similar approved type consisting of minimum six legs (three
props) shall be fixed inside the pipe and the diameter correctly set.
The design and drawings of the props that the Contractor intends to
use shall be approved by the Employer before starting the work. These
props shall be fixed vertically at intervals as directed by the Employer.
The props shall be kept in position for at least three days after the
encasing of the pipe in that section is completed or until refilling is
completed to the full height of fill over the pipe in case the pipes are not
encased. The props shall be removed only after obtaining permission
from the Employer.
2.9.6 Above Ground Pipelines
Pipes shall be laid in accordance with IS 5822 unless otherwise

specified herein. Before commencing the work the Contractor shall
submit the working drawing of the stretch of pipeline laying. The
Contractor shall study the approved L-section of the pipeline for the
section concerned. He shall also study the details of the type of
saddles/ concrete pedestals to be provided before the actual work of
casting is taken in hand.
Before execution the Contractor shall submit detailed designs and

drawings for all supports such as portal frames, saddles, ring girders,
etc, approval of the Employer.
Pipe laying above ground shall generally start from the fixidity points on
either side, the expansion joints provided in the last. Fixing points are
at all anchor blocks. Where such blocks are not required for fixidity
shall be achieved by fixing the pipeline to the special type of RCC or
steel saddles / concrete pedestals/chairs. The Double wearing plates
PAGE 56 OF 161
693 of 2461
MMRDA
shall be provided at each saddle / pedestal / chair, one wearing plate

anchored on to the concrete support and second wearing plate welded
to pipe resting on support. Width of wearing plate on pipe shall be
larger than saddle wearing plate by 100 mm on each side. Curvatures
of both wearing plate shall match and grease shall be applied between
two plates.
Anchor blocks shall be constructed before commencing the pipe laying

work in any section. The construction of the blocks shall be carried out
in 3 Phases. In the first Phase the lower part up to 150 mm below the
invert of the pipeline including concrete chairs to support it shall be
constructed; in the second Phase the pipeline on this part of the block
shall be laid; and lastly, the remaining block around and over the
pipeline shall be constructed.
The fixidity saddles concrete pedestals and ordinary saddles concrete

pedestals shall be cast-at least 3 weeks before the pipeline is laid on
them. After all saddles/ concrete pedestals between successive fixidity
points have been cast, a line plan showing the actual position thereof
shall be prepared, after taking levels and measuring distances. In case
of any errors in casting the pedestals, necessary corrections shall be
made. The pipe laying work shall then start from the fixidity points and
shall proceed towards the expansion joints. The method of jointing the
pipes and erecting them on previously cast RCC saddles/ concrete
pedestals shall be determined by the Contractor depending upon the
type of plant, equipment and personnel available with him.
The pipe strakes shall be assembled in position on the saddles/

concrete pedestals either by cranes, portable gantries, shear legs or
any other equipment approved by the Employer. Normally, not more
than two pipes shall be aligned, tacked and kept in position on
temporary supports. The Contractor shall not proceed with further work
until the circumferential joints of these pipes are fully welded.
During assembly, the pipeline shall be supported on wooden sleepers

PAGE 57 OF 161
694 of 2461
MMRDA
and wedges, with the free end of the pipeline held in position by slings
to avoid deflection due to temperature variations during the day. In
general, the assembly of pipe stretches and one run of welding shall be
done during the day time, while full welding including the external
gouging and sealing runs shall be done after 5 p.m. or as directed by
Employer. The Contractor shall maintain the continuity of the work by
adding at least two more pipes on the second day in a similar manner,
after full welding of the previous joints is completed during the evening.
While this new work is being done, the Contractor shall proceed with
the work of providing permanent supports for the pipeline assembled
and welded previously.
The procedure for handling the pipes, lowering and assembling

specified in previous clauses shall be followed for lifting and laying
pipes on supports. The pipeline should be laid either on saddle or ring
girder supports or as per approved design and Drawings. No material
shall be erected unless it has been previously approved by the
Employer.
Erection of fabricated pipes shall be carried out by the Contractor who

shall equip himself with all necessary tools, machinery, labor, etc.,
required for the purpose. The pipeline shall be constructed in lengths
with a separate full-time gang working on each length.
Except for routine welding of joints, no other work shall be done in the
absence of Employer, either during the day time or at night.
The pipe shall be assembled in position on the pedestal by the

equipment approved by the Employer.
2.9.6.1
Ring Girders and Ring Girder Supports
All above ground, steel pipelines shall be provided with

ring girder supports upon RCC pedestals either on
prepared formation or on piers. The ring girder channel
PAGE 58 OF 161
695 of 2461
MMRDA
shall be assembled at the correct position on the R.G.

strake as directed and tack welded in the factory, care
being taken to ensure that the center of the ring girder is
at least half a meter away from the circumferential joint.
The ring girder support shall consist of the following:-
a)
Ring Girders
A ring girder shall consist of a rolled steel section

such as a channel, etc., reinforced or strengthened
by steel flats or plates, as per approved design.
The MS channel shall be rolled to the exact
curvature, taking due care to see that there is no
distortion whatsoever in any direction or in any of
the dimensions thereof. In channels, extra pieces
of channels may be welded before commencing
the rolling. In case channel sections of the required
size are not available, the Contractor shall have to
fabricate the required section out of plates, angles,
flats, etc., as per detailed drawings and details
approved by the Employer.
b)
Stools
Stools shall be fabricated from MS Channels

and/or flats as per the approved design. For
fabrication of stools and specials, jigs shall be
made to ensure that no deformation takes place
during welding. Stools shall be stacked properly in
the Contractors yard until they are taken to pipe
laying site. If any of the stools are found to have
lost shape and/or developed any other fault, while
they are stacked or during handling inside the
yard, the Contractor shall carry out necessary
repairs to rectify the defects before transporting
PAGE 59 OF 161
696 of 2461
MMRDA
them to the site.
c)
Rollers
Rollers shall be used at all supports, except fixity

and end supports. The pipeline shall be designed
assuming a coefficient of friction as approved by
the Employer. The rollers shall, therefore, be
straight, accurately machined, clean, and free from
any rust or stain or incrustation. The grooves and
surfaces of rollers shall be formed by accurate
machining. The rollers should be assembled to
form a set, as shown in the drawings. After
assembly, the rollers shall be oiled and stacked
carefully, in their yards by the Contractor, till
delivery of the same is taken to the pipe laying
site.
d)
Base Plates
Base plates shall be cut from MS flats or MS plates

to the approved dimensions. They shall have
slotted holes, guide bars for rollers, etc., as shown
in the drawing. The top surfaces shall be ground
and machined to obtain an even surface. They
shall be oiled and stacked under cover in the
Contractors yard until their delivery to the pipe
laying site.
e)
Bolts for Ordinary and Fixity Supports
For fixity supports, the Contractor shall provide

galvanized bolts. These are to be fixed in the
pedestal columns while casting the pedestals. For
roller supports, the Contractor shall provide
PAGE 60 OF 161
697 of 2461
MMRDA
galvanized ragged bolts. These will be grouted in

position in the pedestal columns at the time of
casting the same during laying operation. The
Contractor shall fabricate both types of bolts from
the steel materials such as bars and rounds,
procured by the Contractor under the Contract.
The fabricated bolts shall be hot dip galvanized
and stacked separately in the Contractors yard
until transported to the pipe laying site.
f)
Grease Box Covers
To protect the roller bearings from the effects of

weather and to prevent entry of dust, dirt, grit, etc.,
grease box covers shall be provided. These shall
be fabricated in halves by the Contractor from MS
plates or black sheets. If it is necessary to weld the
grease boxes, gas welding shall be resorted to.
The grease box covers shall be staked in the
Contractors yard under the shed until transported
to the pipe laying site. MS sheets or black sheets
in coils can be used for fabrication of grease box
covers. The Contractor shall have to straighten the
same at the time of fabrication.
2.9.7 Buried Pipelines
Before excavating the trench the alignment of pipeline shall be

approved by Employer. The work of trench excavation should be
commensurate with laying and jointing of the pipeline. It should not be
dug in advance for a length greater than 3 days ahead of the work of
laying and jointing of the pipeline unless otherwise directed by the
Employer. It is proposed to ensure the following:
Safety precautions are to be incorporated in the work process.

PAGE 61 OF 161
698 of 2461
MMRDA
Hindrances to the public are to be minimized.
In agricultural areas, the topsoil is to be carefully removed from the

working area and separately stockpiled before excavation commences,
and replaced and graded over the working area during final cleanup
and restoration.
The trench shall not be allowed to erode
The trench must not be filled with water
The trench must not be refilled before laying of the pipes
Shuttering/formwork shall be provided wherever necessary
The bed for the laying of the pipes has to be prepared according
to the approved
L-section immediately before laying of the
pipes
2.9.7.1
Trenching
Trenching includes all excavation which is carried out

either by hand or by machine and shall be carried out in
accordance with all general requirements. In addition to
these general requirements, the following requirements
shall apply to pipelines.
The width of the trench shall be kept to a minimum

consistent with the working space required and having
regard to the safety of the trench and the method of
laying and jointing the pipe and the need to avoid
damage to pipe coating. The bottom of the trench shall be
properly trimmed to permit even bedding of the pipeline.
The clearance between the sides and bottom of the
PAGE 62 OF 161
699 of 2461
MMRDA
trench and. the outer surface of the pipe shall be in

accordance with the limits prescribed below.
The
Contractor will be responsible to adhere to these limits,

and no extra payment will be made for any over
excavation beyond the prescribed limits, or for any
additional cost of providing bedding and backfill in the
over excavated areas.
Width of trench
D + 600 in
300 mm
mm
Bottom clearance below pipe
The clearance at joints of two pipes may be increased to

allow the welded joints to be made and inspected. When
welding is to be carried out with the pipe in the trench,
additional excavation of not more than 600 mm in depth
and 900 mm in length should be provided all round the
pipe at the position of the joints for facilities of welding.
For all trenches, proper stable slope shall be provided on

both sides of the trench for the excavation upto ground
level.
The Contractor shall erect temporary fencing around all

open excavations and post warning signs in the local
language and in English. The letters shall be in suitable
finish so as to illuminate in dark. All fencing shall be at
least 1 m tall, rigid in nature and strong enough to prevent
vehicle, people, livestock or other animals from falling into
the trench. In addition, foot barriers duly painted in white
paint shall be provided on traffic side of trench as
additional safety measure. The Contractor shall also take
all other necessary measures to ensure the safety of the
public and others.
PAGE 63 OF 161
700 of 2461
MMRDA
The maximum length of excavation that may be left open

in any length shall be 500 m. The opening of two lengths
within 500 m of each other shall require the approval of
the Employer.
The excavation shall be kept free of water to allow

placing of bedding, laying of pipes, welding of pipes,
inspection and testing of joints, coating of joints, placing
of backfill and other activities within the pipe trench to be
carried out in a satisfactory manner.
Pipe laying shall closely follow the progress of trench

excavation and the Contractor shall not permit excessive
lengths of trench excavation to remain open while
awaiting testing of the pipeline. If the Employer considers
that the Contractor is not complying with any of the
foregoing requirements, he may prohibit further trench
excavation until he is satisfied with the progress of laying
and testing of pipes and refilling of trenches.
2.9.7.2
Bedding
Bedding for the pipeline shall be of two different bases

depending on the soil strata or rock.
Tender drawing
provided by the Employer may please be referred.
The bedding and backfilling is divided in 3 zones as

under:
Zone I
From 300mm below bottom of pipe to the
level of D/4 of the center line of the pipe, thus enclosing

angle of sand bedding to 120 from centre of pipe.
Zone II:
From D/4 below the centre line of pipeline to a
PAGE 64 OF 161
701 of 2461
MMRDA
level of 300mm above the crown of the pipe.
Zone III:
From a level 300 mm above the crown of the
pipe to the top of the trench.
(a)
Zone I
Bedding in Ordinary Soil:
When soil strata in the trench is soil (other than

soft or hard rock),bedding shall be provided with
sand consolidated in layers not greater than 120
mm. The sand for bedding shall be clean, well
graded and free from topsoil, clay or vegetable
matter and to the approval of the Employer. The
bedding shall be done as under:
The filling and compaction shall be done up

to appropriate depth
The
bedding
optimum
shall
moisture
be
compacted,
content
and
at
by
mechanical equipment with suitably shaped

tamping feet/ plate, to 90% modified proctor
density
Bedding Rock:
When soil strata in the trench is rocky, or marshy

or consists of any unsuitable material which is
likely in the opinion of the Employer to cause
damage-to the pipe, then concrete base shall be
provided. The bedding shall consists of Concrete
base of 100 mm thickness of M15 of Portland or
Sulphate resisting cement followed with a layer of
PAGE 65 OF 161
702 of 2461
MMRDA
200mm height of sand consolidated in layers not

greater than 120mm. The sand bedding shall be
compacted, at optimum moisture content and by
mechanical means with suitable compactor to 90%
modified proctor density.
(b)
Zone II
Zone II shall be backfilled with granular graded

material
upto
maximum
10
mm
size
and
consolidated in layers not greater than 150 mm.

The bedding backfill shall be compacted at
optimum moisture content and by mechanical
means at each 150 mm thick layer with suitable
compactor to achieve 95% modified proctor
density.
Care shall be taken to ensure that mechanical

compacting equipment is not used in the zone
from the top of the pipe upto 300 mm above the
crown of the pipe.
(c)
Zone III
Backfilling Material
All backfill material shall be free from cinders,

ashes, slag, refuse, rubbish, vegetable or organic
materials, lumpy or frozen material, boulders,
rocks or stones or other material which in the
opinion
of
the
Employer
is
unsuitable
or
deleterious.
For backfilling in Zone III, excavated material

which is suitable for backfilling may be used with
PAGE 66 OF 161
703 of 2461
MMRDA
the prior approval of the Employer. The trench

shall
be
backfilled
with
selected
excavated
material free from topsoil and vegetation, or

boulders, clods of earth or stones larger than 75
mm in size.
All backfill material shall be placed in layers not

exceeding 250 mm and compacted by mechanical
means using equipment with suitably shaped feet/
plates. At the time of placing the backfill, the
Contractor shall ensure that the moisture content
is optimum so that the required degree of
compaction
is
achieved
with
compaction
equipment.
If necessary, the Contractor will be
required to add water to the backfill material in

such a manner so that the moisture content is
uniform throughout each layer during compaction.
The compaction shall be adequate to obtain 90%
modified proctor density.
Care shall be taken during backfilling not to injure

or disturb the pipes, joints or coating. Filling shall
be carried out simultaneously on both sides of the
pipes so that unequal pressure does not occur.
The Contractor will be responsible to ensure that

the water content of the soil shall be kept as near
the optimum moisture content as possible. Regular
measurement of the field dry density shall be taken
by the Contractor at various levels in the backfilling
as required by specifications and the Employer.
Any backfill which fails to achieve the required
degree of compaction shall be re-excavated,
replaced
and
re-compacted
to
the
required
density, all at the Contractor's cost.

PAGE 67 OF 161
704 of 2461
MMRDA
Walking or working on the completed pipeline shall

not be permitted unless the trench has been filled
with the specified bedding and backfilling up to
height of at least 300 mm over the top of the pipe
except as may be necessary for tamping, etc.,
during backfilling work.
The trench shall be refilled so as to build up to the

original ground level, keeping due allowance for
subsequent settlement likely to take place. The
surface of the refilled excavations shall be left
slightly higher than the adjacent ground and shall
be maintained by the Contractor to a smooth even
slope.
Should any subsidence take place either in the

filling of the trenches or near about it during the
works the Contractor shall make good the same at
his own cost. All the surplus excavated stuff
(including rock) will be disposed by making proper
arrangement for disposal of the same.
Field joints which have not been tested shall be left

exposed for a minimum length of 150 mm each
side of the joint, and the Contractor will be
responsible to provide all temporary shoring,
boxing, barricading, etc., for this purpose at no
additional
cost.
After
all
tests
have
been
successfully completed, the remaining backfill shall

be placed and compacted up to finished grade
level, all in accordance with the preceding
specifications.
PAGE 68 OF 161
705 of 2461
MMRDA
2.9.8 Encasement for Road Crossing/Nallah Crossing/Alignment falling in

road
Complete concrete encasement shall be provided to the pipe in case of

road crossing, nallah crossing, etc. Concrete used for this shall be of
M15 grade. Before placing concrete the pipes shall be supported near
each joint with a padding of compressive material on a pre-cast
concrete block. Concrete shall not be placed until the pipes have been
jointed, inspected and tested. The concrete shall be placed to ensure
full contact with the pipe barrel throughout its length. Necessary
reinforcement steel shall be provided as per the approved design and
site conditions. The concrete shall be made discontinuous at flexible
pipe joints by a diaphragm of fiber board or other compressible material
of at least 20 mm thickness extending for the full area of the surround.
No concrete shall be placed around joints of a welded steel pipe until

that length of pipe has passed a sectional hydraulic test.
2.9.9 Testing of Field Weld Joints
Upon completion of the field welding Non Destructive Tests i.e.,

Radiographic test for 10 percentage of the circumferential/longitudinal
welding and Ultrasonic Test for 100 percentage of the welding shall be
carried out. The tests shall be done as per IS 4853 and IS 7343
respectively.
2.10
Please refer the specification in erection, testing and commissioning.
2.11
Cement Mortar Lining
2.11.1.1
Inspection of Pipeline before Lining
The lining shall not be started until the Employer has inspected
PAGE 69 OF 161
706 of 2461
MMRDA
the cleaned pipeline and given his permission to start the lining
process. Any lining done without obtaining the prior permission
of the Employer shall be rejected and shall not be considered for
payment. The Contractor shall have to remove the same and
clean up the pipeline again at his risk and cost before such
portion is lined after any subsequent permission.
2.11.1.2
Determination of Lining Thickness
The lining thickness shall be determined on the freshly

centrifuged mortar at intervals frequent enough to assure
compliance. Thickness of lining may be determined by means of
a steel pin not larger than 1.5 mm in diameter, or on a hardened
mortar by means of a non-destructive measurement process.
The lining shall be measured at four equidistant points on two
cross sections of the barrel at each end of the pipe or fittings.
The first set shall be at least 200 mm from respective ends of the
pipe or fitting. The second set shall be made as far into the
interior of the pipe or fitting as can be readily reached without
injuring the lining.
2.11.1.3
Curing
Curing shall commence immediately after completion of the

mortar lining and hand finishing of a section of pipeline. This
shall, however not be later than 8-hours after mixing of mortar.
The lining shall be kept continuously in moist condition for a
period of 14 days. During the operation of lining, finishing and
curing, exterior surface of the pipe exposed to sunlight-shall be
sprinkled with enough water to keep the pipe cool. Open ends of
pipes shall be suitably closed so as to maintain a moist
atmosphere and prevent draught. Curing of mortar lining and
simultaneous cooling of the pipeline exterior shall be continued
even beyond the period of 14 days if so directed by the
Employer.
PAGE 70 OF 161
707 of 2461
2.11.1.4
MMRDA
Protection of Lining
The lined pipe and fittings shall be protected from extreme heat
due to direct sunrays of the sun, from impact of rainfall and from
freezing temperatures until the linings have cured sufficiently to
withstand these conditions. Every precaution shall be taken to
prevent any damage to the lining. If lining is damaged through
the fault of the Contractor, such damages shall be repaired
conforming to the specifications at the Contractor's expenses.
2.11.2 Factory Lining
2.11.2.1
General
All straight pipes shall be cement lined by the use of a

lining machine designed and built for the purpose of
rotating the pipe and centrifugally applying the lining at
sufficient speeds to meet the requirements set out below.
The support or holding device for the pipe shall be such
as to avoid damage to the pipe coating during the
spinning operation. If the pipe is rotated by direct contact
drive from the machine it shall be supported over at least
90 degrees of its circumference and driven by nonmetallic surfaced belts of sufficient width to avoid coating
damage.
The speed of rotation of the pipe during the lining

compaction stage shall be such as to provide a radial
acceleration .The rotational drive shall be capable of
close control and provide smooth acceleration and
deceleration when working up to and down from the
compaction spinning stage.
2.11.2.2
Materials
PAGE 71 OF 161
708 of 2461
MMRDA
Cement shall be High Strength Ordinary Portland Cement

in accordance with IS 8112. Sand used for lining shall be
tested with standard sieves as per IS 460 and the
requirements specified in IS 11906. The mortar shall stop
100 mm back from the faces of any joints. The end faces
shall be vertical.
2.11.2.3
Surface Preparation
Immediately before lining commences, the pipe bore shall

be cleaned of all loose scale, rust, oil, grease or any other
foreign matter likely to contaminate or harm the cement
mortar. Areas where an approved priming coat has
bonded to the pipe such that wire brushing does not
cause areas to flake off will be acceptable as a base for
applying the lining.
2.11.2.4
Mix Proportion
The proportion of sand to cement shall not be more than

1 part sand to 1 part cement by volume. Mortar
composed of cement, sand and water shall be well mixed
and
of
proper
consistency
to
obtain
dense,
homogeneous lining that will adhere firmly to the pipe

surface. The cement mortar mix shall comply with
strength and density requirements specified in IS
11906/AWWA C602. No admixtures shall be permitted
unless approved by the Employer.
The water cement ratio by mass shall be between 0.3:1

and 0.45:1.
2.11.2.5
Application
PAGE 72 OF 161
709 of 2461
MMRDA
The entire quantity of cement mortar for the lining shall be

applied without interruption, and spinning shall continue
until the specified thickness is evenly distributed over the
inside of the pipe, all surplus water has been removed
and the greatest possible density of cement mortar has
been obtained.
Temporary or semi-permanent end restraints shall be

fixed to the pipe ends on completion of lining and before
removal of the pipe from the lining machine. The pipe
shall not be rotated about its longitudinal axis after the
fixing of the restraints when being handled and
transported to the storage yard and subsequently to the
Site.
Pipe specials shall be cement mortar lined at the factory

in such a manner that the lining shall be of the specified
thickness and comparable in density and smoothness to
the spun lining in straight pipes and generally applied.
During the lining process, all rebound material etc. shall
be removed so that the lining is applied in a
homogeneous mass to a clean surface.
2.11.2.6
Determination of Lining Thickness
The lining thickness shall be determined on the freshly

centrifuged mortar at intervals frequent enough to assure
compliance. Thickness of lining may be determined by
means of a steel pin not larger than 1.5 mm in diameter,
or on a hardened mortar by means of a non-destructive
measurement process. The lining shall be measured at
four equidistant points on two cross sections of the barrel
at each end of the pipe or fittings. The first set shall be at
least 200 mm from respective ends of the pipe or fitting.
The second set shall be made as far into the interior of
PAGE 73 OF 161
710 of 2461
MMRDA
the pipe or fitting as can be readily reached without

injuring the lining.
2.11.2.7
Curing
Curing shall commence immediately after completion of

the mortar lining and hand finishing of a section of
pipeline. This shall, however not be later than 8-hours
after mixing of mortar. The lining shall be kept
continuously in moist condition for a period of 14 days.
During the operation of lining, finishing and curing,
exterior surface of the pipe exposed to sunlight-shall be
sprinkled with enough water to keep the pipe cool. Open
ends of pipes shall be suitably closed so as to maintain a
moist atmosphere and prevent draught. Curing of mortar
lining and simultaneous cooling of the pipeline exterior
shall be continued even beyond the period of 14 days if
so directed by the Employer.
2.11.2.8
Tests
Test blocks of the same material as used for the lining

shall be made in 100 mm cube moulds and subjected to
cube crushing tests. Each block shall be removed from its
mould as soon as practicable and cured under the
conditions of temperature and humidity identical with
those in which the lining of the pipe is cured. The number
of tests shall be at least 4 cubes for each age and each
water cement ratio for each days work. The works cube
strength of the test cube shall not be less than 170
kg/cm after 7 days of curing or 300 kg/cm after 28 days
of curing. The density of the test cube shall not be less
than 2300 kg/m.
2.11.2.9
Inspection
PAGE 74 OF 161
711 of 2461
MMRDA
Inspection of the lining shall be carried out at any time

prior to and after installation of the pipes. Any pipe with
lining that is broken, defective or otherwise not in
accordance with the Specification may be rejected.
Remedial lining operations may be carried out by a
method that has been approved in writing in advance by
the Employer.
The standard of the remedial lining shall satisfy the

requirements of this Specification. Surface crazing of the
lining will be acceptable unless cracks are severe enough
that they can be penetrated to a depth of 2 mm by a 250
microns feeler gauge at 10 points or more over a length
of 300 mm when measured with the lining in a saturated
condition. These cracks shall be cut back to full depth
and sealed with approved epoxy resin filler.
Linings applied to pipes shall be cured in such a manner

as will enable cement mortar to obtain and subsequently
retain optimum strength, density and durability. Linings
shall be kept moist by continuous water spraying for a
period of at least 3 days. They shall then be protected
from sunlight and kept damp by spraying with water or
other means approved by the Employer for a further
period of 7 days. Pipes shall not be removed from the
factory until at least 14 days have elapsed from the date
of lining.
2.11.2.10
Handling and Delivery
Lined pipes shall be lifted and moved only by wide nonabrasive slings or by other means acceptable to the
Employer. Wire ropes, chains and hooks shall not be
permitted to come in contact with the coating. No pipe
PAGE 75 OF 161
712 of 2461
MMRDA
shall be moved by rolling. Coated pipes shall be stacked

in one layer only and in such a manner that the coating is
not damaged. Unless under exceptional situation with
adequate provision for pipe protection and handling,
stacking in two layers may be considered by the
Employer. Adequate packing between pipes for this
purpose must be supplied by the Contractor.
Coated pipes must be kept clear of the ground and rested

on padded sleepers or supports. The pipes shall be so
handled, stored and transported as to prevent undue
distortion and shall not be moved in any manner involving
rotation of the pipe about the longitudinal pipe axis. The
pipes shall be lifted by means of two reinforced canvas
slings at least 300 mm wide suspended from a lifting
beam so that the slings are positioned at a distance of
one-fifth of the pipe length from each end of the pipe.
On no account shall the pipes and specials be dropped or

let fall onto the ground and under no circumstances shall
the pipes and specials be lifted by means of hooks to the
ends of pipes and specials. The Contractor shall provide
suitable timber end struts and sufficient intermediate
struts to strengthen the pipes to the Employer's approval
to prevent distortion during handling and delivery. Such
struts shall be left in position when thin wall pipes of 2235
mm and 1829mm are delivered to the storage areas.
Attention is drawn to the Contractor that thin wall pipes,
defined as pipes with a diameter/plate thickness ratio
greater than 125, shall be so handled, stored and
transported as to prevent distortion or damage to the
pipes and shall not be moved in any manner involving
rotation of the pipe about the longitudinal pipe axis.
Thin wall pipes during delivery and when in transit around

PAGE 76 OF 161
713 of 2461
MMRDA
the Site shall be supported on three rubber covered

saddles shaped to give at least 90 circumferential
support and shall be firmly held in position at each
saddles by straps tightened of turnbuckles in such a
manner that the external coating is not damaged. One of
the saddles shall be in the centre of the pipe length and
the other two shall each be positioned at a distance onefifth of the pipe length each end of the pipe.
Thin wall pipes in temporary storage or strung out along

the pipeline routes shall be supported on hessian bags
filled with the sawdust straw or similar and shaped so as
to give continuous support under at least 40-50 of the
circumference. The positions of supports shall be the
same as that for pipes during transit. The underside of
the pipes shall be kept clear of the ground by at least 300
mm. Any damage to or loss of materials shall be made
good, or the damaged or lost materials enforced, by the
Contractor at his own expense and if approved in by the
Employer, damaged materials shall be returned to the
manufacturer for repair as directed by the Employer.
2.11.2.11
Repair of Lining of MS pipes
Specially competent and skilled persons only shall be

employed to carry out repair work to damaged linings.
Small cracks and flaws in the internal mortar lining of
steel pipes and specials may, with the prior approval of
the Employer and if they are accessible, be repaired on
Site. Such cracks may be repaired by cutting out a 9 mm
x 9 mm dovetailed key and making good with a semi- dry
mortar (proportion 1 part cement to 2 parts coarse sand)
well tamped into the groove, and cured by keeping it
damp for 7 days.
PAGE 77 OF 161
714 of 2461
MMRDA
Alternatively, small cracks may be caulked with epoxy

resin filler. All defects to linings shall be made good to the
entire satisfaction of the Employer. Where in his opinion
the damage is such that satisfactory repairs on Site will
not be practicable, e.g. when damage or cracking is
extensive and/or inaccessible, the pipes or specials in
question shall be either returned to the factory for
repairing properly or replaced completely. The Contractor
shall be responsible in either case for all costs involved in
this respect and for any delays to construction work
thereby caused.
2.11.3 Mortar Lining in situ to the Water Supply Pipelines
2.11.3.1
Scope of the Specifications
These specifications cover the following works:
a)
Making access openings for cleaning and cement

mortar lining for underground and above ground
pipeline.
b)
Cleaning the internal surface of pipelines.
c)
Providing cement Mortar lining (Hand lining and

machine lining) to underground and aboveground
pipelines.
d)
Painting the pipelines on sides of line valve,

expansion joints, saddles of manholes, Air valves,
Scour valves etc.
e)
Testing the lined surface.
f)
Closing the access openings and other ancillary
PAGE 78 OF 161
715 of 2461
MMRDA
works like cleanup of the site etc.
2.11.3.2
Work Plan
The Work Plan which the tenderer / contractor shall along

with his tender for the speedy and efficient execution of
the work should be inclusive of mortar lining activity,
containing the following information.
a)
Locations of the access openings. Normally,

access openings shall be minimum required and
generally spaced at not less than 400 mts.
b)
The work period for each section and for the total
work.
c)
The no. and type of plant and equipment he

proposes to use.
d)
Any other information he thinks necessary.
The mortar lining work shall be executed as per the work

plan submitted by the tenderer/ contractor subject to the
2.11.3.3
Plant and Equipment
i)
The contractor shall use on the work the plant and

equipment that shall be in good working condition
and shall be sufficient, and appropriate for the rate
of progress expected on the work.
ii)
If during the execution of the work, it is found that

the
plant
inappropriate
and
or
equipment
insufficient,
is
inefficient,
the
Employers
PAGE 79 OF 161
716 of 2461
MMRDA
representative shall direct the contractor to repair,

replace or bring additional plant and equipment
and the contractor shall immediately take the
necessary action, so as to comply with the
directions of the Employers representative.
iii)
Before actually using the equipment for the

execution of the work, the contractor shall carry
out test for cement mortar lining for the Employers
approval and only upon such satisfactory test run,
the plant and equipment shall be employed on the
work.
iv)
No claim for any delay on account of such testing,

retesting repairs,
replacement etc. shall be
entertained by the Employer.
v)
Keeping sufficient stock of spares shall be in the

interest of the contractor as no claim on account of
delay
in
procuring
such
spares
shall
be
entertained by the Employer.
vi)
Attention of the tenderers/contractors is invited to

condition no.76 of General conditions of contract in
this regard.
2.11.3.4
Cement Mortar
i)
The composition of-mortar for the lining shall be

composed of cement, sand and water that are well
mixed and of such consistency as to produce a
dense, homogenous lining that will adhere firmly to
the pipe surface.
ii)
The proportion of cement and sand for mortar-
PAGE 80 OF 161
717 of 2461
MMRDA
lining work will generally be 1:1 by weight.

Contractors are expected to quote the rate on the
basis of this proportion.
iii)
The water cement ratio shall be carefully controlled

and shall be kept to the minimum necessary to
obtain the mortar that can be applied well. The
water cement ratio shall not exceed 0.35 in any
case.
iv)
The mortar shall be mixed by machine for a

sufficient length of time to obtain maximum
plasticity. In general it shall be mixed for at least 3
minutes after the last water is added. The method
of mixing shall be subject to the approval of the
v)
Only that quantity of mortar shall be mixed which

can be used up in a continuous process within an
hour after it has been mixed. No mortar that has
attained the initial set and/or one hour has elapsed
after mixing shall be used.
vi)
The lining shall be uniform in thickness except at

joints or deformation in pipeline.
2.11.3.5
Field Tests
The following field tests shall be carried out by the

contractor at his cost for determining the quality of mortar:
a)
Slump Test
b)
Cube Test
PAGE 81 OF 161
718 of 2461
c)
MMRDA
Testing the thickness of lining
Details of each test are described below:
(a)
Slump Test
Fresh mortar mixed in power mix may be taken for

slump test, the water content shall be as minimum
as possible. Slump test should be done once in a
day
or
as
directed
by
the
Employers
representative using the freshly mixed mortar

immediately prior to the mortar being fed to the
lining machine. The slump shall not exceed 25
mm. to 30 mm. The test should be made in
accordance with ASTM C-143.ln the event of any
failure, in respect of the above test, the site
Employers representative will take suitable action
including stoppage of the work.
(b)
Cube Test
After the slump test is carried out cubes of cement

mortar of the size 10 cm x 10 cm x 10 cm shall be
taken out. These cubes shall then be tested at 3
days and 28 days for finding out crushing strength
of mortar
The casting of the cubes shall be done on all the

days of mortar lining. The contractor shall make
the arrangement of cube testing machine at site.
The minimum compressive strength of the mortar

for the designed mix by volume at 3 days shall be
180 kg/cm2 and at 28 days shall be 315 kg/cm2.
PAGE 82 OF 161
719 of 2461
MMRDA
Failure of the cube test may entail partial or

whole demolition of such work, penalties of the
contractor concerned and/or such other similar
steps. In case of any dispute the decision of the
Employers representative shall be binding on the
contractors.
(c)
Testing for layer thickness
The layer thickness test shall be carried on ends

of freshly lined pipes either by inserting gauge
which shall be a graduated needle which will give
accurate measurement. Tolerance in thickness
on positive side shall not be more than 3 mm.
However, there shall be no negative tolerance in
a thickness. This will be measured on the pipe
plate where there are no joints or deformation in
pipe more than 5% in dia.
2.11.3.6
Making Accesses
a)
Excavation
i)
For the lining of underground pipelines,

the contractor shall excavate the trench at
the
predetermined
consultation
with
locations
the
in
Employers
representative for making access in the

pipeline. The excavation shall be kept to
the minimum required for the proper
performance of the work
ii)
The sides of the trench shall be properly

shored to avoid any collapse of sides.
Shoring shall be maintained till the work in
PAGE 83 OF 161
720 of 2461
MMRDA
the
trench
is
completed.
The
gunite/colcrete/concrete cover shall be

broken wherever necessary.
iii)
All excavated material shall be removed

immediately after excavation to a place
identified for disposal. This will keep the site
of work clean and neat. It shall not cause
additional hindrance to the traffic if any. The
excavated
material
transported
to
the
dumping site shall be leveled to the

satisfaction
of
the
Employers
representative. The material for refilling shall

be provided by the contractor at his cost.
iv)
The trench shall be properly fenced and

lighted during pendency of the work to the
satisfaction
of
the
Employers
representative.
v)
All sub-soil water, leakage water, water from

flushing; and water in creek area etc. shall
be pumped out by the contractor by using
suitable water pumps and the trench shall be
kept dry till the work in the trench is
completed. All such pumped out water shall
be properly drained into the nearby water
course or drainage system and in no case
the water shall be allowed to be let out on
the road or close to the work area. The
contractor shall, for this purpose, have
sufficiently long delivery pipes etc.
No extra payment shall be made for the

dewatering and draining out the water as
PAGE 84 OF 161
721 of 2461
MMRDA
stated above.
b)
Cutting the pipe for making Access :
i)
The contractor shall cut the pipe at the

predetermined location.
The number of
openings and the size of opening shall be

minimum required. They shall not be spaced
at less than 400 mtrs. unless approved by
ii)
Depending upon the size of the pipeline and

the equipment to be used either a short
length of pipeline shall be removed or only
the upper half segment of the pipe of the
required min. length shall be cut out. Access
holes shall be cut only after obtaining prior
permission from Employers representative.
iii)
The pipe shall be cut either by gas cutting or

by any other approved method. The cut
pieces shall be numbered and kept in the
contractors yard. The same piece of pipe
shall be used for closing the opening after
cleaning and lining.
iv)
The Contractor shall also be allowed to cut

600 mm. dia. manholes (feed holes) at a
suitable distance according to requirement
for access for the purpose of hand-lining,
ventilation, or inspection etc. Access holes
shall be cut only after obtaining prior
permission of the Employers representative.
2.11.3.7
Cleaning the Internal Surface of Pipeline
PAGE 85 OF 161
722 of 2461
i)
MMRDA
Length of the pipe line to be cleaned and lined

from each access opening shall be the maximum
length possible and the cleaning and lining shall be
done in two directions from the opening wherever
possible
ii)
The pipelines to be cleaned and mortar lined is laid

newly. Normally, cleaning with wire brushes, hard
brooms or such similar devices should be sufficient
to remove all rust, dirt, sift etc. However, where the
thinks that manual cleaning as described above
shall not give proper results in any section of the
pipeline, the contractor shall clean such section
with
mechanical
mechanical
cleaning
scrappers
devices
etc.
such
as
Employers
representative's decision in regard to the method

of cleaning shall be final and binding on the
contractor. Mechanical cleaning shall be done at
no extra cost to the Employer and contractor
should quote accordingly. Hydraulic cleaning,
however, shall not be allowed.
iii)
For small diameter pipes, where manual cleaning

is not possible, the pipe shall be drag cleaned with
steel scraper or brush, immediately, after these
pipes have been scrapped and cleaned, proving
device; fitting exactly, shall be passed through the
pipe in order to check the nominal passage and to
remove any remains of sludge and water.
iv)
After cleaning the internal surface of pipeline as

described above, the pipeline cleaned with duster
shall be flushed with water. All flushing water shall
be pumped out by the contractor as already
PAGE 86 OF 161
723 of 2461
MMRDA
described above. The solid waste shall be disposed

off as directed by the Employers representative.
The rate also includes artificial drying by air drying
etc. for pipeline, in marshy area.
2.11.3.8
Providing Cement Mortar Lining
i)
The cement mortar lining process shall not be

started until inspection of the scrapped and cleaned
main is made by the Employers representative and
permission has been obtained from him.
ii)
Cement mortar lining shall be placed by cement

mortar lining machine. The lining machine shall be
of the type that has been used successfully for
similar works over a period of at least 3 years, and
the trial lining is found to be satisfactory.
iii)
The tenderer shall designate the type (or types) of

the machine, he proposes to use and shall present
evidence that his firm has used similar machine (s)
and has carried out satisfactorily the work of nature
similar to the proposed work.
iv)
Applicator head of the lining machine shall

centrifugally project the mortar against the internal
surface of the pipe at high velocity in such a
manner that it will produce a dense mortar lining of
uniform required thickness.
v)
The cement mortar lining machine shall have an

attachment with rotating or drag trowels following
the applicator head for trowelling the cement mortar
lining to smooth, head surface of uniform thickness.
It shall exert uniform pressure on lining giving the
PAGE 87 OF 161
724 of 2461
MMRDA
finished surface free of spiral shoulders. The

operation to trowels shall be continuous during the
application of cement mortar lining. The trowelsshall be cleaned at frequent intervals to remove the
accumulated mortar on the trowels before it is set
vi)
The cement mortar lining machine shall move

ahead of lining, so that nothing will come in contact
with the trowelled surface until it has attached its
final set.
vii)
The forward movement of the machine and the

mechanical placing of the mortar shall be so
controlled that a uniform required thickness of lining
is assured as specified above. Ridges or uneven
build up caused by irregularity of trowel rate of
machine shall not be allowed.
viii)
Thickness of lining shall be checked frequently as

the Employers representative may direct in order
to maintain proper control on the lining operations.
Graduated needle or another approved appliance
shall be used for measuring the thickness. The
tolerance in the lining thickness shall be +3 mm.
There being no minus tolerance.
ix)
Head placing of mortar shall not be permitted

except adjacent to faces where machine placing is
impossible or impracticable. Hand placing shall
also be permitted for the sections of pipe used to
close the access openings. Same quality of mortar
used for machine lining shall be used for hand
lining. Hand placing of mortar shall also be done for
the short length of pipes used as branches or
manholes and smaller dia pipe, bends, tapers,
PAGE 88 OF 161
725 of 2461
MMRDA
cross connections, dipping etc. where machine

lining is not possible. All such mortar lining of
branches upto 1 m lengths shall be done by the
contractor at no extra cost to the Employer
Employers representative and the rate for cement
mortar lining the main pipeline shall be deemed to
have included this cost. Hand placed lining shall be
trowelled smooth by steel trowels.
x)
All waste materials, spatter and mortar of improper

consistence such as may result from starting or
stopping the lining machine shall be removed from
the pipe ahead of trowels. Only mortar of required
consistence and which adheres to the pipe shall be
trowelled finally to form the finished lining.
xi)
If any section of lining shows evidence of failure,

undue irregularity or inferior workmanship, requires
excessive patching or shows segregation or deficiency in cement content, the contractor shall
remove-the faulty section, clean the pipe and reline
in accordance with these specifications at no extra
cost to the Employer.
xii)
Immediately after the lining of a section of pipeline

is completed, all valves, branches, air valves,
appurtenances etc. in that section shall be cleaned
of mortar by the contractor and as directed by the
Employers representative to bring them to original
working condition.
xiii)
The contractor shall guarantee the finished lining to

be-free from defective material and workmanship
for a period of 24 months from the date of
acceptance
of
the
work
by the
Employers
PAGE 89 OF 161
726 of 2461
MMRDA
representative.
2.11.3.9
Curing
i)
Immediately upon the completion of the lining of a

length of a pipeline between access openings or at
the end of day's run, that section of pipeline shall
be closed at each end and the access openings
shall be covered to prevent the circulation of air. As
soon as practicable after placing of the lining,
sufficient amount of water shall be introduced into
the section between the bulk heads of valves to
create a moist atmosphere and to keep the lining
damp, till that section is charged.
ii)
The
contractor may alternatively use
water
sprinklers to keep the lining moist and cure it,

subject to the satisfactory evidence regarding its
effectiveness.
2.11.3.10
Inspection and Testing
i)
The Employer representative shall examine the

lined sections of the pipeline with regard to the
thickness of lining, its smoothness and cracks in
the surface as well as bonding strength and
homogeneity.
The
contractor
shall
give
all
necessary help and all facilities to the Employers

representative for the inspection.
ii)
Cement mortar lining that has not been applied

and
cured and/or the result of which is not in
compliance with these specifications shall be

declared
unsatisfactory
by
the
Employers
representative and such sections of pipelines shall

PAGE 90 OF 161
727 of 2461
MMRDA
be relearned and relined by the contractor at his

cost
to
the
satisfaction
of
the
Employers
representative.
2.11.3.11
Cleaning and Disinfection
i)
Upon
completion
chlorinating,
of the work and
before
all fragments of mortar and the
debris be removed by the contractor so that the

pipeline is clean and ready for use in all respects
pending chlorination.
ii)
Upon completion of the cleaning as mentioned

above ,and after inspection and approval by the
Employers representative the contractor shall
chlorinate that section of the pipeline to the
satisfaction of the Employers representative by
giving an approved dose of chlorine with water and
keeping it in that section of pipeline for at least 24
hrs. All material, labour and equipment for
chlorination shall be supplied by the contractor.
After disinfection in the above manner that section
of the pipeline shall flushed out.
2.11.3.12
Closing the access openings
i)
The access openings shall be closed by welding

the pipe piece at its original place. Before welding,
this pipe piece shall be scrapped and cleaned
manually and mortar lined by hand application,
trowelled and cured to the satisfaction of the
Employers representative. The edges of the pipe
piece and the opening shall be gas cut to form V
edges and welded together as per the relevant LS.
Specifications for welding M.S. plates.
PAGE 91 OF 161
728 of 2461
ii)
MMRDA
Before the trench is refilled with selected material

in layers not , exceeding 30 cms., the damaged
gunite/concrete/colcrete cover shall be made good
with M-15 cement concrete up to the level of
surrounding encasement in concrete/colcrete or 15
cm in case of gunited pipes as specified. The
refilled material shall be property consolidated by
watering and ramming. The refilling shall be done
upto the original road surface or the surrounding
ground.
A cut hole of suitable size of circular opening shall

be taken as directed, for the internal weldinq of
access opening. The same shall be welded back
to the pipe including fixing doubler plate as
directed by the Employers representative. Before
welding, the internal surface of cut hole piece shall
be scrapped and painted with one coat of zinc, rich
epoxy primer and_ three coats of Inertol -49 W
thick or any other approved equivalent paint as per
specifications given hereinafter. Contractor shall
weld stiffener plate of required size and shape on
the rectangular access opening where necessary
and
as
per
directions
of
the
Employers
representative.
In case of 600 mm. circular opening taken for hand

mortar lining, the internal surface of opening shall
be scrapped and painted with 1 coat of zinc, rich
epoxy primer and 3 coats of Inertol - 49 W thick or
any other approved equivalent paint. The same
shall be welded back by fixing doubler plate of
required size and as directed by the Employers
representative.
PAGE 92 OF 161
729 of 2461
iii)
MMRDA
Reinstatement of the road surface if required shall

also be done by the contractor at his cost.
2.11.3.13
Other Responsibilities of the Contractor
a)
Temporary approach roads
Temporary
approach
roads
to
the
access
openings if required shall be constructed by the

contractor at his cost and they shall be maintained
in good condition till the completion of the work.
Right of way to the access opening shall also be
arranged
by
the
contractor.
The
Employer
however, shall render all necessary help to the

contractor in obtaining the right of way. No extra
payment shall be made for this work.
b)
Temperature control on above ground pipeline
i)
For the sections of the pipeline which are

laid above ground, the contractor shall have
to provide for approved method for keeping
the pipe shell cool during the lining
operation and during curing period so that
the lining does not develop cracks due to
fast evaporation of moisture from the
mortar.
ii)
Temperature in the work area varies from

28 C to 37 C during the day time and from
20 C to 27 C during night time depending
on the season. The shell temperature of the
pipe goes even up to 45 C. In view of this,
the contractor shall keep the pipeline cool
PAGE 93 OF 161
730 of 2461
MMRDA
by either continuouss sprinkling of water

over the pipe or by covering the pipes with
shed, or any other approved method. The
tenderer shall indicate the procedure he will
be using at the time of submitting his
tender.
iii)
No extra payment shall be made for the

above operation and the cost of the above
shall be included in the rates for the items
of work/various work in price schedule.
c)
Removing accessories :
i)
If for the reason of convenience of the work,

the contractor desires to remove the valves,
air
valves,
expansion
joints,
manhole
covers and any other appurtenances, he

shall be allowed to do so if the Employers
representative convinced of the necessity.
ii)
In such a case, these valves, air valves,

expansion joints, manhole covers and other
appurtenances shall be removed by the
contractor stored properly in contractor's
store. When they are to be fixed they shall
be transported back by the contractor and
fixed again on the pipeline under the
Employers
representatives
supervision.
The contractor shall do all the above

operations at his cost. He shall also be
responsible for any damage
appurtenance
during
to
taking
such
out,
transporting to and from and in contractor's

store. Employers representatives decision
PAGE 94 OF 161
731 of 2461
MMRDA
regarding the cost of damage shall be final

and binding on the contractor.
d)
Final Clean-up:
After all the work in a section of the pipeline is

completed, the contractor shall remove temporary
structures etc. and clean the whole area of all
rubbish, construction material, scraps etc. to the
satisfaction of the Employers representative. Cost
of this work shall be deemed to have been
included in the quoted price.
2.12
External Coating for WS Pipe Line below Ground (Buried)
2.12.1 General Stipulations
All MS pipes laid below ground or provided with soil cover shall be
coated externally, in the factory, with prefabricated polyolefin tape
coating as per AWWA C 214/IS 3589 Annex- D. This specification
covers the minimum requirements for procurements and supply of all
materials, plant, equipment, plant sites, consumables, utilities and
application. The contractor shall perform all work in accordance with
these specifications and the latest pipeline coating practices, and shall
complete the work in all respects to the full satisfaction of the
Employer. The entire coating operation starting from cleaning and
surface preparation till coating shall be performed under the
supervision of skilled personnel who are well conversant with the work.
Pipes which have been cleaned and primed, or cleaned, primed and
coated, without having been inspected and approved shall be rejected.
This specification is not intended to be all inclusive and the use of

guidelines set forth here does not relieve the Contractor of his
responsibility for the quality and performance of the applied coating
system, and to supply coating material capable of performing its
PAGE 95 OF 161
732 of 2461
MMRDA
intended service.
Welded field joints shall be coated with heat shrinkable cross-linked

polyolefin coatings as described in AWWA C- 2I6. Heat shrinkable
coating shall consist of a polyolefin backing that has been cross linked
by either electron beam or chemical means and coated with adhesive.
Heat shrinkable coating shall be field applied or shop applied.
All MS special sections, connections and fittings to be used for

underground MS pipeline shall be coated with cold applied tape
consisting of liquid adhesive and prefabricated tape as described in
AWWA C209.
The Contractor shall propose the name of manufacturer of the coating.

The manufacturer shall be ISO certified. The Contractor shall produce
a certificate from the manufacturer stating at least two projects, with
Employer's satisfaction certificate, where the coating has performed
satisfactorily for at least 5 years. The recommendations of the
manufacturer regarding coating process, repairs, etc., shall also be
provided by the Contractor. The manufacturer should give guarantee
for supply of the required quantity as per the project time schedule and
take responsibility for supervising the coating application and repair
works. Suitable certificate from manufacturer shall be provided for the
same.
2.12.2 Plant, Scale and Installation
The contractor will be required to give the details of the premise he

intends to use for manufacture of pipes and coating and will ensure
that:
Plants, equipment, machinery and other facilities shall be in first class

operating conditions to meet the job requirements of quality production.
The Contractor shall, at his own risk and cost, provide and prepare the
PAGE 96 OF 161
733 of 2461
MMRDA
required areas for storage of bare and coated line pipes, other
materials, coating plant sites, stock-piling area and other temporary
installations required under this Contract. For each area, the Contractor
shall provide the Employer in Charge with copies of agreements, as
required with the land owners and/or relevant authorities, covering all
aspects of establishing, operating, maintaining, closing down and
completion activities, including cleaning and restoration of the sites,
and payments for servitude and claims for damages, as applicable.
The Contractor shall, at his own cost, provide a fully equipped

laboratory and test facilities with adequate inventory to carry out all
tests required for testing of raw materials and coated pipes so as to
ensure quality coating and regular production.
The plant coating capacity should be such that it can meet the project
schedule.
2.12.3 Tape Coating for MS Pipe
2.12.3.1
General
The buried Mild Steel pipeline shall be protected with cold

applied tape protective coating conforming to AWWA
C214 (Cold Applied Tape Coating Systems for Exterior of
Steel Water Pipelines). Protective coating shall consist of
a coating system consisting of primer, inner tape wrap
and outer wrap. The coating system shall be applied in a
coating plant. The materials provided shall meet the
provisions of AWWA C214. Work or material that fails to
conform to this standard may be rejected at any time
before final acceptance.
Coating System
System components:
PAGE 97 OF 161
734 of 2461
MMRDA
The prefabricated polyolefin tape coating system shall be

at least three layers consisting of the following
A liquid adhesive layer
An inner-layer tape for corrosion protection.
An outer-layer tape for mechanical protection
The inner-layer tape and outer-layer tape shall be made

of prefabricated tapes in rolls. The properties of the entire
system shall conform to the appropriate values listed in
Tables 2.8.
2.12.3.2
Liquid Adhesive
The liquid adhesive shall consist of a mixture of suitable

rubber and synthetic compounds and a solvent. The
liquid adhesive shall be applied to the properly prepared
pipe surface before application of the inner-layer tape.
The function of the liquid adhesive is to provide a bonding
medium between the pipe surface and the inner-layer
tape.
2.12.3.3
Inner-Layer Tape
The inner-layer tape shall be a two-layer tape consisting

of a polyolefin (only) backing layer with a laminated butylbased adhesive layer. The inner tape shall be compatible
with the liquid adhesive. The manufacturer shall certify
that the backing material shall be polyolefin only,
containing not less than 1.0 percent nor more than 3.5
percent, by weight, of nonpolyolefinic material consisting
of carbon black and antioxidants. The inner-layer tape
shall be applied after the liquid adhesive and before the
outer-layer tape.
PAGE 98 OF 161
735 of 2461
2.12.3.4
MMRDA
Outer-layer Tape
The outer layer shall be of Laminated butyl adhesive. The

manufacturer shall certify that the backing material shall
be polyolefin only containing not less than 3.0 percent or
more than 7.0 percent, by weight, of nonpolyolefinic
material
consisting
of
pigments,
antioxidants
and
stabilizers.
The outer-layer tape shall be compatible with the innerlayer tape. The primary functions of the outer-layer tape
shall be to provide mechanical and outdoor weathering
protection to the tape system, and secondarily, to
contribute to the overall corrosion-protection properties of
the system. The outer-layer tape backing shall be
compounded so that it will be resistant to outdoor
weathering. The outer-layer should be of suitable quality
for the local environment, as follows:
Storage Temperature
: 0 to 50C.
Over-ground Condition
: 0 to 50C.
Under-ground Condition : 7C to 35C.
Soil Nature
: As Provided in Tender
Documents.
Underground Water Table: Generally wet and get

saturated during monsoon
Ultraviolet-ray Protection: Required in outer layer
2.12.3.5
Coating-system Thickness
PAGE 99 OF 161
736 of 2461
MMRDA
Depending on operating and installation conditions, more

than one application of inner-layer tape and outer-layer
tape can be used. The total thickness and combination of
the various layers used shall be approved by the
Employer in Charge, with proper consideration given to
the manufacturer's recommendations. However, in no
case shall the thickness be less than those stated in the
following Tables:
Table 2.5: Physical Properties of the Liquid Adhesive

Color
Base
Black
Rubber
Weight
Flash Point
and 6-8 lb/gal (0.72 - 10F(-17C)or
Synthetic
0.965g/i)
greater
Resins(Flammable)
(Non flammable)
10-12 lb/gal (1.20- none

1.44 kg/I)
Table 2.6: Physical Properties of Inner Layer Tape

Property
Minimum
Maximum
Test
Requirement
Requirement
Method
(Ref
AWWA
C214)
Width Deviation
5% or 1/4 in. (6 +5%
Sec. 5.3.1
mm) whichever is
smaller
Thickness
[20mil 19 mil (483 m)
22
mil
(559 Sec. 5,3.2
(508 m)l Nominal
m)
Ratio of Adhesive 40% of total t
60% of total t
Sec, 5.3.2
to Total Inner Layer

Tape Thickness,t
Adhesion
to 200
ozf/in
width
Sec. 5.3.3
PAGE 100 OF 161
737 of 2461
MMRDA
Property
Minimum
Maximum
Test
Requirement
Requirement
Method
(Ref
AWWA
C214)
Prepared Steel
(2,190 N/m width)
Water Absorption
0.2% by wt
Sec. 5.3.4
Water-vapor
0.2 perms
Sec. 5.3.5
Transmission
[1.15x10-11kg
Percent by Weight
(Pa.s.m)
(24 h)
Dielectric Strength
6,000
V/single
Sec. 5.3.6
thickness
Insulation
500,000 megohms
Sec. 5.3.7
Tensile Strength
3,500 N/m width
Sec. 5.3.8
Elongation
100%
Sec. 5.3.9
Nonpolyolefinic
1.0%
Resistance
3.5%
Sec. 5.3.12
Material Percent by
Weight
Test methods are all for tests performed in laboratories. If

field test methods for any property are required, consult
with the tape manufacturer.
Table 2.7: Physical Property of Outer Layer Tape

Requirement
Property
Minimum
Maximum
Test
Method
(Ref
AWWA
C214-00)
Width Deviation
5% or 1/4 in. (6 +5%
Sec. 5.3.1
mm) whichever is
PAGE 101 OF 161
738 of 2461
MMRDA
smaller
Thickness
[30mil
(762
m)] Nominal
Adhesion to Inner Layer
33
27 mil (686 m)
20
ozf/in
mil
(838
m)
width
Sec. 5,3.2
Sec. 5.3.3
(200 N/m width)

Tensile Strength
40
lbf/in
(7000
Sec. 5.3.8
N/m Width)
Elongation
100%
Nonpolyolefinic
Sec. 5.3.9
Material 1.0%
3.5%
Sec. 5.3.12
Percent by Weight
* Test methods are all for tests performed in laboratories.
If field test methods for any property are required, consult
with the tape manufacturer
Table 2.8: Physical Properties of Total System

Requirement
Property
Minimum
Maximum
Test
Method
(Ref
AWWA
C214-00)
Thickness
80 mil, nominal
73
mil
(1,854 88 mil (2,235 Sec. 5.3.3
m)
Dielectric Strength
Impact Resistance
Penetration/Deformation
Resistance
m)
12000V
Sec. 5.3.6
25 lbf. in. (2.8
Sec.
N.m)
5.3.10
25%
with
no
holiday at 72F
(22C)
Sec.
5.3.11
* Test methods are all for tests performed in laboratories. If field test
methods for any property are required, consult the tape manufacturer.
PAGE 102 OF 161
739 of 2461
2.12.3.6
MMRDA
Component Requirements
1)
Liquid Adhesive
The liquid adhesive shall be supplied by the

manufacturer that supplies the inner layer tape.
The liquid adhesive shall comply with all code and
regulatory requirements in effect at the point of
application. The liquid adhesive shall not settle in
the container forming a cake or sludge that cannot
be easily mixed by hand or mechanical agitation
and
it
shall
have
good
machine-application
properties.
2)
Inner-layerm Tape
The backing and adhesive shall be made from

materials that provide high electrical resistivity,
resistance to corrosive environments, low moisture
absorption and permeability, and shall provide an
effective bond to a properly prepared steel surface.
The inner-layer tape shall be of material that will
resist
normal
excessive
application
mechanical
operations
damage
and
during
shall
be
sufficiently pliable for the intended use. The innerlayer tape shall withstand, without tearing, the
tensile force necessary to obtain a tightly wrapped
inner coating free of voids. The properties of the
inner-layer tape shall conform to the appropriate
values stated in Table 2.6
Form: The inner-layer tape shall be supplied in roll

form wound on hollow cores with a minimum inside
diameter of 75 mm.
PAGE 103 OF 161
740 of 2461
MMRDA
Dimensions: To ensure a proper smooth coating,

the inner-layer tape shall be provided in standard
widths consistent with the pipe diameter. Width
shall be as approved by Employer in Charge
however in no case it shall be less than 300 mm.
3)
Outer-layer Tape
Materials used in the outer-layer tape provide

some electrical resistivity, low moisture absorption
and permeability, and resistance to corrosive
environments.
Materials
used
shall
provide
mechanical protection during handling and outdoor

storage. The outer-layer tape shall be sufficiently
pliable for normal application operations and shall
form an effective bond to the inner-layer tape. The
properties of the outer-layer tape shall conform to
the appropriate values stated in Table 2.7
Form: The outer-layer tape shall be supplied in roll

form wound on hollow cores with a minimum inside
diameter of 75 mm.
Dimensions:
The
outer-layer
tape
shall
be
provided in standard widths and lengths. The width

of the outer-layer tape shall be at least equal to
that of the inner-layer tape.
4)
Tests
The tape coatings shall conform to the physical

properties stated in Tables .The tape manufacturer
shall provide the Employer in Charge with certified
test reports on each order of the tape supplied.
PAGE 104 OF 161
741 of 2461
2.12.3.7
MMRDA
Coating Application
2.12.3.7.1
General
The
coating
application
shall
be
continuous operation starting with properly

prepared pipe surface. Three steps, which
shall be performed consecutively, shall
consist of:
(1)
liquid adhesive application;
(2)
application of the inner-layer tape

directly
onto
the
prepared
pipe
surface; and
(3)
application of the outer-layer tape

directly on top of the inner-layer tape.
The coating materials shall be stored
in a clean, dry area. During steps 2
and 3, one or more layers of innerlayer tape and outer-layer tape may
be applied as specified and approved
by the Employer in Charge.
2.12.3.7.2
Pipe Preparation
Metal Surface Condition:
Bare pipe shall be free from mud, mill scale,

mill lacquer, wax, coal tar, asphalt, oil,
grease, or any other foreign material. Before
blast cleaning, surfaces shall be inspected
and pre-cleaned according to SSPC-SP 1 to
remove oil, grease, and loosely adhering
PAGE 105 OF 161
742 of 2461
MMRDA
deposits. Visible oil and grease spots shall

be removed using a solvent. Only solvents
that do not leave a residue shall be used.
Preheating to remove oil, grease, and mill
scale may be used provided that all pipes
are preheated in a uniform manner to avoid
distortion.
Blast cleaning: After drying and removing all

loosely adhering foreign materials, the pipe
surface shall be cleaned by blasting with
sand, grit, or shot to achieve a surface
preparation at least equal to that specified in
SSPC-SP 6/NACE No. 3. The blast anchor
pattern or profile depth shall be 1 mil to 3 mil
(25 m to 75 m) measured in accordance
with ASTM D4417.
Visual
comparative
standards:
The
Contractor shall prepare a representative

area on an actual work surface, as well as
visual standards on minimum 6 in. x6 in. x
1/4 in. (150 mm x 150 mm x6 mm) panels.
When
the
visual
standard
meets
the
requirements of blast cleaning, the panels

shall be wrapped in plastic, sealed with tape
ox
otherwise
protected
from
surface
contamination or corrosion, and maintained

as a visual reference standard throughout
the
coating
operations.
The
standard
section shall be sealed carefully to prevent

rusting.
accepted
Alternatively,
visual
other
industry-
comparative
standards
agreed on may be used.
PAGE 106 OF 161
743 of 2461
MMRDA
Abrasive
working
mix:
For
consistent
surface finish, a stabilized working mix shall

be maintained in abrasive-recycling blasting
machines by frequent small additions of new
grit, shot, or sand (all commensurate with
abrasive
consumption); infrequent large
additions shall be avoided. The abrasive

working
mix
abrasive-recycling
blasting
machines shall be maintained clean of

contaminants
by
continuous
effective
operation of blasting-machine scalping and

air-wash separators.
Surface inspection: The cleaned exterior

pipe surface shall be in inspected for
adequate
surface
preparation.
Surface
imperfections, such as slivers, scabs, burrs,

weld spatter, and gouges, shall be removed
by hand filing or grinding if necessary to
prevent holidays.
Protection from moisture: Blast-cleaned pipe

surfaces shall be protected from conditions
of
high
humidity,
rainfall,
or
surface
moisture. No pipe shall be allowed to flash

rust before coating. At no time shall the
blast cleaning be performed when the
relative humidity exceeds 90%.
Weld Seam Cover:
Longitudinal and coil splice welds:

Weld seam cover tape shall be
compatible with the liquid adhesive.
Before applying the inner-layer tape,
PAGE 107 OF 161
744 of 2461
MMRDA
the longitudinal and coil splice weld

seams shall be ground flush for a
distance of 450 mm along the length
of the pipe on both ends. These weld
seams shall be coated with liquid
adhesive and then covered with a
strip of tape recommended by the
manufacturer. The width of the weld
seam tape will be as recommended
by the manufacturer and as approved
by Employer in Charge. The weld
seam tape shall conform to the
provisions of these specifications.
Spiral welds: The spiral weld seam

shall be ground flush a full 450 mm
along the length of the pipe on both
ends prior to the coating Process.
Covering the spiral weld seams with
a stripping tape is required only when
the profile and position of the weld
seam prevents conformability .of the
tape to the steel surface. This
condition is encountered more often
on larger diameter (>60 in.[1,500
mm]) pipelines. In these cases, the
weld treatment shall be specified by
the
Employer
consultation
in
Charge
after
with
the
tape
manufacturer.
2.12.3.7.3
Coating Application
2.12.3.7.3.1 Liquid Adhesive Application
PAGE 108 OF 161
745 of 2461
MMRDA
The liquid adhesive shall be

applied in a uniform thin film at
the
coverage
rate
recommended
by
the
manufacturer.
The
liquid
adhesive shall be thoroughly

and continuously mixed and
agitated during application to
prevent settling. The liquid
adhesive may be applied to
the entire exterior surface of
the pipe by spray-type or rugtype methods or other suitable
means to cover the entire
exterior surface of the pipe.
The liquid adhesive coat shall
be uniform and free from
floods, runs, sags, drips, or
bare
spots.
The
liquid-
adhesive-coated pipe surface

shall be free of any foreign
substances, such as sand,
grease, oil, grit, rust particles,
or dirt. Before applying the
inner-layer
tape,
the
adhesive
layer
shall
liquid
be
allowed to dry in accordance

with
the
manufacturer's
recommendation.
2.12.3.7.3.2 Application
of
Inner-layer
Tape
The inner-layer tape shall be

applied
directly
onto
the
PAGE 109 OF 161
746 of 2461
MMRDA
prepared pipe surface using

mechanical
constant-tension
coating equipment. The inner

layer tape shall be spirally
applied with overlap width and
application
tension
recommended
as
by
manufacturer. When applied to

spirally
welded
pipe,
the
direction of the tape spiral

shall be generally parallel to
the weld spiral. The minimum
overlap shall not be less than
25 mm. When a new row of
tape is started, the ends shall
be overlapped at least 150
mm
measured
circumferentially.
2.12.3.7.3.3 Application of Outer-layer

Tape
The outer-layer tape shall be

applied over the inner-layer
tape using the same type of
mechanical equipment used to
apply the inner-layer tape. The
overlap of the outer-layer tape
shall not coincide with the
overlap of the inner-layer tape.
The minimum overlap of the
applied tape and minimum end
lap of two rolls shall be the
same as that of inner-layer
tape.
The
outer-layer
tape
PAGE 110 OF 161
747 of 2461
MMRDA
shall be applied at a minimum

roll temperature of 21 C. The
tape manufacturer shall be
consulted for recommended
temperatures of roll above 21
C to enhance conformability
of the outer-wrap to the pipe
surface.
2.12.3.7.3.4 Cutbacks
Cutbacks shall be 150 mm +

or -25 mm. The cutbacks may
be a straight edge for the total
thickness of the coating, or
they
may
be
tapered,
as
approved by the Employer in

Charge. The bare cutback
portion of each accepted pipe
shall be coated manually with
a
temporary
anti-corrosion
coating.
2.12.3.7.3.5 Coating
Repair
in
Plant/
Field
All
holidays
visually
or
electrically discovered either at

the coating plant or in the field
shall be repaired by peeling
back and removing the outer
and inner layers from the
damaged area. The exposed
areas shall then be coated
with liquid adhesive and either
PAGE 111 OF 161
748 of 2461
MMRDA
(1) a length of inner-layer

tapes shall be wrapped around
the pipe to cover the defective
area; or (2) a patch of innerlayer tape shall be applied
directly to the defective area
as specified by the Employer
in Charge.
The
minimum
lap
at
the
damaged area shall be 100

mm all around. The repaired
area shall be tested with a
holiday
detector
as
per
specifications after the repair

is completed. If holidays are
not found, the repaired area
shall be covered with the
outer-layer
minimum
tape
lap
of
with
100
a
mm
beyond the inner-tape patch.
Tape conforming to AWWA

C209 may be used as a
replacement for the inner-layer
tape when repairs are made.
2.12.4 Field Procedures
At all times during construction of the pipeline, the Contractor shall use
caution to prevent damage to the protective coating on the pipe. No
metal tools or heavy objects shall be permitted to unnecessarily contact
the finished coating. Workmen shall not be permitted to walk on the
coating except when necessary.
PAGE 112 OF 161
749 of 2461
MMRDA
In these cases, they shall wear shoes with rubber or composition soles
and heels or other suitable footwear that will not damage the coating.
Any damage to the pipe or the protective coating from any cause
during the installation of the pipeline shall be repaired.
2.12.4.1
Protection during Field Welding of Joints
A 450 mm wide strip of heat-resistant material shall be

wrapped over the top half of the pipe on each side of the
coating holdback during welding to avoid damage to the
coating by hot weld spatter. The welder grounding clamp
shall not be attached to the coated part of the pipe.
2.12.4.2
Hoisting
Pipe shall be hoisted using only wide-belt nylon slings or

the equivalent. The use of caliper clamps, metal chains,
cables, tongs, or other equipment likely to cause damage
to the coating shall not be acceptable, nor shall dragging
or kidding of the pipe be permitted. The Contractor shall
allow inspection of the coating on the underside of the
pipe while the pipe is suspended from the slings.
2.12.5 Inspection and Testing
2.12.5.1
Material Acceptance
Acceptance of the proposed coating materials shall be as

specified by the Employer in Charge from the following
options:
(1)
Acceptance of the manufacturer's certified test

reports submitted by the Contractor;
(2)
Acceptance of testing of samples of proposed
PAGE 113 OF 161
750 of 2461
MMRDA
materials submitted by the Contractor with testing

conducted by a responsible commercial laboratory
designated by the Employer or
(3)
Acceptance of another basis defined and specified

by the Employer.
2.12.5.2
Inspection and Testing by the Employer
Optional Inspection:
At the option of the Employer i n Charge, the entire

procedure of applying the protective coating material as
described will be inspected from surface preparation to
completion of coating. The inspection shall not relieve the
Contractor of his responsibility to provide material and
perform work in accordance with the specifications.
2.12.5.3
Coating Application Inspection:
The entire coating operation by the Contractor will be

supervised by qualified experts from the manufacturer.
The CV of the manufacturer's expert shall be approved by
the Employer. All coating work will be done in the
presence
of
the
Employer
or
his
authorized
representative. All coating work done in the absence of

the Employer or his authorized representative will be
subject to rejection.
2.12.5.4
Access of Employer
The Employer in Charge or his authorized representative

shall have free access to those parts of all plants that are
involved in the providing of materials or the performance
of work according to specifications.
PAGE 114 OF 161
751 of 2461
2.12.5.5
MMRDA
Facilities for Employer
The Contractor shall provide the Employer in Charge with

reasonable facilities and space without charge to inspect,
test, and obtain any information as desired regarding the
character of material used, how the materials were
applied, the progress and manner of the work, and the
results obtained.
2.12.6 Coated Pipe Tests
2.12.6.1
General
The Contractor shall establish and maintain such quality

assurance system as are necessary to ensure that goods
or services supplied comply in all respects with the
requirements
of
this
specification.
The
minimum
inspection and testing to be performed shall be as

indicated subsequently herein.
2.12.6.1.1
Visual Inspection
Immediately following the coating, each

coated pipe shall be visually checked for
imperfections
and
irregularities
of
the
coating. The coating shall be of natural

colour and gloss, smooth and uniform and
shall be blemish free with no dust or other
particulate inclusions. The coating shall not
show any defects such as blisters, pinholes,
scratches,
wrinkles,
engravings,
cuts,
swellings, disbonded zones, air inclusions,

tears, voids or any other irregularities.
Special attention shall be paid to the areas
PAGE 115 OF 161
752 of 2461
MMRDA
adjacent to the cut-back at each end of pipe

and within the body of the pipe. In addition
inside surface of the pipe shall also be
visually inspected for presence of any
foreign material or shots and grit (free or
embedded/sticking to pipe inside surface).
The pipe inside surface shall be examined
using sharp floodlight focused at the middle
of the pipe at one end while inspection is
carried out visually from other end.
2.12.6.1.2
Width Deviation
The standard width of the inner and outer

layer tapes should be 300mm/12 inches. A
specimen of inner-layer tape and outerlayer tape at least 0.9 m long shall be
removed from each of three randomly
selected rolls. The width of the specimen
shall be measured at several points along
the length of the sample to the nearest 1.6
mm using a standard steel scale. The width
deviation shall not exceed the limits stated
in Tables 2.6 and 2.7.
2.12.6.1.3
Thickness
The thickness of the inner-layer tape and

outer-layer tape shall be measured at not
less than 10 locations on the three rolls of
tape coating used. The measurements shall
be made with a micrometer calibrated to
read a thousandth of an inch and having
contact feet of not less than 6 mm in
diameter .Thickness measurements outside
PAGE 116 OF 161
753 of 2461
MMRDA
the limits stated in Tables 2.6 and 2.7 shall

constitute failure of the tape to meet the
thickness requirements.
2.12.6.1.4
Holiday Detection
a.
Each coated pipe length shall be

checked
over
100%
of
coated
surface by means of a "holiday

detector" of a type approved by
Employer for detecting holidays in
the finished coating.
b.
The holiday detector shall be a low

pulse
D.C.
full
circle
electronic
detector with audible alarm and

precise voltage control complying
with DIN VDE 0433 Part 2. The set
voltage between electrode and pipe
shall be 1KV for each 0.1mm of
coating thickness upto a maximum
25 kV. Travel speed shall not exceed
300 mm/s.
c.
Contractor shall calibrate the holiday

detector at least once every 4 hours
of production. Contractor shall have
necessary instruments or devices for
calibrating the holiday detector.
d.
Any pipe coating shall be rejected if

more than 1(one) holiday & area
more than 100 cm2 in size are
detected in its length attributable to
coating process.
PAGE 117 OF 161
754 of 2461
MMRDA
e.
Holidays which are lesser in size

than those mentioned in (d) above,
shall be repaired in accordance with
an approved procedure and shall be
at Contractor's expense.
f.
If excess occurrences of holidays on

successive pipes are detected, the
contractor shall immediately stop the
coating operation to determine the
cause and remedy it.
2.12.6.1.5
Adhesion
The prefabricated inner-layer tape shall be

tested for adhesion to a prepared steel
surface in accordance with ASTM D1000
(modified to include a 24-hour dwell time of
tape to primed substrate prior to adhesion
peel test). The outer-layer tape shall be
tested for adhesion to the inner-layer tape in
accordance with ASTM D1000 with above
modification. An average value below the
limits stated in Tables 2.6 and 2.7 shall
constitute failure of the tape to meet the
adhesion requirement.
2.12.6.1.6
Water Absorption
The prefabricated inner-layer tape coating

shall be tested for water absorption in
accordance with ASTM D 570. An average
value in excess of the limits stated in Table
2.6 shall constitute failure of the tape to
PAGE 118 OF 161
755 of 2461
MMRDA
meet the water-absorption requirements.
2.12.6.1.7
Water-vapor Transmission:
The prefabricated inner layer tape coating

shall be tested for water-vapor transmission
in accordance with ASTM E96, method B
(at 23C). An average value in excess of
the limits staled in Table 2.6 shall constitute
failure of the tape to meet the water-vapor
transmission requirements.
2.12.6.1.8
Dielectric Strength
The prefabricated inner-layer tape and the

outer-layer tape together shall be tested for
dielectric strength in accordance with ASTM
D149. Any below the limits stated in Table
2.8 shall constitute failure of the tape to
meet the dielectric-strength requirements.
2.12.6.1.9
Insulation Resistance
The prefabricated inner-layer tape coating

shall be tested for insulation resistance in
accordance with ASTM D1000. An average
value below the limits stated in table 2.6
shall constitute failure of the tape to meet
the insulation-resistance requirements.
2.12.6.1.10 Cathodic Disbondment Test
a.
48 hours CD test shall be conducted

as per ASTM G42/ASTM G8.
PAGE 119 OF 161
756 of 2461
MMRDA
b.
The frequency of this test shall be

once in every two weeks or one test
representing each batch of epoxy
powder used, whichever is more
frequent.
c.
In case the test fails to conform to the

specified requirement, at the option
of the Contractor, all pipes coated
after the previous acceptable test
and prior to next acceptable test shall
be rejected or the test shall be
repeated
using
two
additional
samples taken from the same end of

the affected pipe.
2.12.6.1.11 Tensile Strength
The prefabricated inner-layer tape and

outer-layer tape shall be tested for tensile
strength in accordance with ASTM D1000.
An average value below the limits stated in
Tables 2.6 and 2.7 shall constitute failure to
meet the tensile-strength requirements.
2.12.6.1.12 Elongation
The prefabricated inner-layer tape and

outer-layer
tape
elongation
in
shall
be
accordance
tested
with
for
ASTM
D1000. An average value below the limits

stated in Tables 2.6 and 2.7 shall constitute
failure to meet the elongation requirements.
2.12.6.1.13 Impact Resistance

PAGE 120 OF 161
757 of 2461
MMRDA
The total tape system shall be tested for

impact resistance in accordance with ASTM
G14. Five samples shall be tested and the
results averaged. An average value below
the limits stated in Table 2.8 shall constitute
failure of the coating system to meet the
impact-resistance requirements.
2.12.6.1.14 Penetration / Deformation Resistance
The total tape system shall be tested in

accordance with ASTM G17 at 22C. Five
samples shall be tested and the results
averaged. An average value above the
limits stated in Table 2.8 shall constitute
failure to meet the penetration-deformation
resistance requirements with no holiday.
2.12.6.1.15 Nonpolyolefinic Material Content
The inner-layer tape and the outer-layer

tape shall be tested for nonpolyolefinic
content in accordance with ASTM D4218.
Sections 9.11, 9.12, and 9.13 of ASTM
D4218 need not be performed in this test
method to obtain accurate results. The
adhesive layer must not be present on the
tape backing when performing the ASTM
D1218 test. Consult the tape manufacturer
for the preferred method of adhesive
removal. The tests should be performed
only on samples taken from tape supplied
by the tape manufacturer. Five samples
shall be tested and the results averaged. An
PAGE 121 OF 161
758 of 2461
MMRDA
average value outside the limits given in

Tables 2.6 and 2.7 shall constitute failure to
meet this requirement.
2.12.7 Rejection
Pipe: The Employer may reject pipe if the surface condition does not
comply with the requirements. Pipe rejected because of inadequate
cleaning shall be re-cleaned and re-inspected.
Coating Works: When inspection is provided by the Employer all

coating work not done in the presence of the Employer may be subject
to rejection. If at any time the procedure of applying the coating
material does not meet the requirements of the specifications all the
coating work shall be rejected.
Coating Materials: If any sample of coating material is found not to

conform to the specifications, then the coating material represented by
that sample shall be rejected. If samples of the Contractor's coating
materials that have been previously approved are found not to conform
to the specifications, then all the coaling material shall be rejected.
Damages occurring to pipe coating during above tests shall be repaired

in accordance with approved coating repair procedure. Repairs
occurring on account of the production tests are however excluded
from above mentioned limitations at Para (d) of holiday detection test
above.
The employer reserve the right to perform inspection and witness tests
on all activities concerning the pipe coating operations starting from
bare pipe to finished coated pipe ready for dispatch and also testing of
raw materials. Contractor shall give reasonable notice of time and shall
provide without charge reasonable access and facilities required for
inspection to the Employer. Inspection and tests performed or
witnessed by Employer shall in no way relieve the contractors
PAGE 122 OF 161
759 of 2461
MMRDA
obligation to perform the required inspection and tests.
In case rate of defective or rejected pipes and/or samples tests are

10% or more for a single shift (typically 8 hours), Contractor shall be
required to stop production and carry out a full and detailed
investigation and shall submit findings to Employer for approval.
Contractor shall recommence the production only after getting the
written permission from Employer. Under no circumstances any action
or omission of the Employer shall relieve the Contractor of his
responsibility for material and quality of coating produced. No pipes
shall be transported from the coating plant unless authorized by
Employer in writing.
2.12.8 Delivery
2.12.8.1
Marking
Contractor shall place marking on the outside surface of

the coating at one end of the coated pipe, and marking
snail indicate, but not limited to the following information:
a.
Pipe number, Heat number
b.
Diameter & Wall thickness, Pipe Material Grade
c.
Coated pipe number and Type of Coating
d.
Colour band
e.
Pipe Manufacturers Name
f.
Coating Contractors Name
g.
Inspection Mark/Punch
h.
Date of coating
i.
Any other information considered relevant by
Employer
Contractor shall obtain prior approval on marking

procedure to be adopted from the Employer.
PAGE 123 OF 161
760 of 2461
2.12.8.2
MMRDA
Packaging
All inner-layer tapes, outer-layer tapes, and liquid

adhesives shall be packaged in suitable containers to
ensure acceptance and safe delivery to their destination.
Preference of individual or multiple packaging of the
tapes and size liquid adhesive container shall be as
specified by the Employer. Rolls of inner-layer pipe and
outer-layer tape shall be packaged in quantities not to
exceed
the
weight
limitations
of
the
container
specifications. Each roll of inner-layer tape and outerlayer tape shall be protected from adhering to other rolls,
to the container, or to the packaging material itself using
separators. Liquid adhesive shall be packaged in 5 gal
(19 l) pails, 55 gal (210 l) drums, or other suitable
containers.
2.12.8.3
Handling, Transportation and Storage
The Contractor shall be fully responsible for the pipe and

for the pipe identification marking. All pipes shall be
checked for bevel damages, dents, gouges, corrosion
and other damages. Employer shall decide whether pipe
defects / damages are suitable for repair. Inspection of
bare pipe for laminations and other steel defects shall
only be done after blast cleaning.
All pipes shall be checked for external and internal

contamination by items such as oil, grease, temporary
coating, chlorides or other substances which may affect
the blast cleaning process/plant.
The Contractor shall unload, load, stockpile and transport

the bare pipes within the coating plant(s) using suitable
means and in a manner to avoid damage to pipes. The
PAGE 124 OF 161
761 of 2461
MMRDA
Contractor shall stockpile the bare pipes at the storage

area of the coating plant. The Contractor shall prepare
and furnish to Employer a procedure/calculation for
stacking of pipes of individual sizes and wall thickness
which shall be approved by him prior to commencement.
The contractor shall load, unload, transport and stockpile

the coated pipes within the coating plant using approved
suitable means and in a manner to avoid damage to the
pipe and coating. The Employer shall approve such
procedure prior to commencement of work.
Coated pipes may be handled by means of slings and

belts of proper width made of nonabrasive/non-metallic
materials, in this case, pipes to be stacked shall be
separated row by row to avoid damages by rubbing the
coated surface in the process of taking off the slings. Use
of round sectional slings is prohibited. Fork lifts may be
used provided that the arms of the forklift are covered
with suitable pads, preferably rubber.
Bare/ coated pipes at all times shall be stacked

completely clear from the ground, at least 300 mm, so
that the bottom rows of pipes remain free from any
surface water. The pipes shall be stacked at a slope so
that driving rain does not collect inside the pipe. Bare /
coated pipes may be stacked by placing them on ridges
of sand free from stones and covered with a plastic film or
on wooden supports provided with suitable cover. This
cover can be of dry, germ free straw covered with plastic
film, otherwise foam rubber may be used. The supports
shall be spaced in such a manner as to avoid permanent
bending of the pipes.
Stacks shall consist of limited number of layers such that

PAGE 125 OF 161
762 of 2461
MMRDA
the pressure exercised by the pipe's own weight does not

cause damages to the coating. Contractor shall submit
calculations for Employer approval in this regard. Each
pipe section shall be separated by means of spacers
suitably spaced for this purpose. Stacks shall be suitably
secured against falling down and shall consist of pipe
sections having the same diameter and wall thickness.
Bevel protectors provided by pipe manufacturer shall
always be re-installed after coating and before handling of
the pipes.
The vehicles used for transportation shall be equipped

with adequate pipe supports having as many round
hollow beds as there are pipes to be placed on the
bottom of the lorry bed. Total width of the supports shall
be at least 5% of the pipe length and min. 3 no. support
shall be provided.
These supports shall be lined with a rubber protection

and shall be spaced in a manner as to support equal load
from the pipes. The rubber protection must be free from
all nails and staples where pipes are in contact. The
second layer and all following layers shall be separated
from the other with adequate number of separating layers
of protective material such as straw in plastic covers or
mineral wool strips or equivalent, to avoid direct touch
between the coated pipes. All stanchions of Lorries used
for transportation shall be covered by non-abrasive
material like rubber belts or equivalent. Care shall be
exercised to properly cover the top of the stanchions and
other positions such as reinforcement of the truck body,
rivets, etc. to prevent damage to the coated surface.
Slings or non-metallic straps shall be used for securing
loads during transportation. They shall be suitably padded
at the contact points with the pipe
PAGE 126 OF 161
763 of 2461
MMRDA
Materials other than pipes and which are susceptible of

deteriorating or suffering from damages especially due to
humidity, exposure to high thermal excursions or other
adverse weather conditions, shall be suitably stored and
protected. Deteriorated materials shall not be used and
shall be replaced at CONTRACTOR's expenses. These
materials shall always be handled during loading,
unloading and storage in a manner so as to prevent any
damage, alteration and dispersion. When supplied in
containers and envelopes, they shall not be dropped or
thrown, or removed by means of hooks, both during the
handling operations till their complete use. During
unloading, transport and utilization, any contact with
water, earth, crushed stone and any other foreign
material shall be carefully avoided. Contractor shall
strictly follow manufacturer's instructions and local
regulations regarding storage temperature and methods
for volatile materials that are susceptible to change in
properties and characteristics due to unsuitable storage.
If necessary the Contractor shall provide for a proper
conditioning.
2.12.9 Coating of Welded Joints for MS Pipeline
2.12.9.1
General
This section provides with the requirements for heatshrinkable
coating,
including
material
application,
inspection, testing, marking and packaging requirements.
2.12.9.2
Quality
All materials provided by the Contractor shall be of the

specified quality. The entire operations of applying the
PAGE 127 OF 161
764 of 2461
MMRDA
heat shrinkable coating shall be performed by workers

trained in the application of heat-shrinkable coating
system.
The materials provided shall meet the provisions of

AWWA C216. Work or material that fails to conform to
this standard may be rejected at any time before final
acceptance
2.12.9.3
Coating System
Heat-shrinkable coatings consist of material fabricated

from cross-linked polyolefin sheet or tubing pre-coated
with an adhesive. After they are installed, the coating
shall conform to all surface contours of the pipe.
2.12.9.3.1
Sleeve Requirements
Heat shrinkable polyolefin material shall

conform to the following requirements:
2.12.9.3.2
Material
The Heat Shrinkable polyolefin coating shall

be a laminate that consists of a cross linked
polyolefin backing and a homogeneous
adhesive layer. The adhesive may be either
a
tack,
pressure-sensitive
amorphous
adhesive (mastic) or a non-tacky, semi

crystalline adhesive (hot melt).
The prefabricated heat-shrinkable polyolefin

coating shall be one of the following types:
Type I, Tubular-type Coatings: These are

PAGE 128 OF 161
765 of 2461
MMRDA
installed before joining the pipe ends by

sliding the coating from a free end of the
pipe onto the area to be coated.
Type II, Wraparound-type Coatings: These are

wrapped circumferentially around the pipe area to
be coated. Each wraparound coating is provided
with either a separate or a built-in closure, as
supplied by the manufacturer that secures the
overlap during the shrinking process.
The closure shall meet the technical requirements

given in Table 5, with the exception of thickness
which shall be a minimum of 24 mil (0.6 mm) as
supplied.
2.12.9.3.3
Form
Type I coatings are provided in sleeves of

predetermined diameters to fit the steel pipe. Type
II coatings may be supplied in individually precut
sizes or in roll form. A roll form product is wound
on hollow cores with a minimum inside diameter of
75 mm.
2.12.9.3.4
Dimensions
The manufacturer shall provide precut coatings

standard widths as specified by Employer in
Charge but not less than 450 mm. It should be
adequate to provide the stipulated overlaps on the
pipe/ fittings coating.
PAGE 129 OF 161
766 of 2461
MMRDA
Table 2.9: Physical Properties of Heat-shrinkable Coatings

Property
Minimum
Maximum
Test Method
(Ref AWWA
C216)
Width Deviation
10% width or 0.25 in -
Sec 5.3.1
(6mm), whichever is
smaller
Thickness
(as Type I: 60mil (1.5mm)
supplied)
Type
II:
60mil --
(1.5mm)
Water-vapor
0.05
Transmission
g/h/m2
Dielectric Strength
400 V/mil (15 V/m)
Volume Resistivity
1014
Adhesion to Steel
8 lbs/linear in.
Heat Shock (test for

cross
linking
backing)
of
No
ohm
Centimeter
visual
cracking,
Sec 5.3.2 Sec

5.3.2
Sec 5.3.3
Sec 5.3.4
Sec 5.3.5
Sec 5.3.6
Sec 5.3.7
flowing, or dipping
Tensile Strength
2200 psi (15.2 MPa)
Sec 5.3.8
Elongation
400%
Sec 5.3.9
Impact Resistance
25 in-lb (282 cm-N)
Sec 5.3.11
Thickness
Type I and Type II heat-shrinkable polyolefin

coatings shall have a minimum thickness of 60 mil
(1.5 mm) as supplied.
Coating requirements
Table 2.9 shows the requirements for the physical

properties of heat shrinkable coatings.
2.12.10 Field Coating Application

PAGE 130 OF 161
767 of 2461
2.12.10.1
MMRDA
Equipment
The Contractor's equipment for cleaning and coating shall

be designed and maintained to comply with the
procedures and to obtain the results required by these
specifications
2.12.10.2
Surface Preparation
2.12.10.2.1 Bare Surface
Bare surface shall be free from mud, mill

scale, lacquer, wax, paint, coal tar, asphalt,
oil, grease, or any other foreign material.
Before blast cleaning, surfaces shall be
inspected and, if required, pre-cleaned
according to SSPC-SP1 to remove oil,
grease, and loosely adhering deposits. Only
prevailing code safety solvents that do not
leave a residue shall be used. Preheating to
remove oil, grease, mill scale, water and ice
may be used, provided all surfaces are
preheated in a uniform manner to avoid
distortion. Welds shall be cleaned of all
welding slag, spatter and scale and shall be
allowed to cool before the coating is applied.
Sharp edges or burns that could puncture or
cut the coating shall be removed by grinding
or filling.
2.12.10.2.2 Blast Cleaning
All metal surfaces shall be blast cleaned to

achieve a surface preparation equivalent to
PAGE 131 OF 161
768 of 2461
MMRDA
SSPC-SP 6/NACE No.3.
2.12.10.2.3 Protection from Moisture
Blast-cleaned surface shall be protected

from conditions of high humidity, rainfall or
surface moisture and shall not be allowed to
flash rust before the coating is applied. If
rust occurs, the surface must be prepared
again by blast cleaning in the mill or shop or
by either blast cleaning or wire-brush
cleaning in the field. At the time of
coating/adhesive
application
the
steel
substrate shall be at least 3C above the

dew point.
2.12.10.2.4 Wire Brush Cleaning
Surfaces that have been blast cleaned in a

mill or shop before shipment to a field
location shall be cleaned using a solvent
wash and wire brushing or other approved
means at the time the heat-shrinkable
coating is applied. All wire brushed metal
surfaces shall be prepared according to
SSPC-SP 2 or SSPC-SP3.
2.12.10.3
Coating and Wrapping
The manufacturer/Contractor shall provide the Employer

in Charge with the specific application procedure used for
each type of coating system. The total thickness applied
shall
as
specified
by
Employer
in
Charge,
with
consideration of the manufacturer's recommendations,

but in no instance shall the total thickness be less than
PAGE 132 OF 161
769 of 2461
MMRDA
the minimum thickness stated in Table 10.
The heat-shrinkable coating shall bond to and overlap the

mill coating by a minimum of 50 mm after final
application. The supplied width should be a minimum of
127 mm wider than the exposed steel area to be covered.
Maximum and minimum temperatures for applying and
handling coatings specified by the manufacturer shall be
followed.
2.12.10.3.1 Coating Repair
All damaged or flawed areas, holidays, and

mislays shall be repaired by using Type I,
Type II coatings, Alternatively, cold-applied
tape coatings conforming to AWWA C209 or
polyethylene patch sticks or patch materials
as recommended by the manufacturer and
approved by Employer in Charge may also
be used. The damaged area shall be
covered with a minimum of 50 mm overlap
around the damaged area by using either a
precut patch or wraparound coating. The
repaired area shall be tested with a holiday
detector after the repair is completed.
2.12.10.3.2 Outdoor Storage
Because environmental conditions vary, the

Employer
should
consult
with
the
manufacturer as to the specific conditions,

including ultraviolet light exposure, to which
the coated pipe will be subjected when it is
stored above ground prior to installation.
PAGE 133 OF 161
770 of 2461
MMRDA
2.12.11 Other Requirement
Field procedure, inspection, test etc. shall be as applicable for coating

in factory.
Laboratory tests to establish material compliance with the provision of

these specifications are as follows:
2.12.11.1
Coating Width
For Type I and Type II coatings, three discrete product

sleeves shall be selected at random and placed on a
smooth, flat surface. The width of the specimen shall be
measured to the nearest 1/16 in. (1.6 mm) at 10 locations
along the length of the sample. Any deviation from values
in Table 10 shall constitute failure of the width
requirement.
2.12.11.2
Impact Resistance:
The heat-shrinkable coating shall be tested for impact

resistance according to ASTM G14. Alternatively, DIN
30672 Class B (pass/ fail) testing may also be used.
2.12.11.3
Coating Thickness
The thickness of the coating as supplied shall be

measured at not less than 10 locations on each of the
three
specimens.
The
coating
thickness
shall
be
measured with a micrometer calibrated to read in

thousandth of an inch and having contact feet of not less
than 1/4 in. (6 mm) in diameter. The average of the 10
measurements shall be not less than that shown in Table
10. No single measurement shall deviate more than 15
percent from the average value. The thickness of the
PAGE 134 OF 161
771 of 2461
MMRDA
adhesive shad be at least equal to, but not more than

three times, the thickness of the cross-linked polyolefin
backing.
2.12.11.4
Water-vapor Transmission
The heat shrinkable coating shall be tested for watervapor transmission according to ASTM E96 (method B).
A value in excess of the limit in Table 2.9 shall constitute
failure
of
the
coating
to
meet
the
water
vapor
transmission requirement.
2.12.11.5
Dielectric Strength
The heat shrinkable coating shall be tested for dielectric

breakdown according to ASTM D149 using a 1-in (25mm) diameter electrode and 500-V/s voltage rise. A value
below the limit in Table 2.9 shall; constitute a failure of the
coating to meet the dielectric strength requirement.
2.12.11.6
Volume Resistivity
The heat-shrinkable coating shall be tested for volume

resistively according to ASTM D257. A value below the
limit in Table 2.9shall constitutes failure of the coating to
meet the volume receptivity requirement.
2.12.11.7
Adhesion
The heat shrinkable coating system shall be tested for

adhesion according to ASTM D1000. A value below the
limit in Table 2.9 shall constitute failure of the coating to
meet the adhesion requirement.
2.12.11.8
Heat Shock
PAGE 135 OF 161
772 of 2461
MMRDA
This test is to be conducted and values determined to

ensure that the backing of the heat shrinkable coating is
sufficiently cross linked. The heat-shrinkable coating shall
be tested for heat shock by removing the adhesive from
the coating before performing the test and hanging a strip
of the prepared backing in a 392F (200"C) oven for 4 hr.
The backing will shrink but should show no dripping,
flowing, or cracking as specified in Table 2.9.
2.12.11.9
Tensile Strength
The heat-shrinkable coating shall be tested for tensile

strength according to ASTM D638. An average value
below the limit In Table 2.9.shall constitute failure to meet
the tensile requirement.
2.12.11.10
Elongation
The heat-shrinkable coating shall be tested for elongation

according to ASTM D638. An average value below the
limit in Table 2.9 shall constitute failure to meet the
elongation requirement.
2.12.12
Electrical Inspection for Continuity
After the heat-shrinkable coating has been properly

applied, the Contractor shall conduct an electrical
inspection of all wrapped surfaces with an electrical
holiday detector. Any defect in the coating shall be
satisfactorily repaired at the expense of the Contractor.
Detector
The electrical equipment used to coat the heat-shrinkable

PAGE 136 OF 161
773 of 2461
MMRDA
coating in the shop or yard and in the field shall be a

portable, low-amperage, adjustable-voltage pulse holiday
detector that employs an audible signaling device.
The holiday detector shall use coil spring electrode or a

brush electrode.
The primary input power shall be no higher than 20 W,

and the minimum pulses at crest voltage shall be 20 Hz.
The operating voltage of the detector shall be determined
by the following formula:
V= 1,250 Vt Where:
V = the inspection voltage
t = average system thickness in mil (0.001 in.)
Because of variables, such as relative humidity and

temperature, the detector voltage shall be checked no
less than twice daily that is before starting work in the
morning and before resuming work in the afternoon. To
ensure proper inspection voltage the equipment shall be
properly grounded and the voltage adjusted according to
the instructions of the equipment manufacturer.
Detector Use
After the voltage has been properly checked, the

electrode shall be passed over the coated surface one
time only, at a rate of approximately 30-60 ft/min (9-18
m/min). If the electrode is stopped while passing over the
coated surface, the current to the electrode should be cut
off immediately to avoid possible damage to the coating.
PAGE 137 OF 161
774 of 2461
MMRDA
Holiday Detection and Repair
Any holidays will be indicated by an electric spark

between the electrode and the metal surface and by an
audible signal. The heat-shrinkable coating shall pass the
electrical inspection test if no electrical spark occurs. If an
electric spark occurs between the electrode and the metal
surface, the holiday shall be marked with a suitable
indicator such as chalk or crayon to identify the area for
repair.
2.12.13 Delivery
2.12.13.1
Packaging
Heat-shrinkable coatings shall be packaged in containers

that ensure acceptance and safe delivery to their
destination.
packaging
Preference
of
for
heat-shrinkable
individual
or
coating
may
multiple
be
as
suggested by manufacturer.
Individual Items
Each heat-shrinkable coating item shall be packaged to

prevent adherence to the packaging material or the
container.
Multiple Items
Coating shall be packaged in quantities not to exceed the

weight limitation of the container specification
2.12.13.2
Marking
The carton packaging shall be plainly marked with the

PAGE 138 OF 161
775 of 2461
MMRDA
name of the manufacturer, type of material, batch or lot

number, date of manufacture and information as required
by federal and state laws.
2.12.13.3
Shipping, Handling and Storing
Coated articles shall be handled, stored and shipped in a

manner that will prevent damages to the coating. The
Contractor shall be responsible to repair any coating
damaged in handling or other operations at no additional
cost.
2.12.14 Coatings for Exterior of Special Sections, Connections and

Fittings
2.12.14.1
General
This section provides the requirements for cold applied

tapes for the exterior of special sections, connections and
fittings, including material application, inspection, testing,
marking and packaging requirements.
The protective coating system described in this section

consists of a prefabricated cold-applied tape and liquid
adhesive applied to the exterior surface of steel water
pipe specials, connections, and fittings.
2.12.14.2
Materials and Workmanship
The materials provided shall meet the provisions of

AWWA C209. Work or material that fails to conform to
this standard may be rejected at any time before final
acceptance.
2.12.14.3
Material Requirements
PAGE 139 OF 161
776 of 2461
MMRDA
2.12.14.3.1 Liquid Adhesive
Liquid adhesive shall be of a type that can

be applied without heat and produce an
effective bond between the surface to be
protected and the applied tape.
Liquid adhesive shall comply with pollution

control requirements that are in effect at the
location of use. Liquid adhesive that may
settle in the container shall not form a cake'
that cannot be mixed easily by hand stirring
or agitation.
Liquid adhesive shall have satisfactory

properties for spraying, brushing, or other
acceptable application methods, and a
minimum tendency to produce bubbles
during application. Liquid adhesive and
prefabricated tape shall be from the same
manufacturer.
2.12.14.3.2 Prefabricated Tape
2.12.14.3.2.1 Materials
Prefabricated
tape
shall
cold-applied
be
made
from
materials that provide high

electrical resistivity, resistance
to corrosive environments and
low moisture absorption and
permeability,
conform
to
and
the
shall
physical
PAGE 140 OF 161
777 of 2461
MMRDA
property requirements stated

in
Table
accordance
established
with
the
in
test
procedures.
In addition, the tape shall be

compatible with and provide an
effective bond to the primed
steel
surface
and
the
previously applied plant or field

coatings, and shall seal to
itself.
The prefabricated, cold-applied

tape shall consist of a laminate
composed of a plastic film
backing and a homogeneous
elastomeric sealant layer.
The sealant layers, in some

instances, are covered with
release liners or separators.
These
liners
or
separators
must be removed prior to

performing physical property
tests and before application to
primed steel surfaces.
Tapes shall resist excessive

mechanical
damage
during
normal application operations

and be sufficiently pliable so
as to conform to the surface to
be coated. The tapes also
shall
withstand,
without
PAGE 141 OF 161
778 of 2461
MMRDA
tearing,
the
tensile
force
necessary to obtain a tightly

wrapped coating.
2.12.14.3.2.2 Form
The prefabricated tape shall

be supplied in sheets, pads, or
rolls wound on hollow cores as
directed
by
Employer
in
Charge. Hollow cores shall

have
minimum
inside
diameter of VA in. (38 mm).
2.12.14.3.2.3 Dimensions
Prefabricated tape shall be

provided in standard widths of
2, 3, 4, 6, 8, 9 and 12 in. (50,
75, 100, 150, 200, 225 and
300 mm) as approved by the
Employer in Charge.
Typical standard lengths are

50, 75, and 100 ft. (15, 23, and
30 m). Pads and sheets shall
be sized to fit the area to be
covered allowing for overlap.
2.12.14.3.2.4 Thickness
Prefabricated tape rolls shall

be (provided in the minimum
thickness as approved by the
Employer, but in no case shall
PAGE 142 OF 161
779 of 2461
MMRDA
the thickness be less than

shown in Table 2.10.
Table 2.10: Physical Properties of Tape and Coating

Property
Minimum
Test Method
(Ref. AWWA
C209-00)
Width
Deviations: 5% of width or 1/4 in. Sec 5.3.2.1
Maximum
(6mm),
whichever
is
smaller
Thickness: Minimum
30
mil
(750um)
5% Sec 5.3.2.2
minimum
Water-vapor Transmission
0.25
perm
(1.44 Sec 5.3.2.3
ng/fpa.s.m*}, minimum
Dielectric Breakdown
Insulation
400V/mil(15V/pm)
Resistance:, Minimum
minimum
500,000
Sec 5.3.2.4
Sec 5.3.2.5
megohms
Adhesion (Bond) to Primed 20 ozf/in. (220 g/cm) width, Sec 5.3.2.6

Steel: Minimum
2.12.14.4
minimum
Coating Application (Field and Shop)
2.12.14.4.1 Equipment, Surface Preparation
The specification as applicable for pipes

shall prevail.
2.12.14.4.2 Visual
Comparative
Standards,
Protection from Moisture
The specification as applicable for pipes

PAGE 143 OF 161
780 of 2461
MMRDA
shall prevail.
2.12.14.4.3 Priming
uniform,
continuous
coat
of
liquid
adhesive shall be applied according to the

manufacturer's
recommendations,
as
approved by Employer in Charge. The liquid

adhesive coverage and curing or drying time
shall be sufficient to ensure an effective
bond
between
the
substrate
and
the
coating. Liquid adhesive application shall be

limited to the amount of surface area that
can be wrapped during the same workday
as
application
of
the
liquid
adhesive;
otherwise, the steel must be re-primed. After

liquid adhesive application, and before the
tape is applied, care shall be taken to
prevent the contamination of the primed
surface by any foreign materials such as dirt
and moisture.
In case of restriction on use of liquid

adhesive because of emission regulation,
tape systems not requiring the use of liquid
adhesives may be used provided that the
tape
material
requirements
continues
with
prior
to
meet
the
approval
of
Employer in Charge.
2.12.14.4.4 Coating and Wrapping
The total thickness to be used shall be as

approved by Employer in Charge, but in no
instance shall the total applied thickness be
PAGE 144 OF 161
781 of 2461
MMRDA
less than the thickness shown in Table 11

using a minimum overlap of 1 in. (25 mm).
Where the tape coating joins with millapplied coatings, it shall overlap the mill
coatings by a minimum of 3 in. (75 mm) and
bond to them. When the use of hand-or
power-operated machines to apply the tape
is recommended, the Contractor shall use
the machine approved by the Employer in
Charge.
Maximum and minimum temperatures for

application and handling specified by the
manufacturer shall be followed.
2.12.14.4.5 Coating Repair
Damages, flawed areas, holes or mishaps

to coatings applied to special sections,
connections, and fittings from any cause
during
installation
and
before
final
acceptance shall be repaired by peeling

back and removing the tape layers from the
affected area. The repair area shall be
brushed with a primer, then a patch of tape
covering a minimum of 4 in. (100 mm)
around the affected area shall be applied by
wrapping it around the pipe or by applying a
patch of tape as specified by manufacturer
and approved by Employer in Charge. After
the repair is completed, the repaired area
shall be tested with a holiday detector.
2.12.14.5
Field Procedures
PAGE 145 OF 161
782 of 2461
MMRDA
The specification as applicable for pipes shall prevail.
2.12.14.6
Inspection
2.12.14.7
2.12.14.8
Testing
Acceptance of the proposed coating materials shall be as

specified by the Employer n Charge from the following
options: (1) acceptance of the manufacturer's certified
test reports submitted by the Contractor; (2) acceptance
of testing of samples of proposed materials submitted by
the Contractor with testing conducted by a responsible
commercial laboratory designated by the Employer in
Charge; or (3) acceptance of another basis defined and
specified by the Employer in Charge.
2.12.14.8.1 Tape and Coating System Tests
2.12.14.8.1.1 Tape Width
Remove a specimen of tape at

least 3 ft. (0.9 m) long from
each
of
three
randomly
selected rolls, or select three

sheets
or
pads
of
tape
specimens at random, and

place
on
smooth,
flat
surface. Measure the width of

the specimen tape at several
PAGE 146 OF 161
783 of 2461
MMRDA
points along the length of the

sample to the nearest 1/16 in.
(1 mm). Any width deviation
outside the limits shown in
Table
2.10
shall
constitute
failure of the width test.
2.12.14.8.1.2 Tape Thickness
Measure the tape thickness at

not less than 10 locations on
each of three sheets, pads or
rolls
of
specimens.
The
measurements shall be made

with a micrometer calibrated to
read in thousandths of an inch
(millimeters) and shall have
contact feet not less than % in.
(6
mm)
in
diameter.
Any
thickness measurement below

the limits shown in Table 2.10
shall constitute failure of the
thickness test.
2.12.14.8.1.3 Water Vapor Transmission
Test the prefabricated cold

applied tape for water vapor
transmission
according
to
ASTM E96, method B. A value

in excess of the limits shown
in Table 2.10 shall constitute
failure of the tape to meet the
water
vapor
transmission
requirements.
PAGE 147 OF 161
784 of 2461
MMRDA
2.12.14.8.1.4 Dielectric Breakdown

applied
tape
for
dielectric
breakdown according to ASTM

D1000. A value below the
limits shown in Table 2.10
shall constitute a failure of the
tape to meet the dielectric
strength requirements.
2.12.14.8.1.5 Insulation Resistance

applied
tape
for
insulation
resistance according to ASTM

D1000. A value below the
limits shown in Table 2.10
tape to meet the insulation
resistance requirements.
2.12.14.8.1.6 Adhesion to Primed Steel
Test the coating system for

adhesion according to ASTM
D1000, method A, modified for
use of primer. A value below
the limits shown in Table 11
tape to meet the adhesion
requirements.
2.12.15 Rejection
PAGE 148 OF 161
785 of 2461
MMRDA
2.12.16 Delivery
2.12.16.1
Marking
The containers shall be plainly marked with the name of

the manufacturer, type of material batch or lot number,
date of manufacture, and information as required by
federal and state laws.
2.12.16.2
Packaging and Shipping
2.12.16.2.1 Packaging
All tapes and liquid adhesives purchased or

used according to these specifications shall
be packaged in containers that ensure
acceptance and safe delivery to their
destination. Preferences for the individual or
multiple packaging of tape and the size of
liquid adhesive containers may be specified
by the Employer in Charge.
Individual Items: Each sheet, pad, or roll of

tape
shall
be
packaged
to
prevent
adherence to the packaging material or the

container.
Multiple Items: Multiple sheets, pads, or rolls

shall be packaged in quantities not to
exceed the weight limitation of the container
specification. Each sheet, pad, or roll of tape
shall be protected from adhering to other
PAGE 149 OF 161
786 of 2461
MMRDA
sheets, pads, rolls of tape, the container, or

to the packaging material using separators.
Liquid Adhesive: Liquid adhesive shall be

packaged in 1 gal (3.8 I) cans, 5 gal (18.9 I)
pails, or other containers acceptable to the
Employer in Charge and the manufacturer,
and
that
comply
with
internationally
accepted best practices and regulations.
2.12.16.2.2 Shipping, Handling and Storage
Coated articles shall be handled, stored and

shipped in a manner that will prevent
damage to the coating. Coating damaged in
handling or other operations shall be
repaired satisfactorily at no additional cost
to the Employer. Damaged coatings shall be
repaired.
2.13
External coating on MS pipe above ground
2.13.1 Coating and Lining Systems
The coating and lining systems shall consist of two-part, chemically

cured epoxy primer and two coatings of a different two-part, chemically
cured epoxy topcoat.
2.13.1.1
Liquid-Epoxy Coatings
The coatings used shall be based on liquid, chemically

cured epoxies. The curing agent may be an amine,
amine-adduct, or polyamide; and the epoxy may be
modified with the coal rat, phenolic, or other modifiers.
Materials used in both the primer and finish coat(s) shall
PAGE 150 OF 161
787 of 2461
MMRDA
be products of one manufacturer.
2.13.1.2
Coating Thickness
Unless otherwise specified by the purchaser, the

minimum dry film thickness DFT provided shall be at least
406 m.
After curing but prior to burial, the coating system shall be

a continuous film, free of thin spots and other
imperfections as defined and shall pass electrical
inspection.
2.13.1.3
Coating Application
The pipe coating shall be applied in accordance with the

manufacturers recommendations. Application by airless
spray or centrifugal wheel equipment is preferred.
2.13.2 Pipe Preparation
2.13.2.1
Cleaning
Prior to abrasive blast cleaning, surfaces shall be

inspected and, if required, cleaned according to remove
oil, grease, or other foreign matter. Only approved
solvents that do not leave a residue shall be used.
Preheating to remove oil, grease, mill scale, water and ice
may be used provided all pipes are preheated in a
uniform manner to avoid distorting the pipe.
2.13.2.2
Abrasive Blast Cleaning
The exterior pipe surfaces shall be abrasive blast cleaned

to achieve a near white metal surface. The interior pipe
PAGE 151 OF 161
788 of 2461
MMRDA
surfaces shall be abrasive blast cleaned to achieve a

white metal surface. Abrasive blasting and coating shall
only be performed when the metal temperature is more
than 3C above dew point.
2.13.2.3
Surface Inspection
The exterior and interior pipe surfaces shall be inspected

for surface imperfections, such as slivers, scabs, burrs,
weld spatter, and gouges, shall be removed by grinding.
2.13.2.4
Interior Cleaning
If abrasives or other loose foreign matter has entered the

interior of the pipe, then clean, dry oil free compressed air
shall be used to remove the loose foreign matter in a
manner that does not adversely affect the cleaned
surface. Alternatively, vacuum cleaning or other methods
may be used in place of compressed air.
2.13.2.5
Application Temperature
The temperature of the mixed coating material and of the

pipe at the time of application shall not be lower than
10C. Preheating of the coating material, the use of in line
heaters to heat the coating material; or heating of the
pipe, fittings or specials may be used to facilitate the
application.
Heating
shall
conform
to
the
recommendations of the coating manufacturer.
2.13.2.6
Application of Epoxy Coating System
If more than one coat is applied, the second coat shall be

applied within the time limits, surface conditions, and
temperature recommended by the manufacturer, if the
PAGE 152 OF 161
789 of 2461
MMRDA
period between coats is exceeded, then a repair

procedure
shall
be
obtained
from
the
coating
manufacturer and its recommendations followed.
2.13.3 Cure
After application, the coating system shall be tested for cure.
2.13.4 Electrical Inspection for Continuity
After curing, but prior to installation, the coating system applied to the
pipe shall be tested for holidays according to the procedures and using
the voltage settings. Any holidays indicated by the detector shall be
marked with chalk or felt-tip marker to identify the area to be repaired.
2.13.5 Coating Repair
Accessible areas of pipe requiring coating repairs shall be cleaned to

remove debris and damaged coating using surface grinders or other
means acceptable to the purchaser. The adjacent coating shall be
feathered by sanding, grinding, or other methods approved by the
purchaser. Accumulated debris shall be removed by vacuum, blowing,
or wiping with clean rags.
2.13.6 Welded Field Joints
2.13.6.1
Preparation
The weld joint shall be cleaned so as to be free from

mud, oil, grease, welding flux, weld spatter, and other
foreign contaminants. The cleaned metal surfaces of the
weld joint shall then be abrasive blasted, vacuum blasted,
or abraded using rotary abrading pads. The adjacent
liquid epoxy coating shall be feathered by adbrading the
coating surface for a distance of 25 mm.
PAGE 153 OF 161
790 of 2461
2.13.6.2
MMRDA
Electrical Inspection
After curing, the coating system applied to the welded

joints shall be holiday tested. Any holidays indicated by
the detector shall be marked with chalk or felt-tip marker
to identify the area for repair.
2.13.6.3
Bedding and Trench Backfill
Where the trench traverses rocky ground containing hard

objects that could penetrate the protective coating, a layer
of screened earth, sand, or rounded river run gravel not
less than 150 mm thick with a maximum particle size of
20 mm shall be placed in the bottom of the trench prior to
installation of the coated article.
2.14
Civil Works
The following civil works are required for the pipeline and associated works.
Specifications for material used, workmanship, testing and sampling of
materials shall be in accordance with the respective provisions laid down in
corresponding subsection.
2.14.1 Supports
The MS water main, in general, shall be laid below the ground. In the
portions on bridge where it is exposed the pipes will be supported on
Ring Girders.
Pipeline supports shall be provided generally at intervals of not more

than 10 m center to center, and the precise spacing shall be
established based on the Site conditions and structural design of the
MS pipe for each section. The material and construction of the RCC/
steel structures, such as saddles, anchor blocks, thrust blocks,
PAGE 154 OF 161
791 of 2461
MMRDA
crossings, etc., associated with the pipe line work shall conform with
the relevant IS codes, good Employering practice and as mentioned in
technical specifications for civil works.
2.14.2 Valve Chambers
Valve chambers of adequate size considering the working space during

erection and operation shall be provided to house the different valves.
The chambers shall be in RCC of minimum grade M20. A leveling
course of PCC M15 shall be provided below the chamber slab.
The roof of the valve chamber shall be of RCC slab or precast slab as
shown in tender drawing. The walls shall be designed to withstand
lateral earth pressures. The roof and slabs shall be designed to
withstand a dead load of butterfly valve and live load as per IS:
875.Heavy duty manhole of required size 600 mm as per tender
drawing, is to be provided to provide access within the chamber. The
manhole shall be air ventilated type for air valve chambers.
The general arrangement for scour valve chambers and other details
are as shown in the drawings.
Wherever longitudinal forces occur due to closing of a butterfly valve or

scour valve, these shall be taken into account by anchoring the valve
either with an anchor block or against the chamber walls. The same
applies for reducers and tees installed in chambers. The forces have to
be calculated considering the maximum pressure which can occur due
to hydraulic, static or transient conditions. The minimum force has to
correspond to a pressure of 2 bars. The calculations for the
dimensioning and the type of such anchoring and the clamps are to be
approved by the Employer. The backfill for the chambers has to be of
approved select material, compacted to the required density.
2.14.2.1
Flow Meter Chambers and Room
PAGE 155 OF 161
792 of 2461
MMRDA
Flow meter chambers, of adequate size considering the

required working space during erection and operation
shall be provided to house the flow meters. The
chambers shall be in RCC of minimum grade M20. A
leveling course of M15 PCC shall be provided below
chamber slab.(Refer Tender Drawing )
The walls shall be designed to withstand lateral earth

pressures. The roof and slabs shall be designed to
withstand a dead load of the flow meter and live load as
per IS: 875.
2.14.3 Safety Foot Rests
Safety foot rests of minimum 6 mm thick encapsulated plastic as per

IS:10910 on 12 mm diameter steel bar confirming to IS 1786 shall be
provided in butterfly valve chambers and scour valve chambers as per
IS standard drawing. Steps shall be provided in the inner side wall with
a vertical spacing of 30cm and horizontal spacing 30cm c/c
2.14.4 Thrust Blocks/Anchor Block
Anchorage in the form of a thrust block at each deflection in the vertical

alignment of the pipeline shall be provided as per the design
requirements to resist any unbalanced pressure at the bends. If
restraining length of buried pipe is adequate on both sides of a
horizontal bend, thrust blocks shall be avoided. Gravity type thrust
blocks shall be provided at vertical bend in the pipeline, which shall be
designed according to the test pressure and the soil conditions at the
site of the thrust block. Before designing the thrust blocks the
Contractor shall assess the stability of the soil considering erosion due
to wind and water. The general guidelines to follow for providing and
designing of thrust blocks shall be as under:
The thrust blocks may not be required for bend angles up to 5%.
PAGE 156 OF 161
793 of 2461
MMRDA
However, necessary calculations shall be submitted by the

Contractor for approval by Employer to establish that the thrust
shall be taken care by pipe itself and that it is safe not to have
the thrust block.
The thrust shall be according to the field test pressure of the

pipe.
For above ground pipelines, or partially covered pipe line, thrust

blocks shall be designed to take 100% thrust with adequate
factor of safety.
For buried pipelines no thrust blocks on continuous pipe line

sections need to be provided if restraining length on both side is
adequate
In rock the passive pressure of rock shall be considered for

thrust block design
The thrust blocks shall be of concrete M 15, cast in-situ, with minimum
surface reinforcement of 5 kg/m. No formwork is required to be used
for construction of thrust blocks in buried conditions, unless desired by
the Contractor. The calculations for the dimensioning and the shape of
the thrust blocks shall be approved by the Employer.
The Contractor shall construct the thrust blocks as early in the program
of work as is practical, and at least six months prior to installation of the
above ground pipeline in order to reduce the risk of settlement
imposing additional loads on the pipeline supports. All thrust blocks are
to be completed on each section before the sectional hydraulic testing
is conducted.
Where possible, the base of the thrust block shall be cast against solid
rock in order to prevent any settlement. Any material overlying the rock
shall be excavated and replaced with class M15 mass concrete. In the
PAGE 157 OF 161
794 of 2461
MMRDA
event of no rock being encountered, the base of the thrust block shall
be cast against undisturbed ground. Any ground, which in the
Employer opinion is unsuitable, shall be excavated and replaced with
class M15 mass concrete.
2.15
Pipelines under Existing Roads
Pipelines crossing existing roads shall be encased in M15 concrete, including

necessary reinforcement. The Contractor shall program the Works so as to
reduce disruption to road traffic to a minimum. Before any work commences,
the contractor shall obtain permission and approval of all concerned
authorities, serve notices of intent to start the work as may be necessary, and
observe all local Laws and Regulations. The Contractor shall submit details of
his proposals, obtain approval from the Employer and local highway authority,
and construct any required temporary diversion roads before starting the
work.
2.16
Reinstatement of Roads/Pavements/Fences/Compound Walls Etc.
The Contractor will be responsible to ensure that all existing structures/ roads/
pavements/ fences/ compound walls/ etc., are reinstated to their original
condition or better as soon as practicable after backfilling has been
completed.
Any part of the structure or road, etc., which has been damaged beyond the
width of trench must be cut out and made good, irrespective of whether the
damage was caused by the trenching work or other causes related to the
construction. In case of roads, the finished levels of the completed
reinstatement
shall
conform
to
the
adjoining
carriageway
surface.
Reinstatement of road wearing courses or existing structures shall match as

nearly as practicable the color or other characteristics of the existing surfaces.
2.17
Internal Cleaning of Pipeline
Pipelines after completion of weld joints and all internal works in field shall be
PAGE 158 OF 161
795 of 2461
MMRDA
cleaned of all dirt, debris, dust or other deposits by repeated hosing of

copious quantities of water on the pipe surface and simultaneously rubbing
the surface with gunny cloth to the satisfaction of Employer. Cleaning with
metal cleaning solution, acid, wire brushes, scrapers or sand paper shall not
be permitted.
The section of the pipeline once cleaned shall not be entered into for any
purpose later. Sufficient precaution shall be taken to prevent the ingress of
any dirt, debris, or dust inside the section. Failing this the section shall be
cleaned again at the discretion of the Employer.
In the case of above ground pipeline, the length of the section to be taken up
for cleaning shall be decided in consultation with the Employer from the point
of view of ventilation, etc.
In case of buried pipeline a section shall be taken up for cleaning after the
work of back filling around and over the pipeline is completed and the spiders
have been removed from inside with prior approval of the Employer.
During pipe laying operations in the adjoining sections, the Contractor shall
take all precautions to prevent ingress of water, debris, dirt, etc., in the
cleaned section, failing which the section shall be cleaned again at the
discretion of the Employer. When deemed necessary by the Employer
suitable closures shall be provided at the open end or the ends of the cleaned
sections.
2.18
Pipeline Disinfection
Upon completion of a newly laid main, the main shall be cleaned, disinfected
and dewatered as directed by the Employer.
The internal surfaces of pipeline, specials and appurtenances shall be

disinfected using chlorine solution in accordance with procedure specified in
IS 5822. Alternative methods may be adopted with the approval of the
Employer. The chlorinated water shall stand in pipeline for a minimum period
PAGE 159 OF 161
796 of 2461
MMRDA
of 24 hours and all valves in the system shall be operated twice during this
period.
The chlorinated water shall be neutralized and disposed off as directed by

Employer. After final flushing and before the pipeline is placed into service,
water samples shall be collected and tested for bacteriological quality and
shall not indicate the presence of coliforms. If the initial disinfection fails to
produce satisfactory results, disinfection shall be repeated until satisfactory
samples are obtained.
The Contractor is expected to carry out the cleaning, disinfecting and

dewatering work as a part of laying the pipes.
2.19
Markings
Details like valve type, size, and chamber number shall be painted on all valve
chambers as directed by Employer.
In case of the pipeline laid above ground, details such as chainage, invert
levels of pipe, pedestal/saddle number, culvert number, anchor/thrust block
number, flow direction etc., shall be suitably painted either on the pipeline or
the supporting structure in distinct color.
2.20
Fencing, Watching and Lighting
Some stretches of the alignment falling close to populated or frequented

areas will have to be barricaded as per the directions of the Employer.
Fencing for trenches shall be on both sides of trench using 40 mm dia Gl pipe
as vertical post, at least 1.50 m above ground level and at least 30 cm below
ground level at a spacing approved by employer. Two rows of 40 mm Gl pipes
as horizontal members shall be painted in red and white color. It shall also be
covered with Gl corrugated sheets of minimum thickness 0.63 mm in two rows
one above the other.
The Gl corrugated sheets shall be painted in red and white strips. Proper
PAGE 160 OF 161
797 of 2461
MMRDA
provision shall be made for lighting at night and watchman shall be kept to
see that this is properly done and maintained. In addition to the normal
lighting arrangements the Contractor shall provide, wherever such work is in
progress, battery operated blinking light (6 volts) in the beginning and end of a
trench with a view to provide suitable indication to the vehicular traffic. The
Contractor shall provide and display special boards printed with fluorescent
paints indicating the progress of the work along the road.
The Contractor shall be held responsible for payment of all claims for
compensation as a result of accident or injury to any person or property due to
improper fencing, inadequate lighting or non-provision of red flags. The
Contractor shall provide all notice boards before opening of roads as directed
by the Employer. Arrangements shall be made by the Contractor to direct
traffic whenever work in a thoroughfare is in progress.
2.21
Damage to Public Utilities
All precautions shall be taken during excavation and laying operations to

guard against possible damage to any existing structure/pipeline of water,
gas, sewage, etc.
2.22
Clearing the Site
All surplus materials, tools and temporary structures shall be removed from
the site as directed by Employer. The construction site left in a neat, clean
and tidy condition to the satisfaction of Employer.
2.23
Valves
Specification for air valves, butterfly valves and sluice valves shall be generally
as per specification in General Mechanical Requirement section. However
class/ pressure rating shall be as required for pipeline field test pressure.
PAGE 161 OF 161
798 of 2461
MMRDA
Table of Contents
SUB-SECTION 6B.3: MECHANICAL WORKS ............................................................................ 1
3.1
Introduction ............................................................................................................................. 1
3.2
Vertical Turbine Pumps (Self Water Lubricated) .......................................................... 1
3.2.1
Features of Construction ..................................................................................................... 2
3.2.2
Pump Performance Guarantees ........................................................................................ 6
3.3
Centrifugal Pumps ................................................................................................................. 8
3.4
End Suction Pumps ............................................................................................................. 10
3.5
Dewatering Pump ................................................................................................................. 11
3.6
Sump Drainage Pumps ....................................................................................................... 12
3.7
Chemical Bulk transfer Pumps ............................................................................................. 13
3.8
General( for all pumps ) ...................................................................................................... 14
3.9
Sluice Gate ............................................................................................................................. 14
3.10
Valves ...................................................................................................................................... 17
3.10.1
General ................................................................................................................................ 17
3.10.1
Butterfly Valve ..................................................................................................................... 19
3.11
Electric Actuator for Butterfly valve / sluice gate ........................................................ 21
3.11.1
Sluice Valves....................................................................................................................... 25
3.11.2
Kinetic Air valve ............................................................................................................... 26
3.11.2.1 General ................................................................................................................................ 26

3.11.2.2 Design Requirements & Marking: ................................................................................ 28
3.11.2.3 Material of Construction .................................................................................................... 30
3.11.2.4 Workmanship: ................................................................................................................... 31
3.11.2.5 Painting ............................................................................................................................... 31
3.11.2.6 Testing: ............................................................................................................................... 32
3.11.3
Dual Plate Check valve (Non-Return Valve) .................................................................. 33
3.11.4
Dismantling joints ............................................................................................................... 34
3.11.5
Coarse Bar screen ............................................................................................................. 35
3.11.6
Stop logs ............................................................................................................................ 36
3.12
Electric Actuator................................................................................................................... 40
3.13
Hand Operated CP block and Trolleys ( HOT / monorail )......................................... 41
3.13.1
EOT CRANE ....................................................................................................................... 42
799 of 2461
MMRDA
3.13.2
Pipe work ............................................................................................................................. 46
3.13.3
Ventilation Fans .................................................................................................................. 51
3.13.4
Dismantling joints, flexible couplings and flange adaptors .......................................... 56
3.13.5
Progressive Cavity Pumps ................................................................................................ 57
3.13.6
Pressure Gauges ............................................................................................................... 59
3.13.7
Chemical Dosing Pumps ................................................................................................... 60
3.13.8
Chemical Gravity Feeders ................................................................................................ 62
3.13.9
Sampling pumps ................................................................................................................. 62
3.13.10 Chemical Gravity Feeders ................................................................................................ 63

3.14
Air Blowers ........................................................................................................................ 63
3.14.1
General Design Requirements...................................................................................... 64
3.14.2
Ancillary Equipment for Blowers ................................................................................. 66
3.14.3
Blower Noise limits .......................................................................................................... 66
3.14.4
Positive Displacement Blower ...................................................................................... 67
Materials of Constructions .................................................................................................... 68

3.14.5
Filters and Silencers ....................................................................................................... 68
3.14.6
Flexible Connections ...................................................................................................... 68
3.14.7
Pressure Relief Valve ...................................................................................................... 69
3.14.8
Non-Return Valves ........................................................................................................... 69
3.14.9
Isolating Valves ................................................................................................................ 69
3.14.10 Temperature Measurement............................................................................................ 70

3.14.11 Piping Vibration ................................................................................................................ 70
3.14.12 Blower Discharge Pipework .......................................................................................... 70
800 of 2461
MMRDA
SUB-SECTION 6B.3: MECHANICAL WORKS
3.1
Introduction
This part of the Standard Specification sets out the general standards for
mechanical equipment used by the Contractor for the Works. Reference to
any specific item does not necessarily imply that such equipment is to be
included in the Works. All equipment used for the Works shall, unless
otherwise specified, comply with the provisions of this specification and
particular specification.
3.2
Vertical Turbine Pumps (Self Water Lubricated)
Codes and Standards
The design, manufacture and performance of the pumps specified herein

shall comply with the requirements of the applicable Codes and Standards,
including but not limited to the following:
S. No.
1
Standard
IS: 1710
Title
Vertical Turbine Mixed and Axial Flow, for Clear
Cold Water
IS: 9137
Acceptance Test for Centrifugal Mixed Flow and

Axial Pump Class B
IS: 5120
Technical Requirements for Roto-dynamic Special

Purpose Pumps
ANS/ HI21-
Standards of Hydraulic Institute of USA
25
5
IS/ISO-
Mechanical
Vibration-
1940
Requirements of Rigid Rotors
Balance
Quantity
PAGE 1 of 70
801 of 2461
MMRDA
3.2.1 Features of Construction
Materials of Construction
S.
(a)
No.
(b)
(c)
(d)
(e)
(f)
Component
Bell Mouth*
Bowl, Impeller Guide*
Impeller*
Column Pipe
Shafts
Shaft Sleeve with
Material
surface
Cast Iron: IS 210 Gr. FG 220

Stainless Steel: ASTM A 351
Mild
Steel: IS 2062
CF8M
Stainless Steel: AISI 431
hardening of 350 BHN- min.

(g)
Transmission Shaft Couplings
Stainless Steel: AISI 410 /
(h)
Sleeve for Bearing
(i)
Suction Strainer
Stainless
Steel: AISI 304
431
The impeller shall be enclosed type and fastened securely to the

impeller shaft with keys and lock nuts. They shall be adjustable
vertically by means of a nut. Impeller shall be dynamically balanced to
Grade G 6.3 of IS: 1940. Impeller shall be with replaceable wearing
ring. The hardness of impeller ring shall be at least 50 BHN higher than
that of casing ring.
The casting of bowls shall be free of blowholes, sand holes and other
detrimental defects. The bowls shall be capable of withstanding a
hydrostatic pressure equal to twice design pressure or one and a half
times the shut off pressure, whichever is higher.
The bowls shall be equipped with replaceable wear ring. Water

passages shall be smooth and the bowl shall contain bushes to serve
as bearings for the impeller shaft.
Shafts shall be designed to withstand the torque loads throughout the

whole range of operating conditions for the selected particular impeller
diameter as well as all the impeller diameters covered between
minimum and maximum impeller diameters when coupled to the motor
PAGE 2 of 70
802 of 2461
MMRDA
shaft through flexible coupling. The pump shaft / Line shaft dia. shall be
measured at root of thread
The shaft shall be guided by bearings provided in each bowl or above

and below the impeller shaft assembly. The butting faces of the shaft
shall be machined square to the axis and the shaft ends shall be
chamfered on the edges. Shaft shall have a surface finish of 0.75
microns minimum.
The design of the shaft shall also take into consideration the critical
speed of the shaft in such a way that the critical speed shall have
adequate margin with respect to the operating speed by at least 30 %
on either side.
The shaft shall be furnished with interchangeable sections having a

length not exceeding 1.5 m. The designed diameter of shaft shall be
measured at root of threads. The butting faces of the shaft shall be
machined square to the shaft axis and the shaft ends shall be
chamfered on the edges. To ensure correct alignment of the shaft they
shall be straight within 0.5 mm for 1.5 m length total dial indicator
reading. Shaft shall have a surface finish as per IS 3073 & 0.75
microns minimum.
Replaceable shaft sleeves shall be provided to protect the shaft where

it passes through bearings and stuffing boxes. The end of the shaft
sleeve assembly shall extend through the packing gland. Shaft sleeves
shall be securely locked or keyed to the shaft to prevent loosening.
Shaft and shaft sleeve assembly shall ensure concentric rotation.
Transmission bearings shall be designed to be lubricated by pumped

water (self water Lubricated).
Anti-friction thrust bearings of adequate capacity to carry the weight of

all rotating parts plus the hydraulic down thrust shall be provided at
discharge head. The thrust bearing shall be either grease or oil
PAGE 3 of 70
803 of 2461
MMRDA
lubricated. Anti-friction bearings shall be of standard type and shall be

selected to give 40,000 hours continuous operation at rated operating
conditions. Bearings shall be grease/ oil lubricated and should absorb
the radial and axial thrusts under all operating conditions.. Bush
bearings will not be acceptable
The column pipe shall be of welded mild steel pipes as per IS: 2062.
Flanges shall be machined flat, with flange faces vertical and at right
angles to the pump mounting surface. The thickness of column pipe
shall be considered for withstanding the 1.5 times maximum pressure
(shut of pressure) &3 mm corrosion allowance for the entire life
Flexible pin bush type coupling shall be provided, duly bored and
keyed to the pump and motor shafts. For line shafts, threaded barrel
couplings shall be used.
The couplings and pump shafts have to be designed so that the

breaking load of the coupling system is less than that of shaft.
The base plate for pump shall be fabricated from mild steel sections
and have sufficient rigidity to resist vibration and distortion. Suitable
holes shall be provided for grouting and they shall be so located that
the base will be able to be grouted in place without disturbing the pump
and motor. All pumps and motors shall be properly and accurately
aligned, bolted and doweled to the base plate. Adequate space shall
be provided between pump drain connections and base plate for
installation of minimum 20 mm diameter drainpipe. Foundation bolts
shall be complete with nuts and flat and shake proof washers below
that of the shaft.
A sole plate of 40 mm thick shall be provided between the discharge

head of Pump & base plate. The sole plate shall have machined
surface. The sole plate shall be aligned with precision level & rigidly
bolted to base plate. The contact area of pump discharge head shall
have minimum 80% blue matched surface area.
PAGE 4 of 70
804 of 2461
MMRDA
Replaceable shaft sleeves shall be provided to protect the shaft where

it passes through stuffing boxes. The end of the shaft sleeve assembly
shall extend through the packing gland. Shaft sleeves shall be securely
locked or keyed to the shaft to prevent loosening. Shaft and shaft
sleeve assembly shall ensure concentric rotation. Minimum surface
hardness of shaft sleeves shall be 350 BHN.
Stuffing boxes at driving end shall be of such design that they can be
re-packed, without removing any part, other than the gland and lantern
ring. An axially split gland should be used to facilitate changing the
gland packing. Sufficient space shall be available for maintenance
purposes.
Pump shall be provided with air valve to vent air which may get
accumulated in the pump.
Self-sealing water connections should be provided. Flanges shall be

machined flat, with flange faces vertical and at right angles to the pump
mounting surface. Flanges shall be as per Subsection 3, Mild Steel
Pipe and Coating Works.
Mild steel fabricated coupling guard shall be provided for safeguarding

against the open rotating parts of the pump and motor. Guard shall be
designed for easy installation and removal, complete with necessary
support, accessories and fasteners.
Eyebolts for pump top casing shall be provided for ease of lifting and
installation.
Drawings and Information to be provided by Contractor
General arrangement, cross-sectional drawing with materials of

construction and dimensional drawings with pump parameters
PAGE 5 of 70
805 of 2461
MMRDA
Performance curves with initial, intermediate and final impellers
a)
H - Q curves Shaft Power - Q curves
b)
Efficiency -Q curve
c)
Submergence - Q Curve Hydraulics study report

for intake
d)
General arrangement drawing of pumping plant As built drawing

of pumping plant
3.2.2 Pump Performance Guarantees
The pump performance guarantee shall relate to the flow rate, the total
head and the efficiency of the pump when tested at the manufacturer's
work and shall obtain approval of Engineer.
The pump shall operate at its design point within acceptance

tolerances for flow rate and total head laid down in BS EN ISO
9906:2000.
Each pump shall be tested at the manufacturer's factory in accordance

with BS EN ISO 9906:2000 or other relevant standards in conjunction
with one of the contract motors.
This test shall be carried out on at least one pump set using the flexible
coupling and contract drive shaft arrangement to establish that the
drive arrangement with supports and couplings operates satisfactorily
under all operating conditions.
Where similar drive shaft arrangements have been installed by the

Contractor and have been proven satisfactory in service this
requirement may be withdrawn subject to the approval of the Engineer.
PAGE 6 of 70
806 of 2461
MMRDA
A test shall be carried out of the performance from closed valve to the
maximum quantity that can be delivered under abnormally low
discharge heads.
Sufficient readings shall be taken at each test to produce accurate

curves of the heads, flow, pump speed and power required at pump
coupling throughout the operating range of the pump.
Vibration and noise dB(A) levels shall be measured and shown to be

acceptable and shall have Engineers approval. The Contractor shall
have Engineer approval and provide acceptable test certificates,
showing the NPSH requirement for the pump is at least 2 m less than
the NPSH available under all working conditions.
In the absence of the approved test certificates the supplier shall carry
out a test on one pump of each type to verify the NPSH requirement
based upon the 3% output drop criterion and shall take approval of
Engineer.
Test Certificates in duplicate shall be submitted to the Engineer

immediately following each of the tests mentioned above. Performance
curves shall also be incorporated in the Operation and Maintenance
Manual.
(a)
Single Pump Operation
(i)
Head/quantity curve
(ii)
Motor kW input/quantity curve
(iii)
Overall efficiency/quantity curve
(iv)
NPSH required/quantity curve
(v)
Vibration and Noise dB (A) levels
PAGE 7 of 70
807 of 2461
(b)
3.3
MMRDA
Parallel Pump Operation
(i)
Head/quantity curves
(ii)
Motor kW input/quantity curve
(iii)
Overall efficiency/quantity curve
(iv)
NPSH required/quantity curve
(v)
Vibration and noise dB(A) levels
Centrifugal Pumps
Centrifugal pumps shall have head/quantity characteristics which fall

continuously from the maximum pressure at closed valve conditions.
The design speed of any pump with a duty flow greater than 20 l/s shall not
exceed 1500 rpm. Waterways through the pump shall be smooth in finish and
free from recesses and obstructions. Impeller passageways shall be as large
as possible. The leading edges of the impeller vanes shall be rounded and
smooth.
Water velocities in the pump suction side shall not exceed 1.5m/s and on
delivery branches of a pump the velocity shall not exceed 2.0 m/s when the
pump is operating within its specified duty range and within this working range
there shall be no discernible noise due to hydraulic turbulence or cavitations
within either the pump or its associated pipe work and valves.
The NPSH requirements of the pumps, based on the 3% output drop criterion
shall be at least 2 m less than the NPSH available at every working condition.
PAGE 8 of 70
808 of 2461
MMRDA
Materials of Construction
S. No.
Component
Material
(a)
Casing*
(b)
Impeller*
Bronze: IS 318 Gr. LTB2
(c)
Shaft
(d)
Wear Rings
Bronze: IS 318 Gr. LTB2/ SS 410
(e)
Shaft Sleeve
* Hydraulic passages of these parts shall be coated after conducting

performance test, to enhance pump efficiency
All parts exposed to wear shall be adequately protected by means of

renewable sleeves, bushes, wear rings etc. which shall be arranged for easy
inspection, adjustment, or replacement without removal of the pump casings,
pipe work etc, or the need to disturb the drive shaft alignment.
The pump thrust shall be taken by a combined thrust and radial type bearing
assembly capable of taking the weight of the moving parts and the hydraulic
loads under all conditions of operation with a minimum life of 100 000 hours.
The pump casing and other parts of the pump subject to pressure shall be
hydraulically tested by the manufacturer to at least one and a half times the
maximum working pressure.
Integral inlet and discharge flanges shall be provided and integral lifting lugs
shall be incorporated. Facilities shall be provided for the removal of air during
priming and for draining. Glands may be fitted with mechanical seals or
conventional soft packing. The gland arrangement shall be designed for easy
adjustment and removal of the seal. When soft packed glands are used
suitable means shall be provided for collecting and preventing splashing of
the gland leakage water. Drainage and gland leakage water shall be piped
into the building drainage system.
PAGE 9 of 70
809 of 2461
MMRDA
The shafts of pumps fitted with conventional packed glands shall be fitted with
removable gland sleeves.
The rotating element of the pump and the motor shall be readily removable
from the pump casing without the need to disconnect the adjoining pipe work.
Rotating assemblies of pumps of 100 mm diameter inlet and over shall be

statically and dynamically balanced and shall be designed so that the first
critical speed is at least 50% greater than the maximum operating speed.
Lubrication arrangements shall be so designed that there is no contamination

of the pumped fluid.
On pumps of 100 mm inlet and over, tapping shall be provided at both the
suction and discharge flanges of suitable size for pressure gauges.
3.4
End Suction Pumps
End suction pumps shall be horizontally mounted complete with drive motor
on a common base plate. The pump/drive coupling shall be of the spacer type
to facilitate removal of the pump rotating element and bearing housing without
dismantling the pump casing, adjoining pipe work or drive motor. These types
of pumps shall be used for Filter backwash, Chlorination motive water and
service water pumping applications etc.
The dimensions of the pump shall be metric conforming to BS 5257 or its

equivalent standard. Flanges shall conform to BS EN 1092-2/BS 4504.
The bedplate shall be of substantial fabricated steel construction with floor

fixing bolt holes ready drilled. All holding down bolts etc. shall be supplied with
the units.
The velocity at the entrance to the pump impeller shall not exceed 3.5 m/s.
Impellers shall be provided with means to prevent abrasive matter reaching

PAGE 10 of 70
810 of 2461
MMRDA
the glands and with fully shrouded impellers, to prevent the trapping of matter
between the impeller vanes and the casing.
The speed of any pump shall not exceed 1500 rpm.
Glands may be fitted with suitable mechanical seals or conventional soft

packing. The gland arrangement shall be designed for ease of adjustment or
removal of the seal or packing material. Shafts shall be sleeved around the
area of the gland when soft pack glands are used.
Flushing facilities shall be provided for mechanical seals or packed glands

where pump fluid may be contaminated with abrasive material. Where soft
packed glands are used, means shall be provided for collection of the gland
leakage water, which shall be piped into the drainage system through
adequately sized ports.
Lubrication arrangements shall be so designed that there is no contamination

of the pumped fluid.
The pumps and associated pipe work shall be, wherever possible, arranged
so that air can be completely expelled during priming. Where this is not
possible, facilities shall be provided for the removal of the trapped air.
Adequate facilities shall be provided for drainage of the pumps for inspection
purposes.
Tapping shall be provided at both the suction and discharge flanges for
pressure gauge equipment.
3.5
Dewatering Pump
a)
The pump motor shall be suitable for working with or without

submergence in water/waste water. The motor rating shall be more
than the maximum power required by the pump.
b)
Pump shall be vertical, centrifugal, submersible, non-clog & single
PAGE 11 of 70
811 of 2461
MMRDA
stage type. The pump set shall be portable with necessary hooks.
c)
The pump shall have double mechanical seals to prevent ingress of

moisture in to the motor in case of electrical pump. The pump impeller
shall be mounted on the extended shaft of the motor. The motor shall
be suitable for operation on 440 V, 3 Phase, 50 c/s Electrical power.
d)
The pump shall be supplied with flexible hose pipe of 80 mm dia. & 50
m length. Suitable cable of 50 M length shall be supplied with the
pump.
3.6
Sump Drainage Pumps
Sump drainage pumps shall be of the open impeller centrifugal type vertically
mounted close coupled to their fully submersible electric drive motors. The
motor shall be suitable for operation on 440 V, 3 Phase, 50 c/s Electrical
power.
Sump pumps of 1.5 kW and under shall incorporate an integral level detector,
control and motor starter and shall be powered only with a suitably fused
three phase or single phase low voltage supply and with supply isolation at
the building distribution board.
Sump pumps over 1.5 kW shall be controlled and started from the building
distribution board and be fed with a 3 phase supply. Control shall be via
adjustable float level switches mounted adjacent to the pump.
The pumps shall be supplied with all necessary discharge pipe work, including
non-return and isolating valves and suitable lifting gear for lowering and
removing the pump from the sump. Pumps weighing 40 kg and more shall be
lowered in the sump via guide rails and be located to their respective
discharge pipe work with an angle flange connection and self-locating clamps.
The pump impeller shall be designed to pass solids of sizes which pass
through the inlet ports of the pump and shall be capable of pumping solids of
PAGE 12 of 70
812 of 2461
MMRDA
up to 20 mm diameter.
3.7
Chemical Bulk transfer Pumps
Pumps shall be selected taking into account the chemical being pumped, form
of chemical, wear leakage and resistance to corrosion.
For centrifugal pumps, the pump shaft shall be of stainless steel to BS: 970
Grade 410S21 compatible with the impeller which shall be of stainless steel
ASTM A743 CF8M and the impellers and shaft sleeves shall be secured to the
shaft by means of a key or keys. The impeller retaining nut shall be fitted with a
locking device. The pump casing shall be of stainless steel ASTM A743 CF8M,
wearing rings shall be of Bronze to IS:318 Gr.LTB2 and shaft sleeve shall be of
stainless steel to ASTM A 743 CA 15.All stainless steel parts shall be hard
chrome plated.
Each pump shall be provided with inlet and outlet isolating valves and where
necessary, with pressure relief and non-return valves and also Pressure
Gauges with stopcock.
A relief valve shall be incorporated in the delivery lines under conditions

where the pump discharge pipe can be shut off or where pressure may rise to
an excessive point.
The relief valve shall be sized to handle the system
pressure and to discharge maximum pump output freely, and shall be located
in the discharge line between the pump and the first downstream isolating
valve. Relief valves when used on pumps handling non-hazardous chemicals
shall discharge the vented liquid to waste.
When used on hazardous
chemicals the valve outlet shall be piped back to the suction supply tank or
bunded-area. The open end of the return pipe shall be located where it is
visible, so that any relief valve leakage/operation can be detected.
Pump transferring chemicals to systems under pressure shall incorporate a

pressure gauge on the pump delivery. Air cocks shall be provided for release
of air where necessary.
PAGE 13 of 70
813 of 2461
MMRDA
Flushing connections shall be provided at each pump inlet and flushing shall
be manual. When flushing, water shall be discharged either locally through a
drain valve or to the point of application of the chemical. Facilities shall also
be provided for flushing chemical pump suction and delivery manifolds and
delivery lines to point of application.
3.8
General( for all pumps )
The noise level produced by any equipment like pump sets, compressor sets
and blower sets shall not exceed 85 dBA measured at a distance of 1.86 m
from the outer surface of the equipment.
At the time of operation, the
mechanical vibration shall not exceed the limits given below, at recommended
points of measurement as per ISO 10816:1995.
Equipment
All
rotating
equipment
not
Velocity of
Noise level dBA
Vibration
at 1.86 m from
mm/sec
equipment
1.12
85
1.8
85
2.8
8/5
having
reciprocating parts with motor KW less

than or equal to 15 KW
All
rotating
equipment
not
having
reciprocating parts with motor KW more

than 15 KW and less than or equal to 75
KW
All
rotating
equipment
not
having
reciprocating parts with motor KW greater

than 75 KW
3.9
Sluice Gate
(a)
Design Requirements and Construction Features
The construction of sluice gates shall be in accordance with the
PAGE 14 of 70
814 of 2461
MMRDA
specification and generally as per IS: 13349-1992 or other applicable

standard. All sluice gates shall be of the rising spindle type.
(b)
Frame
The frame shall be of the flange back type and shall be machined on
the rear face to bolt directly to the machined face of the wall thimble.
(c)
Seating Faces
Seating faces shall be made of full width, solid section; dove-tail strips
of stainless steel. They shall be secured firmly by means of counter
sunk fixings in finished dove-tail grooves in the frame and slide faces in
such a way as to ensure that they will remain permanently in place,
free from distortion and loosening during the life of the sluice gates.
(d)
Wedging Devices
Sluice gates shall be equipped with adjustable side, top and bottom
wedging devices as required providing contact between the slide and
frame facing when the gate is in closed position.
(e)
Lifting Mechanism
i)
Sluice gate shall be operated through suitable lifting mechanism

which shall incorporate suitable gearing if required, to keep the
torque requirement within 7 kg.m.
ii)
Lifting mechanism shall incorporate a strong locking device

suitable for use with a padlock or padlock and chain.
iii)
Lift mechanism shall be provided with a suitable position

indicator to show the position of the gate at all times.
(f)
Wall Thimbles
PAGE 15 of 70
815 of 2461
MMRDA
The cross section of the thimble shall have the shape of the
letter 'F'.
(g)
Lifting Lugs
Lifting lugs shall be provided for all gates.
(h)
Flush Bottom Seal
When sluice gates are provided with flush bottom seals, the wedging
device and facing along the bottom edge of the slide and frame shall
be omitted.
(i)
A solid square cornered, resilient rubber seal shall be provided on the

bottom facing of slide. The seal shall be securely fastened to the
bottom face of the slide by a retainer bar and corrosion resistant metal
fasteners. The top surface of the bottom facing of frame shall be flush
with invert of the gate opening. Bottom facing of the slide shall be
accurately machined to make contact with the seal when the slide is
closed.
(j)
Suitable arrangement shall be made on all the sluice gates and

actuators such that the actuator is capable of operating the sluice gate,
under this contract.
(k)
The sluice gate shall be suitable for operation from pump floor.
(l)
Headstock meant for mounting on operating platform shall be supplied

with a pedestal/floor stand to provide a convenient operating height of
approximately 900mm.The pedestal of the headstock shall be provided
with a covered window opening to enable cleaning and greasing of
stem threads.
(m)
All the Gears in the headstock shall be kept completely encased in cast
PAGE 16 of 70
816 of 2461
MMRDA
iron housing to protect them from dirt. Dust, damage etc. and other
atmospheric effects and thus ensure smooth operation. Grease nipples
shall be provided at proper places for lubricating with grease.
(n)
The material of construction of sluice Gate shall be as follows:
Component
Material
Wall Thimble
Cast Iron : IS 210 Gr. FG 200
Frame and Slide
Seating faces
Stainless Steel : ASTM Countersunk

fixing A276 type 316
Wedge
Stainless Steel : ASTM A743 CF8M or

SS316
Stem
Stainless Steel: ASTM extension A276

type 316
Stem guide bracket
Stem nut
Stainless Steel : ASTM A743 CF8M
Stem Coupling
Stainless Steel : ASTM A276 type 316
Fasteners, anchor
Stainless Steel : ASTM A276 type 316
Lifting mechanism, Pedestal Cast Iron : IS 210 Grade FG 200

gear house cover and stem
guide
Lift nut
Bronze : ASTM B 148 (CA952, CA954

or CA958)
Headstock Body
(o)
Pipe hood shall be provided on the top of headstock to protect the

spindle from damage, dirt, dust, water etc. The hood shall be made of
transparent fracture resistant polycarbonate material. The hood shall
have vent holes to prevent condensation.
3.10
Valves
3.10.1 General
PAGE 17 of 70
817 of 2461
(a)
MMRDA
Valves shall be as per Indian standards. Flanges shall be

machined on faces and edges and drilled to relevant IS
specification.
(b)
Valves shall be double flanged and the face shall be parallel to

each other and flange face should be at right angles to the valve
centerline. Backside of valve flanges shall be machined or spot
faced for proper seating of the head and nut. Valve buried or
installed in underground chamber, where access to a hand
wheel would be impractical, shall be operated by means of
extension spindle and/or keys. Valve shall be suitable for
frequent operation as well as operation after long periods of
idleness in either open or closed position.
(c)
The valve stem, thrust washers, screws, nuts and all other
components exposed to the water shall be of a corrosion
resistant grade of stainless steel. Valves shall be free from
sharp projections. Butterfly and non-return valves shall be
provided with bypass arrangement having rising spindle gate
valves. Bypass may be integral with valve or connected between
pipes.
(d)
The work of fixing appurtenances, i.e. butterfly valves, sluice

valves, air valves, scour valves, etc. shall be carried out
carefully so as not to damage them during handling, erection
and fixing.
(e)
All the butterfly valves and for pumping plants and isolation
valves on pump delivery side.
(f)
For butterfly valves the gearbox shall be provided with self

locking devices. A locking facility shall be provided for the BF
valve in either the fully open, fully closed or intermediate
position. Gate valves and butterfly valves shall be provided with
PAGE 18 of 70
818 of 2461
MMRDA
position indicators, to show whether the valve is in the open or

close position.
(g)
The sluice valve on pump delivery main, scour valves on

pumping main and the isolation valves for air valves shall be
manually operated, operated , through a suitable gearbox( if
required ) and hand wheel. Operation must be possible by one
man against maximum design working pressure.
(h)
Scour valves shall be provided with extension spindle with

supports for operation from operating level / ground level.
(i)
Gaskets shall be of Nit rile rubber and ready made matching

with respective flanges. Gaskets cut out from rubber sheets are
not acceptable.
(j)
Valves for operation shall be so geared that under the operating

conditions as specified herein, the maximum force on the rim of
the hand wheel, crank, or other necessary for operation shall not
exceed 20 kg and the maximum torque shall not exceed 5.5
kg/m. A spur, bevel, or worm gear reduction unit, if required,
shall be attached to the pinion shaft of the operating
mechanism.
3.10.1 Butterfly Valve
Butterfly valves shall be of double eccentric and resilient seated type

generally as per and IS 13095.
Butterfly valves shall be suitable for bi-directional pressure testing with deadtight shut off .The valves shall be of double flanged long type.
The valves shall be electrically operated to suit the operation on delivery line
of a pump. The valve shall be free from induced vibrations. Valve shall be
suitable for mounting in any position.
PAGE 19 of 70
819 of 2461
MMRDA
The valve seat shall be of replaceable design. When the valve is fully closed,
the seal shall seat firmly. The seat surfaces shall be machined smooth to
provide a long life for the seal. All fasteners shall be set flush so as to offer the
least resistance possible to the flow through the valve.
The shaft shall be stainless steel with Bronze or equivalent seal with selflubricating bearings. Disc pins shall be stainless steel. Rings shall be bidirectional self-adjusting suitable for pressure or vacuum service. Removal
and replacement of seals shall be possible without removing the operating
mechanism, valve shaft and without removing the valve from the pipeline.
Valve shafts shall be a one-piece unit extending completely through the valve
disc, or of the "stub shaft" type, which comprises two separate shafts inserted
into the valve disc hubs.
All valve spindles and hand wheels shall be positioned to give good access
for operational personnel. Valve of diameter 450 mm and above shall be
provided with enclosed gear arrangement for ease of operation. The gear box
shall be of worm and worm wheel design type, totally enclosed, grease filled
and weather proof. The operation gear shall be such that they can be opened
and closed by one man against an unbalanced head of 1.15 times the
specified rating. Valve and gearing shall be such as to permit manual
operation in a reasonable time and not exceed a required rim pull of 200 N. All
hand wheels shall be arranged to turn in a clockwise direction to close the
valve, the direction of rotation for opening and closing being indicated on the
hand wheels.
Material of construction of valves shall comply with following requirement:

Item
PN 10Valves
Body
Cast Iron IS 210 Gr FG 220
Disc
Cast Iron IS 210 Gr FG 220
Shaft
Stainless Steel BS 970 Grade 431 S

29
Body Seat
Nickel weld overlay micro finished
PAGE 20 of 70
820 of 2461
MMRDA
Item
PN 10Valves
Disc seal
EPDM
Seal Retaining ring
Stainless steel AISI 304.
Shaft Bearing
Bronze with EPDM O ring seals
Internal Fasteners
Stainless steel AISI 316
Nuts, bolts & washers for pipe flanges
High tensile steel hot dip galvanized
The disc shall be designed to withstand the maximum pressure differential

across the valve in either direction of flow. The disc shall be contoured to
ensure the lowest possible resistance to flow and shall be suitable for
throttling operation.
Valves shall be capable of closing against the maximum flow that can occur in
system. The shaft shall be designed to withstand the maximum torque that will
be imposed by the operator. It shall be secured to the discs by tapered
stainless steel cotter pins.
Valves shall be provided with position indicator to show the position of the
disc, mounted on the driven shaft end.
Rigid adjustable stop mechanism shall be provided within the gear box or
elsewhere on the valve to prevent movement of the disc beyond the fully open
or closed position (i.e. set points).
3.11
Electric Actuator for Butterfly valve / sluice gate
The butterfly valve on pump discharge lines and Sluice gate in intake work
and pumping main shall be operated by electric actuator conforming to IS:
9334- 1986 and the operating mechanism shall consist of the following
accessories:
i)
AC Electric Motor operating on 440 V, 3 phase , 50 c/s electrical supply

the climatic conditions given in the Specification.
PAGE 21 of 70
821 of 2461
MMRDA
ii)
Reduction gear unit.
iii)
Torque switch mechanism
iv)
Limit switch mechanism complete with set of limit switches and

additional two spare sets for Open/close position.
v)
Hand wheel, for manual operation.
vi)
Valve position indicator.
vii)
Hand-auto lever with suitable locking arrangement.
viii)
10 W single phase space heater in the switch compartment
ix)
Blinking light throughout the valve operation.
x)
Junction box for terminating power and control cables.
xi)
The actuator shall be a SMART & provided with a RS 485

communication port to send & receive signals and commands from
SCADA
The actuator shall be capable of producing not less than 1 1/2 times the
required operator torque at the required time cycle of valve operation. The
transmission shaft connecting the actuator to the valve shall be provided with
2 bearings one at actuator end and one at valve end with universal couplings
at suitable places. Adequate no. of switch/contacts shall be provided to meet
following requirements.
Valve close/open/in operation indications
(i)
To prevent starting of motor if discharge valve is not fully closed.
(ii)
To trip the motor, if the discharge valve fails to open within specified
PAGE 22 of 70
822 of 2461
MMRDA
time.
They shall also be suitable for operating on 440 V, 3 phase, 50 c/s electric
supply and shall satisfactorily open and close the valve under variations of
electric supply specified.
The electric motors shall be induction, squirrel cage type as per IS :325 with
insulation to IS:1271 Class B. The windings shall be impregnated to render
them non-hygroscopic and oil resistant. All internal metal parts shall be
painted. The motor shall be rated for 15 minutes.
Motor shall be protected by suitable overload protection device.
The reversing contactor starter and local controls shall be integral with the
valve actuator. The starter shall comprise mechanically and electrically
interlocked reversing contactors of appropriate rating transformer. The
common connection of the contactor coils at the transformer shall be
grounded.
HRC cartridge type primary and secondary fuses shall be
provided.
Local control shall comprise pushbuttons for open, close and stop operations
and a Lockable Local/Remote/off selector switch.
The control schematics
shall be subject to approval.
Internal wiring shall be of 650/1100 volt grade PVC insulated stranded copper
conductor of minimum 1.5 sq. mm for control circuits and of minimum 4
sq.mm copper for the power circuit. Each wire shall be number identified at
each end. The terminals shall be of stud type. Cable entries shall be suitable
for PVC insulated/ sheathed, armored cables. A separate terminal box shall
be provided for cabling to control circuits.
The actuator enclosure shall be fully weatherproof and hose proof to IP 67.
Reduction Gear Unit shall be of the totally enclosed oil bath lubricated type.
The gear box shall be provided with the first charge of oil lubricants and
appropriate filling and drain connections. Gearing shall be adequate to open
PAGE 23 of 70
823 of 2461
MMRDA
and close the valves under full indicated maximum operating pressure
differential at a speed sufficient to cover the full extent of travel.
The operator shall have a hammer-blow device to loosen stuck valve or

retrieve jammed valve position.
The torque switch mechanism shall function as follows to stop the motor on
closing or opening of the valve, or upon actuation by the torque when the
valve disc is restricted in its attempt to open or close.
The torque switch in the closing direction shall interrupt the control circuit if
mechanical overload occurs during the closing cycle or when the valve is fully
closed.
The torque switch in the opening direction shall interrupt the control circuit if
mechanical overload occurs during the opening cycle or when the valve is
fully open.
The mechanism shall facilitate adjustment of the torque at which the switches
are required to operate.
Non-adjustable limit switches shall stop the motor and give indication when
the disc has attained the fully open or closed position.
The adjustable limit switches shall have control rated 2A, 48 V DC for
specified system interlock, at the desired value position in both the opening
and closing directions.
Motor operators shall be provided with clearly visible local valve position
indicators mounted on the operator assembly to give an indication whether
the valve is fully open, fully closed or in an intermediate position.
A hand wheel of Stainless Steel construction shall be provided for emergency

operation. The hand wheel drive shall be mechanically independent of the
motor drive and any gearing should be such as to permit emergency manual
operation in a reasonable time.
PAGE 24 of 70
824 of 2461
MMRDA
Handwheel Operation - Electric motor operated actuators should have the

facility of handwheel operation. Whenever required, by pressing a change
lever, the motor is uncoupled and the handwheelis coupled to the drive shaft.
The mechanically independent handwheel drive is engaged by means of a
clutch, which declutches the motor drive from the output shaft. When the
motor starts, the handwheel shall be decoupled automatically and the motor is
re-coupled. Unless otherwise stated, clockwise operation of handwheel shall
close the valve.
3.11.1 Sluice Valves
Sluice valve shall generally confirm to IS 14846. They shall be of nonrising spindle type except for the valves for bypass. The gate face rings
shall be securely pegged over the full circumference. Valve of 400 mm
and above shall be furnished with a bushing arrangement for
replacement of packing without leakage. They shall also have
renewable channel and shoe linings. The gap between the shoe and
channel shall be limited to 1.5 mm. Valve of 200 mm and above shall
be provided with thrust bearing arrangement for ease of operation.
Valve of diameter 400 mm and above shall be provided with enclosed

gear arrangement for ease of operation. The operation gear of all
valves shall be such that they can be opened and closed by one man
against an unbalanced head 15% in excess of the maximum specified
rating. Valve and any gearing shall be such as to permit manual
operation in a reasonable time and not exceed a required rim pull of
200 N.
Valves spindles and hand wheels shall be positioned to give good

access for operational personnel. Hand wheels shall be arranged to
turn in a clockwise direction to close the valve, the direction of rotation
for opening and closing being indicated on the hand wheels.
Valves shall have two position marked at the shut end of the scale, first
one corresponding to the position of the gate tangential to the bore of
PAGE 25 of 70
825 of 2461
MMRDA
the seating and the second position below the first, corresponding to
the position of the gate as it sits on the seating after moving a further
distance equal to the depth of the seating.
All valves on pump suction and delivery piping shall be with electrical
actuators. Operation of valves shall be with electric actuators mounted
on floor stand at motor floor. The remaining sluice valves shall be
manually operated unless specified elsewhere in this tender document.
Material of construction shall comply with the requirements given

below:
Item
PN 10 Valves
Body, Door, Dome
Cast Iron IS 210 Grade FG220
Wedge
Cast Iron IS 210 Grade FG220

Rubber lined with EPDM
Seat, Face ring
IS :318 Gr.LTB 2
Spindle / Stem
SS: IS 6603 04 Cr17 Ni 12 M0 2 / AISI

316
Bonnet Gasket
EPDM
Internal Fasteners
Stainless steel SS316
Nuts, bolts & washers for
High tensile steel Hot dip galvanized
pipe flanges
All Sluice valves shall be open end tested.
Bypasses for valves 400 mm and over shall be fitted with integral
bypasses as follows.
3.11.2 Kinetic Air valve
3.11.2.1
General
1.
The Kinetic Air valve shall comprise the design,
PAGE 26 of 70
826 of 2461
MMRDA
manufacture,
supply,
testing
&
delivery
for
installation on water mains, which form the part of

the Water Operation. The valves will be installed
on welded mild steel pipe lines.
2.
The kinetic air valve shall remove air through large

orifice, with high velocity (which carry kinetic
energy) from water pipe line while charging and
shall seal the large orifice only by water. It also
shall not allow developing vacuum inside the pipe
line by admitting air through large orifice, while
dewatering the main.
The main chamber shall be integral bucket type

aerodynamic design to give high discharge of air &
prevent air lifting of ball/premature closing. The
large ball shall be with high buoyancy to seal the
large orifice at very low pressure of 0.2 Kg/cm2.
The small orifice of air valve with small orifice shall
be fitted on tope cover of the main chamber i.e. top
cover of the kinetic air valve. The air valve with
small orifice shall remove the small air pockets
under pressure from water pipe line, automatically
& seal without leakage of water. The small orifice
seating shall be with rolling seal mechanism, which
shall not act as a cantilever& weight of float apply a
torque to open the orifice, while air pocket is
created. The small ball shall be oval shaped with
high buoyancy, to seal small orifice at low pressure
of 1.35kg/cm2. The guides shall be provided to the
movement of small ball. An air vent shall be
provided. The air vent shall be integral and tamper
proof type to prevent steeling of water or damaging
the ball & seal with enough air flow capacity. The
small orifice of air valve shall be provided with
PAGE 27 of 70
827 of 2461
MMRDA
proper locking arrangement to prevent tampering.

The air valve shall be in accordance with
ANSI/AWWA C-512-92.
3.11.2.2
Design Requirements & Marking:
a.
Allowable stress at valve design pressure shall not

exceed one third of the yield strength or one fifth of
the ultimate strength of the material used.
b.
Air release valves and the air release mechanism

of air valves shall be designed to open positively
and vent air to the atmosphere at system pressure
up to the maximum working pressure as required
by the venting orifice size.
c.
The body inlet port and the cover outlet port for
air/vacuum valves & combination air valves shall
be sized such that the minimum flow area of each
port shall be equal to or greater than the flow area
of a circle of diameter equal to the nominal valve
size.
d.
Valve connection shall confirm to the following

specifications:
All valve flanges shall be designed to withstand the

stresses to which they would be subjected under
hydraulic test. Flanges shall be machined flat with
skirting. The flanges shall be drilled in accordance
with IS 1538 to suit the flanges of respective sluice
valve. Threaded connections shall confirm to the
specifications for tapered pipe threads for general
use, National pipe threads (NPT) as per ANSI/
ASME B 1.20.1.
PAGE 28 of 70
828 of 2461
e.
MMRDA
For valves with inlet size less than 100 mm the

float shall be capable of withstanding a collapse
pressure of 6900 Kpa (gauge). For inlet sizes 100
mm & larger, the float shall be capable of
withstanding collapse pressure of 5180 Kpa
(gauge).
f.
Gasket shall be used on all flanged joints & shall

comply with section of the
ANSI/AWWA C 512-92.
g.
Orifices:
Air/Vacuum Valve orifice The orifice shall be
suitable sized, using manufacturers sizing data to
permit the required airflow rate to be discharged
and / or admitted. Air release valve orifice The
orifice shall be suitable for the volume of air
expected to accumulate in the system at the
maximum working pressure. The orifice size is
specific to the system application.
h.
The bolts, nuts stands shall confirm to Table A
i.
Seat shall confirm to Table A.
j.
Each valve shall bear on their bodies as BBs in

raised letters showing
i.
Size of Valve
ii.
Year of Manufacture
PAGE 29 of 70
829 of 2461
MMRDA
iii.
Manufacturers Name
iv.
MMRDA. (engraved on S.S.plate screwed

to the valve body)
v.
Pressure rating
vi.
Heat Number
vii.
Valve operating & closing direction on hand

wheel.
The serial number of valves shall be punched on

the flanges distinctly and legibly on both side
flanges of valve.
3.11.2.3
Material of Construction
The material to be used in the manufacture of sluice

valves shall conform to the following table.
Table A
S.No. Description
1
Material
Valve body, orifice chamber Cast Iron /Gray Cast Iron IS

Cover
210 FG
Small orifice floats
Stainless Steel S.S.304 With

rolling
Large orifice floats
Stainless Steel S.S.304
Large orifice
Bronze or Stainless IS318LTB-2 or
Small orifice plug
Stainless Steel IS6603
Large orifice seat ring
Neoprene with Gun metal
Guides for small orifice float
P.V.C.
Joint Ring
Rubber -Neoprene
PAGE 30 of 70
830 of 2461
MMRDA
Fasteners
SS 304
10
Flange
As per IS 1538
3.11.2.4
Workmanship:
a.
The workmanship employed in the fabrication &

assembly of valves manufactured in accordance
with the standard specified and shall ensure that
the valves function as designed.
b.
Valve parts shall be designed with manufacturing

tolerances set to provide
c.
Inter-changeability in the products of the units of

same size & type.
d.
All castings shall be clean & sound without defects

that will impair their service.
e.
Plugging, welding, or repairing of such defects will

not be allowed. Internal surfaces of the casting
shall be smooth & free from the sharp corners.
3.11.2.5
Painting
a.
Internal surfaces Interior surfaces of the valve

body shall be clean & smooth and shall not be
coated unless required.
b.
Internal protective coating of an internal

protective coating is required, all wetted parts,
except machined or bearing surfaces & corrosion
resistant
components
shall
be
coated
in
accordance with ANSI/ AWWA C-550.
PAGE 31 of 70
831 of 2461
c.
MMRDA
Exterior cast iron surfaces of each valve shall be

coated with the manufacturers standard with 2
coats of primer & enamel paints.
3.11.2.6
Testing:
a.
All the components of the valve which are subject

to chemical analysis are to be carried by the
manufacturer and the necessary test certificate
shall be submitted to the inspection authority for
review.
b.
The manufacturer shall provide all measuring

instruments of valid calibration period and shall
produce
such
test
certificate
for
engineers
verification.
c.
Body test: - shall be carried out with the valve

completely closed, an internal hydrostatic pressure
equal to 1.5 times the rated pressure shall be
applied with the opposite or outlet end open to
atmosphere. The test pressure shall be maintained
for 1 minute for valve size up to 200 mm & 3
minutes for valve sizes above 300 mm. During the
test there shall be no evidence of leakage through
the valve nor shall any part show evidence of
permanent damage or distortion.
d.
Low pressure sealing: - The valve shall be

pressurized by water for a minimum pressure of0.2
Kg/cm2 for large orifice and 1.35 kg/cm2 for small
orifice (as per AWWA C 512-92) for duration of 3
minutes. During this period there shall be no
leakage.
PAGE 32 of 70
832 of 2461
e.
MMRDA
The valve shall be pressurized by water for one &

half times of maximum working pressure for a
duration of 3 minutes. During this period there
shall be no leakage.
f.
Release of air under working pressure: - The valve

shall be pressurized by water for 14Kg/cm2 in
steps of 2 kg/cm2 up to 14 kg/cm2 and the air shall
be injected to the air valve without reducing the
water pressure. The air must be released through
small orifice continuously without any spillage of
water at the same pressure. The air must be
released within one minute and the same shall be
observed for a minimum duration of 5 minutes.
3.11.3 Dual Plate Check valve (Non-Return Valve)
(a)
The valve shall be suitable for mounting on a horizontal pipeline

and flow direction shall be clearly embossed on the valve body.
(b)
Valves shall possess high speed closing characteristics and be

designed for minimum slam condition when closing.
(c)
Dual plate check valves shall conform to API : 594. They shall
have metal to metal sealing. The spring action shall optimize
the equal closing rates of each plate especially when the friction
coefficients are uneven due to one plate resting upon one
another. The plates shall not drag on the seat while opening.
The plates shall not vibrate under full or partial flow condition.
Valves shall possess high speed closing characteristics and be
designed for minimum slam condition when closing.
(d)
If self closing without slamming can not be achieved, external

mechanism may be used to control the closure rate. Details of
mechanisms will be subject to approval.
PAGE 33 of 70
833 of 2461
MMRDA
(e)
The minimum body-wall thickness shall conform to IS Standard.
(f)
The face-to-face dimensions of valves (including valves with

ring-joint facings) shall as per IS standard
(g)
The valve shall be with bye pass arrangement of adequate size.
(h)
The valve body shall be furnished with a clearly visible forged,

machined-in, or die-stamped arrow to indicate the direction of
flow through the valve.
(i)
Maximum permissible seat leakage is 7cc/Hr/cm nominal

diameter of valve.
(j)
Material of construction of valves shall comply with following

requirements
Body
SGI IS : 1865 Gr. 500/7
Disc
SS ASTM A 351 Gr. CF 8
Body Seal
EPDM
Springs
SS. 316
Hinge pin
SS 410
Body / plate bearing
SS 304
Plug
SS 304 /316
(k)
Testing & inspection as per API 598
(l)
Hydraulic test pressure Seat 10 kg/cm2 & Body 15 kg/cm2
(m)
Flange drilling standard : IS 1538
3.11.4 Dismantling joints
PAGE 34 of 70
834 of 2461
MMRDA
The Dismantling joint is provided with double flanges to connect with

the valve and pipeline. The joints shall be having studs for full length.
The dismantling joints shall be in CI/ DI / MS suitable for installations

prior to sluice / butterfly valves for easy access to the valve for
maintenance.
The axial load can be transferred by the joint to protect the valve and
the pump. The adjusting scope by the joint shall be 0-50 mm. The
deviation of the pipe centre line is 2-4 mm and the permissible
declining angle degree is less the 2 degrees. The M.o.C. of gasket
shall be of EPDM.
The joint shall be tested hydraulically as per IS 6157-1981
3.11.5 Coarse Bar screen
General Requirements for Coarse and Medium Screens
The screen shall be conforming to IS 6280-1971.
The top of the screen shall be at least 500 mm above the highest level.
The SS flat for screens shall be 50x10 mm thick.
A MS grating platform shall be provided for manually cleaning the

screen
The c/c distance between the flats shall be 25 mm.
The stiffeners shall be provided at 1 m distance
Head loss in 50% clogged screen shall be less than 30 mm
The Frame of screen shall rigidly fixed in wall. The channels of frame at
PAGE 35 of 70
835 of 2461
MMRDA
the end corner and bottom shall be embedded in concrete.
The monorail type lifting arrangement shall be provided at top of screen

with adequate capacity chain pulley block.
The Moc of all wetted parts shall be SS 316
The screen shall be installed below lowest water level by minimum

distance, not less than head loss in the screen.
The screen shall be installed in each pump bay , including a bay for
future requirement
3.11.6 Stop logs
The Stop Logs shall be designed steel bulkhead to hold back the water
at intake work to isolate it for carrying out maintenance for screen /
sluice gates.
A.
The stop log shall have:
a.
Designed for mounting / fixing between two parallel wall /

columns on incoming side of intake.
b.
Vertical lift type with downstream SS skin plate & rubber

seal.
c.
SS shutter comprising of SS skin plate & rubber seal.
d.
Multi piece constriction, with height of each log shall be

1.0 m. Skin plate of gate with horizontal & vertical
members at its upstream side.
e.
Interchangeable in any slot of intake slot.
PAGE 36 of 70
836 of 2461
f.
MMRDA
Sealing system: Rubber seals located in the bottom &

lateral sides (three sides of each stop log).
g.
The seals shall be replaceable type. The rubber seals

fastened on gate shutter by means of SS clamp bars &
SS bolt.
h.
The lifting beam for smooth raising & lowering of Stops

Logs in their guides to achieve the required height.
i.
SS guide shoes on each side of gate to engage with

embedded guides during lowering lifting the gate in
frame.
j.
Two SS lifting pins/ rods on top of gate to engage with

lifting beam during lowering & lifting the gate in frame.
k.
B.
One spare log shall be provided.
Guide Frame
a.
One set of guide frames of each opening suitable for

embedment in 500 x 200 mm deep grooves in side wall of
channel.
b.
Each set of guide frames comprising of two side seal

bearing and guide plates, one bottom seal beam bearing
plate. Inner surface side guide frames will work as seal
seat.
c.
The side seal bearing & guide plates/ guide angles form a
continuous slot lining from the sill beam to the top of
operating gate
C.
Lifting beam
PAGE 37 of 70
837 of 2461
a.
MMRDA
Welded construction type lifting beam made of galvanized

mild steel.
b.
Lifting beam equipped with two semi automatic engaging

and disengaging hooks.
c.
Two guide rollers on each side of lifting beam for

engaging with gate guides embedded in the concrete.
d.
SS pin & self lubricating bronze bushing for semi

automatic hooks & guide rollers.
e.
the provision of overhead monorail and connecting chain

shall suitable for maximum weight to be lifted of stop log
gate
They shall be strong enough to withstand the maximum water

pressure which could be applied to them in service without
distortion causing any leakage. The Stop Logs shall be multi
piece type with its height shall be above normal water level.
Stop logs to be provided in structures shall be fitted with channel

section inserts, built-in to the structure during construction.
Materials used for inserts shall be corrosion resistance and
designed for long life in installed conditions at site. The slot
inserts shall be designed to ensure effective sealing with stop
logs.
Stop logs shall be fitted with
suitably durable sealing
arrangements, designed for long life when kept in storage

provided, and designed to ensure minimal leakage between the
adjacent stop logs slot inserts when in position. The side seals,
bearing against the fixed slot inserts, shall be low friction type, to
minimize the lifting force needed. Rubber seals shall not be
PAGE 38 of 70
838 of 2461
MMRDA
used.
Stop log lifting beam
Stop log lifting beam shall be designed to couple & decouple

automatically in service when lifting & lowering stop logs and
shall be fit in the stop logs slots to felicitate operation.
Beams shall be of galvanized steel, with self lubricating bronze

bushes at bearing points.
D.
Material of Construction
S.
Particulars
Material
No.
1
Guide frame
SS 316
Seal seat
Resilient rubber seal for side ^ bottom
EPDM
Seal retainer, fasters
SS 316
Guide block , guide shoes , assembly

fasteners . lifting pins
Lifting beam
Galvanized MS with
200 microns
E.
lifting Arrangement for Stop Logs
Unless otherwise specified, stop logs hoists shall be manual

monorail gantry designed for operation an endless chain by one
man. The gantry shall be as per IS 3177.
Stop log hoist shall run on overhead monorails leading from

each stop logs slots to the position to the stop log storage to be
provided. The hoist hook shall incorporate safety catch to
felicitate safe operation.
PAGE 39 of 70
839 of 2461
MMRDA
Gantry shall be provided with enough lifting chain to enable stop

logs to be positioned at the bottom of lowest of the stop logs
slots provided.
The complete
lifting system including monorail, hoists, slings,
lifting beam, and stop logs pins shall be strong enough to lift the
weight of one stop log and overcome the friction in the stop logs
slots when the stop log is fully loaded by water pressure on top
of the stop log with designed safety factor of not less than 2.
Stop log storage
Stop log storage shall be in corrosion protected steel racks,

designed to accommodate stop log & lifting beam.the protection
for rubber seals from mechanical damage shall be provided.
3.12
Electric Actuator
Electric actuator for closing and opening of each sluice gate shall be provided
as per the process requirement mentioned elsewhere in this document, so
that the closing and opening operation time shall be maximum of 10 minutes.
a)
The local control shall be protected by a Lockable cover.
b)
The Actuator shall be adequately sized to operate all the penstocks

and be continuously rated to suit the modulating control required. The
Gear box shall be Oil or Grease filled, and capable of installation in any
position. All operating spindles, gears and headstocks shall be
provided with adequate points for lubrication.
c)
The Actuator shall be capable of producing not less than one and half
times the required torque and shall be suitable for at least 15 minutes
continuous operation.
PAGE 40 of 70
840 of 2461
d)
MMRDA
The Actuator starter shall be integrally housed with the Actuator in

robustly constructed and totally enclosed weatherproof housing. The
motor starter shall be capable of starting the motor under the most
severe conditions.
e)
The starter housing shall be fitted with contacts and terminals for power
supply, remote control and remote positional indication.
f)
Each starter shall be equipped as follows:
i)
2No.Three phase magnetically operated line contactors with novolt release and electrical and
mechanical interlock.
ii)
1 No. Three phase thermal cut-out device.
iii)
1 No. control circuit transformer fully protected by fuses on

primary and secondary circuits.
iv)
1 No. Set of open, close and stop buttons.
v)
1 No. Local-off-Remote switch with padlocking facilities.
vi)
1 No. set of Torque and Limit switches for open and Close
positions.
3.13
vii)
3 No. sets of Auxiliary limit switches in each direction.
viii)
Gate position indicator and Hand wheel for Manual operation.
ix)
Reduction Gear unit.
Hand Operated CP block and Trolleys ( HOT / monorail )
Manual hoists shall be complete with
hand-chain, trolley, pulley block,
hook, hand and load chains, brake and other accessories. They shall
PAGE 41 of 70
841 of 2461
MMRDA
comply with the latest applicable standards, regulations and safety codes
in
the locality where equipment will be installed.
Each hoist shall be operated on a monorail (I-Beam). The factor of safety

shall not be less than 2. The load chain may be heat-treated to give ductility,
toughness and conforming to I.S. 3109.
heavy duty malleable castings.
The load wheel is to be made from
The hand chain is to Conform with B.S.
6405:1984 and hand chain wheel may be made from pressed sheet steel with
roller type guarding. Gears shall be cut from solid cast or forged steel blanks
or shall be stress relieved welded steel construction. Pinions shall be of
forged carbon or heat treated alloy steel. Strength, Quality of Steel, heat
treatment, face, pitch of teeth and design shall confirm to BS-436, BS-545 and
BS-721. Spur and helical gears must comply with B.S. 436 and worm with
B.S. 721. Bearing must be ball and roller type conforming to I.S. 2513. Proper
lubricating arrangements are to be provided for bearings and pinions. The
brake for the lifting gear shall be automatic and always in action.
The proof testing of each chain pulley block is to be carried out as per latest
applicable standards. The safe working load is to be marked in such way that
is clearly visible from the operating level.
3.13.1 EOT CRANE
The crane shall be electrically operated, bridge type complete with all
accessories including down shop conductor, crane rails and fixtures
and shall conform to IS 3177 Mechanism Class M4.
The crane shall consist of bridge girders on which a wheeled trolley is to

run. The bridge trucks and trolley frames shall be fabricated from
structural steel. Access walkway with safe hand railing is required
along the full span length of the bridge girder. Steel shall be tested
quality conforming to IS 2062 the bridge shall be designed to carry
safely the loads specified in IS 807. The maximum deflection under full
load shall not exceed 1/900 of the span. All anti-friction bearings for
bridge and trolley track wheels, gearboxes and bottom sheaves shall
PAGE 42 of 70
842 of 2461
MMRDA
be lubricated manually by hand operated grease pump through

respective grease nipples.
Wheel and structural frame of the wheel mounting of the end carriages
shall be designed so as to ensure that the crane remains square and to
prevent skewness. Bridge and trolley track wheels shall be of forged
steel and shall be double flanged type. The wheel diameter and rail
sizes shall be suitable for the wheel loads. The crane rails shall be
manufactured from wear resistant steel. Mountings of the wheels shall
be designed to facilitate easy removal for maintenance. Walkways shall
be at least 500 mm clear inside width with a 6 mm thick non-skid steel
plate surface. Steel rail stops to prevent rails from creeping and trolley
from running off the bridge shall be abutted against ends of rails and
welded to the girders. Bridge and trolley stops to match the wheel
radius shall be provided before the buffer stops.
All exposed couplings, shafts, gears, wheels, pinions and chain drives,
etc., shall be safely encased and guarded completely to prevent any
hazard to persons working around. All bearings and gears shall have a
design life of 10,000 hours. Electro-magnetic and hydraulic thrustor
brake shall be provided for the main hoist. One electro-magnetic brake
shall be provided for each of the cross travel and long travel motions.
Hook shall be solid forged, heat treated alloy or carbon steel suitable for
the duty service. They shall have swivels and operate on ball/thrust
bearings with hardened races. The lifting hooks shall comply with the
requirements of IS 3815/5749 and shall have a safety latch to prevent
rope coming off the hook.
Hoist rope shall be extra flexible, improved plough ungalvanised steel

rope with well lubricated hemp core and having six strands of 36 or 37
wires per stand with minimum ultimate tensile strength of 1600000
kN/m2 of Right Hand Ordinary (RHO) lay construction. Rope drums
shall be grooved and shall be either cast steel or welded steel
conforming to IS 3177.
PAGE 43 of 70
843 of 2461
MMRDA
Gears shall be cut from solid cast or forged steel blanks or shall be
stress relieved welded steel construction. Pinions shall be of forged
carbon or heat treated alloy steel. Strength, quality of steel, heat
treatment, face, pitch of teeth and design shall conform to IS 4460.
A Name plate, showing year of manufacture and rated capacity of hoist

in figures not less than 150 mm height shall be placed on each side of
the crane girder.
All accessory and auxiliary electrical equipment including drive motors,

electrically
operated
brakes,
controllers,
resistors,
conductors,
insulators, current collectors, pendant push button station, protective

devices, operating devices, cables, conduits, etc., necessary for the
safe and satisfactory operation of the crane shall be provided.
Power to the crane shall be provided by down shop conductors
manufactured from high conductivity hard drawn copper. Conductors
shall be completely shrouded such that they have no exposed current
carrying surfaces. Pendant type push button station shall be sheet steel
enclosed and shall comprise the following push buttons and indicating
lamps:
`Start and `Stop.
Long travel - `Right and `Left.
Cross travel - To and `Fro.
Hook - `Hoist and `Lower.
Red indicating lamp for supply ÒN indication.
Pendant type push button shall be supported independently of the

electrical cable and shall be earthed separately, independent of the
suspension. Automatic reset type of limit switches shall be provided to
PAGE 44 of 70
844 of 2461
MMRDA
prevent over travel for each of the following:

For Ùp and `Down motions of the hook.
Long travel motion
Cross travel motion
Crane structures, motor frames and metal cases of all electrical

equipment including metal conduit and cable guards shall be earthed.
All motors, brakes, limit switches, panels, drum controllers, resistor unit
sets shall be provided with two studs for earthing.
Acceptable indigenous makes are ACME Manufacturing Engineers,

Batliboi Ltd., Electromech Engineers, Reva Industries or equivalent, as
approved by the Employers Representative.
Drawings and information to be provided by Contractor shall include

the following:
Drawings showing general arrangement, clearance requirement,

assembly, and materials of construction for:
EOT Crane
Crane rail fixing arrangement
Run way conductor system details
Trolley arrangement
Drive and transmission details for bridge travel, trolley travel and
main
hoist.
Design calculations for the following:
Rope drum, wire rope, gearboxes, motor ratings, brake

selection wheels etc.
Characteristics and other data
PAGE 45 of 70
845 of 2461
MMRDA
3.13.2 Pipe work

The term pipe work means pipe of any description and includes
associated flanges, adopters, couplings, jointing materials, fittings,
supports, valves, traps and the like which are necessary to complete
station pipe work systems associated with Pumping Station.
(a)
Purpose
(b)
Contents
(c)
Related documents
(d)
Definitions
(e)
Application standards
(f)
Drawings
(g)
Materials
(h)
Fabrication - general;
tolerance;
preparation;
fit-up;
threading;
bends;
welding;
heat treatment:
after fabrication treatment
inspection
(i)
Preparation and protection finishing of surfaces
(j)
Marking and coding for identification and matching
(k)
Acceptable welders qualification
The Contractor shall design, manufacture, supply, fabricate, and install

the pipe work in accordance with the Specification and to satisfy pipe
work function of Pump Station. The Contractors specification for the
fabrication of pipe work shall be submitted for the Employers approval.
The information provided shall be, when applicable, as listed below:
PAGE 46 of 70
846 of 2461
MMRDA
All pipes, fittings, bolts, nuts, jointing materials, pipe supports, thrust
blocks and appurtenances for piping to be required for execution of the
Works shall be manufactured and erected in accordance with the
erection plans, specifications to be
provided by the Contractor and
approved by the Employer. All pipe work and fittings shall be rated to
the higher pressure class in excess of the maximum pressure attained
in service including any surge pressure. Minimum 2 mm corrosion
allowance shall be considered. Where pipe material is specified as Mild
steel, the pipe thickness shall not be less than 12 mm. Buried pipes in
addition to above, shall be designed to withstand external loading
exerted by soil, water, and live loads as relevant. The external ground
water shall be taken at ground level for design purposes.
All pipe line shall be marked the flow direction, and print ink the name
of liquid to be carried as well as name of the destination of facility.
Underground pipe line must be shown the location by concrete pole

that indicates its lay underground depth and its flow direction.
The pipe work installation shall be so arranged to offer ease of

dismantling and removal of pumps or other major items of equipment.
Stainless steel to Grade AISI 304 expansion bellows which can take
radial and axial misalignment of minimum 1 percent of valve nominal
size with tie rods shall be included in the suction and delivery pipe work
of all pumps as well as on delivery header for easy dismantling, and
provision shall be made for a flexible joint arrangement to building
structures.
All loose flanges shall be secured to fixed flanges by
suitable tie-bolts.
All necessary supports, saddles, slings, fixing bolts and foundation

bolts shall be supplied to support the pipe work and its associated
equipment in an approved manner. Valves, meters, strainers and other
devices mounted in the pipe work shall be supported independently of
the pipes to which they connect. All brackets or other forms of support,
PAGE 47 of 70
847 of 2461
MMRDA
which can conveniently be so designed, shall be rigidly built up of steel

by welding and coated by paint after wielding works.
All pipe work shall be adequately supported with purpose-made fittings.

When passing through walls, pipe work shall incorporate a puddle
flange or other suitable sealing device.
Flange adapters and unions shall be supplied and fitted in pipe work
runs, wherever necessary, to permit the simple disconnection of
flanges, valves and equipment. The final outlet connection of the pipe
work shall match the connecting point of the transmission main.
Flanged joints shall be made with minimum 3 mm thick full face, fabric
reinforced rubber gaskets, pierced to take the bolts, and the face of all
flanges shall be machined to give a true angle of 90o to the centre line
of the pipe or fittings. All necessary supports, saddles, slings, fixing
bolts and foundation bolts shall be supplied to support the pipe work
and its associated equipment in an approved manner. Valves, meters
and other devices mounted in the pipe work shall be supported
independently of the pipes to which they are connected.
Bolts for flange connection must be tightening adequate force in

comply with international standards or approved by the Engineer.
Material of construction of pipes and fittings shall confirm to the

following specifications:
Size
Pipes
mm Material
Dimensional Standard
(NB)
Specification
Up to 150
IS:1239
PT-1, 1239 PT-1 C1 Heavy
ERW Black
Elbows
200 &bove
IS:2062, Gr. B
IS 3589
Upton 50
ASTM - A 105
ANSI B 16.11 3000 #

S.W.
PAGE 48 of 70
848 of 2461
Size
MMRDA
mm Material
Dimensional Standard
(NB)
Specification
65 to 300
ASTM - A 234 ANSI B 16.9
Above300
LR. BE.
Gr WPB
Sch 40
IS : 2062, Gr. B
ANSI B 31-1
ASTM - A 105
ANSI B 16.11
(mm)
Coupling
Upton 50
3000 #
S.W.
Tees
Upton
50 ASTM - A 105
65 to 200
ANSI B 16.113000 #
S.W
ASTM - A 234 ANSI B 16.9BE, Sch 40

Gr WPB
Reducers
Above 200
IS:2062, Gr. B
IS : 2825
Upton 50
ASTM - A 105
ANSI B 16.113000 #
S.W.
65 to 300
ASTM - A 234 ANSI b 16.9BE, Sch 40

Gr WPB
Reducers
Above 300
IS : 2062, Gr. B
IS:
2825,
Thickness
matching with that for

the higher dia.
Flanges
& Sizes up to ASTM -A 105
ANSI B 16.5
BlindFlanges 200
Flanges
& Sizes 200 IS : 2062, Gr. B
BS EN:1092-1 SORF
BlindFlanges up to 2000
Bolts & nuts
All
SS 316
Gaskets
MS
IS:638Rubber
3 mm thickness up to
reinforced
900 mm pipe5 mm for
CAF:(air
900-1200
service)
above 1200 mm
mm6
mm
The thickness of MS pipe shall not be less than the value indicated
below:
Pipe Size
Minimum Pipe Thickness (mm)
PAGE 49 of 70
849 of 2461
MMRDA
mm NB
Pump Suction
Pump Discharge
500
12
12
600
12
12
700
12
12
900
12
12
1000
12
12
1200
14
14
1400
14
14
2000
16
16
2300
18
18
2600
18
18
Facilities shall be provided for draining the pipe system and releasing
air.
The pipe work layout within all process pumping area shall have the
approval of the pump manufacturer.
The whole of the jointing work and materials necessary to fix and
connect the pipes, including adequate and efficient pipe support shall
be included in the Contract. The Contractor shall be responsible for
ensuring that the internal surface of all pipe work is thoroughly cleaned
before and during erection and before commissioning.
Cleaning shall include removal of all dirt, rust, scale and welding slag
due to Site welding. Before dispatch from the manufacturers works,
the ends of the pipes, branch pipes, etc., shall be suitably capped and
covered to prevent any accumulation of dirt or damage. This protection
shall not be removed until immediately prior to connecting adjacent
pipes, valves or pumps. All small bore pipes shall be blown through
with compressed air before connection is made to instruments and
other equipment. No point of passage of pipes through floors or walls
shall be used as a point of support, except with the approval of the
Employer.
PAGE 50 of 70
850 of 2461
MMRDA
Hydraulic shop test for pipes and fittings shall be conducted as per
relevant code/standard requirement. After erection at Site, complete
pipes and fittings shall be hydrostatically tested for a pressure of1.5
times design pressure.
Flanges, if fabricated in segments shall be fully radio graphed and

stress relieved. If fabricated out of billets/bars by cold rolling, welded
flanges shall be radio graphed and normalized.
Protection for pipes laid underground shall be by coating and wrapping

system giving a final coat thickness of 4.5 mm shall be employed. Such
protection shall comprise 1.5 mm of coal tar primer application on a
thoroughly cleaned surface, to be followed with fiber glass wraps set in
coal tar enamel coats conforming to American Water Works
Association specification C/203/57 for a total thickness of 3 mm. Such
lining shall meet a spark test to be approved with a holiday detector of
10000 Volts.
The Contractor shall indicate on his detailed drawings what thrust

blocks are required to anchor pipe work supplied by him. Particular
care shall be taken to ensure that pipe work thrusts are, as far as
possible, not transmitted to machinery or other associated apparatus.
Puddle flanges shall be fitted to pipes where the structure through

which they pass is required to take thrust resulting from the pipe.
Puddle flanges shall also be fitted where a water barrier is required. All
puddle flanges shall be clearly shown on the drawings and the
resultant thrust clearly indicated. Puddle flanges shall only be fitted
with the prior approval of the Employer.
3.13.3 Ventilation Fans
Based upon the values of Air flow required, resistance to air flow, duct
work & total distribution system; the contractor shall design & provide
PAGE 51 of 70
851 of 2461
MMRDA
fans capable of delivering required air volume when operating at

Pumping station.
The fans shall be type tested in accordance with requirements of BIS:

3588& shall be selected to give the designed air flow rate & sound
power specified. The fan shall be directly coupled to motor & suitable
for continues duty
Unless otherwise specified, the shaft & impeller assembly shall be

statically & dynamically balanced. The vibration severity shall be
accordance with BIS .: part 1. Vane blade shall not vibrate or
flutter in any possible operating condition.
The fan bearing shall be suitable for installed attitude of fan. They shall
be ball & or roller bearings & grease lubricated type. All bearing
housing shall be precision located and arranged so that bearing may
be replaced without the need of realignment. All bearing lubricators
shall be located to facilitate maintenance.
Ceiling Fan
Ceiling fan shall comply with IS: 374.
The fan shall be having speed control in at five discrete steps using a
separate surface mounted controller. The controller shall use a tapped
auto transformer for speed control.
Motor shall be capacitor start / run type, with inner wound stator and
rotating outer body and incorporating ball type bearing.
The motor shall be suitable for use in tropical environment.
Centrifugal Fan
The centrifugal fan shall be complying with IS: 4894.

PAGE 52 of 70
852 of 2461
MMRDA
Unless otherwise specified, centrifugal fans of more than 7.5 kW at the

fan shaft shall be of backward bladed type having a fan total efficiency
not less than 75%
Fan shall be built to permit withdrawal of impeller after installation.

Fans other than those in air handling units shall be provided with
flanged outlet connections &spigot inlet connection, unless otherwise
specified, except that, for negative pressure less than 500 Pa, inlet
connection shall be flanged. A plugged drain point shall be fitted at the
lowest point in fan casings. Permanent indication shall be provided
showing the direction of rotation of the fan impeller. Fan casings shall
be provided with removable access panels incorporating purposemade air seals. The sizes of access panels shall facilitate cleaning and
maintenance.
Impellers shall be of mild steel or aluminum alloy, of riveted, welded or

other approved construction, with spiders or hubs of robust design.
Axial-flow fans
Axial-flow fan casings shall be rigidly constructed of mild steel or

aluminum alloy, stiffened and braced where necessary. Mounting feet
shall be provided where necessary for bolting to a base or to supports.
Inlet and outlet ducts shall terminate in flanges to facilitate removal. For
in-duct mounting fans, the length of the fan casing shall be greater than
the combined length of the impeller(s) and motor(s) and electrical
connections to the motors shall be through an external terminal box
secured to the casing.
Impellers shall be of steel, aluminum or plastics and the blades shall be

secured to the hub or the blades and the hub shall be formed in one
piece. The hub shall be keyed to the shaft. Blades shall be aerofoil or
laminar section, capable of pitch adjustment where specified.
PAGE 53 of 70
853 of 2461
MMRDA
For axial-flow fans driven by motors external to the fan casing, the
requirements for drives and guards mentioned elsewhere in this
Specification shall be met. Unless otherwise indicated, a guard is not
required for any part of a drive which is inside the fan casing. An
access panel with purpose-made air seals shall be provided in the fan
casing. The access panel shall be sized to facilitate maintenance.
Where axial-flow fans of the bifurcated type are specified, the motors
shall be out of the airstream. Motors may be placed between the two
halves of the casing in the external air or may be placed within the fan
casing, provided that effective ventilation is given to the motors.
Propeller fans
Propeller fans shall be ring-mounted or diaphragm-mounted as

specified. Impellers shall be of steel, aluminum, or plastics. Blades
shall be securely attached to the hub, or the blades and hub shall be
formed in one piece.
In-line centrifugal and mixed-flow fans
Mixed-flow fan casings shall be rigidly constructed of mild steel, or

aluminum alloy stiffened and braced where necessary. Mounting feet
shall be provided where necessary for bolting to a base or supports.
Inlet and outlet shall terminate in flanges to facilitate removal. Stator
vanes shall be of mild steel or aluminum alloy. The design shall
facilitate access to the impeller. Where motors are mounted external to
the casing, the requirements for drives and guards given elsewhere in
this Specification shall be met. An access panel with purpose-made air
seal shall be provided in the fan casing. The access panel shall
facilitate maintenance.
Mechanical roof-extract units
The fans used in roof extract units shall meet the appropriate
PAGE 54 of 70
854 of 2461
MMRDA
requirements of the preceding clauses relating to fans generally and to

particular types of fans. Cowls and bases shall be of materials which
are resistant to the weather and solar radiation, and are appropriate to
the location of the fan. Casings shall be formed to facilitate a
weatherproof fitting to the building structure. Adequate access to
electrical supply terminals and lubrication points shall be provided by
means of hinged cowls or otherwise as appropriate. Back-draught
dampers or fire-release dampers shall be provided where specified.
Bird guards of not greater than 25mm mesh shall be provided as an
integral part of the unit.
Protectively-coated fans and fans for corrosive or hazardous

applications
Where fans are required to handle toxic, corrosive, flammable,

explosive or high-temperature gases, the materials of construction shall
be chosen appropriately and all relevant safety regulations shall apply.
Bearings and lubrication arrangements shall be suitable for the
conditions. Protectively-coated fans shall meet the appropriate
requirements of the preceding clauses relating to fans generally and to
particular types of fans, and the form of protection shall be as
indicated. Where a protective coating is required for use with corrosive
gases the coating shall cover all parts of the complete fan, motor and
casing assembly which will be affected No fan shall be installed if the
protective coating has been damaged. Impellers shall be of coated
steel, stainless steel, aluminum or plastics as specified.
For fans are installed in hazardous atmospheres, requirements shall be

as specified.
Air Filter
Filters shall be complete with robust purpose-made holding frames

which shall not distort in operation. Filters shall be arranged to facilitate
access for cleaning, removal and refitting. Purpose-made seals shall
PAGE 55 of 70
855 of 2461
MMRDA
be provided to minimize air leakage around filters and the effectiveness

of the seals shall not be impaired by periodic removal and refitting of
the filter cells.
Where a flame-proof filter medium is required, the material shall

comply with the requirements of BS 476.
The design air velocity at the face of the filters shall not exceed 2.5
m/s. At the design air volume flow rate the initial (clean) resistance
shall not exceed 90Pa for filters.
Enough spare filter elements shall be provided to replace the complete

filter bank.
Unless otherwise indicated, filters shall be selected from the following
range of preferred nominal sizes:600 mm x 600 mm; 500 mm x 500
mm
3.13.4 Dismantling joints, flexible couplings and flange adaptors
Where dismantling joints, flexible couplings or flange adaptors are used

these shall be of the Viking-Johnson type except where otherwise
specified or approved.
Pressure ratings shall match the pressure rating of the pipework in which
they are installed, and materials used and methods of protection shall not
be inferior to those used for the pipework.
Where needed, joints and couplings shall be provided with tie bolts to
restrain the maximum axial thrust arising when in service.
Detachable flexible couplings shall be suitable for the angular deflections

specified below without leakage. Flange adaptors shall be suitable for half
the angular deflection stated.
PAGE 56 of 70
856 of 2461
MMRDA
Nominal pipe diameter
Angular Deflection
(mm)
Up to 600
601 to 750
751 to 900
4
3
901 to 120
1201 to 180
1801 upward
2
1
Flexible couplings for each size of pipe shall also be capable of

withstanding the shear force applied by the weight of a 4 m length of pipe of
the diameter full of water suspended between two couplings.
Detachable flexible coupling shall be provided with central registers or

location plugs only where specified or detailed in the drawing.
Flange adaptors shall have flanges as specified for flange joints Bolts, nuts
and washers shall comply with the requirements for both nuts, bolts and
washers for flanges.
Bolts, nuts and washers shall comply with the requirements for both nuts,
bolts and washers for flanges.
The metal components of detachable flexible couplings and flange adaptors

shall be protected by thermoplastic polyamide or fusion bonded epoxy
coatings unless otherwise specified or detailed in the Drawings
3.13.5 Progressive Cavity Pumps
These pumps shall be used for handling thickened sludge transfer and
BFP feed applications.
Pumps shall be of the type in which a pumping action is generated by a

helical rotating eccentrically within a resilient stator in the form of a
double internal helix. The eccentric motion of the rotor shall maintain a
constant seal across the stator as it travels through the pump to give a
PAGE 57 of 70
857 of 2461
MMRDA
uniform positive displacement.
Pumps shall be arranged generally with a single shaft seal at the

suction end. Mechanical seals shall be used. If a flexible shaft is used to
accommodate the eccentric motion, a corrosion resistant shroud shall
be fitted to prevent fibre build-up on the shaft. Enlarged inspection
access holes shall be fitted to the suction chambers of all pumps for
periodic removal of accumulated debris.
The shaft bearing shall be positively isolated from the fluid being
pumped.
The rotor material shall be selected for corrosion and abrasion

resistance for the fluid being pumped, and for prolonged service life.
Hard chrome or other approved coatings shall be not less than 250
micron thickness and shall be diffused in to the base material. The rotor
shall generally be single-stage and shall incorporate not less than 360 0
of twist, but for high-head applications, it may be necessary to use more
than a single-stage. The stator shall be of a resilient material selected
for chemical and abrasion resistance for the fluid being pumped.
Pump speed shall suit the application, where variable delivery output is
needed; the pump shall be provided with a variable-speed drive. The
size and speed range of the pump shall ensure that the highest
expected duty point shall lie within the available speed range.
Pumps shall normally be driven by a fixed-speed electric motor through

reduction gearing and the combined drive shall be continuously rated.
Pump and motor shall preferably be mounted in-line on a common base
plate. Alternatively, the drive motor may be top-mounted above the
pump to minimize floor area, and shall be connected by external V-belts
and pulleys. V-belt drives shall have full guards of the type that allow the
belts observed without removal of the guard. Facilities shall be provided
for ready adjustment of belt tension.
PAGE 58 of 70
858 of 2461
MMRDA
Coupling guards shall be provided, which shall be rigid, securely fixed,

and designed so that removal is not necessary during normal operation,
routine maintenance and routine inspections. All motor enclosures shall
be provided with ingress protection to IP55. Motor anti-condensation
heaters shall be provided and shall be suitable for use on a 220V singlephase, 50Hz supply.
All bearing shall have a B10 design life of not less than 40,000 running
hours and shall be designed for loading 20% in excess of calculated
maximum loading. Pumps shall be fitted with individual dry-running
protection to initiate pump trip. Dry-running protection by under-current
monitoring or pipeline-intrusive device shall not be used.
MATERIAL OF CONSTRUCTION
Pump Housing
CI IS 210 GR. FG220 or

FG260
Rotor
SS AISI 316(Hard chrome

Plated)
Shaft
SS AISI 410(Hard chrome

Plated)
Stator
Nitrite black
Type of drive
V belt & Pulleys
Base plate
MS fabricated
Seal type
Gland
packing
(Asbestos
Free)
3.13.6 Pressure Gauges
Pressure gauges shall comply with BS EN 837.1:1998 and shall not be

less than 100 mm in diameter.
Unless otherwise specified, scales shall be calibrated in metres head of

water, with zero representing atmospheric pressure. The lettering shall
be in black.
PAGE 59 of 70
859 of 2461
MMRDA
Compound gauges shall read at least 5 m below atmospheric pressure

using red lettering.
Where the working fluid is of a corrosive or dirty nature the pressure

gauge shall be protected from the working fluid by a diaphragm or
similar arrangement.
Each pressure gauge shall be fitted with a stopcock immediately

adjacent to the gauge and all pressure gauge piping shall be fitted with
an isolating valve at the point of connection to the main system. Where
pressure gauges are mounted within or on a panel a suitable
connection for a test gauge shall be provided.
3.13.7 Chemical Dosing Pumps
Chemical dosing pumps shall be piston diaphragm or mechanical

diaphragm type as specified. Pumps may be simplex or duplex
arrangements to suit the capacity or process requirements. The pump
design shall incorporate positive stroke return. The maximum stroking
speed shall not exceed 100 strokes per minute (spm). Pump, motor
and driving arrangement shall be mounted on a robust combined
baseplate.
Pump liquid ends shall be selected for compatibility with the pumped
liquid. Suction and discharge valves shall be the single ball type
allowing a free flow self cleaning action. Ball and seat materials shall
be resistant to abrasion.
Pumps shall incorporate a variable stroke mechanism to allow the

output to be varied while the pump is running. Stroke adjustment shall
be manual or where specified by electrical or pneumatically controlled
stroke positioner. A stroke length indicator and digital stroke counter
shall be fitted. Pumps shall be driven by a flange mounted IP 55 motor,
via an oil bath reduction gearbox and variable stroke mechanism giving
PAGE 60 of 70
860 of 2461
MMRDA
stepless adjustment between zero and maximum stroke length. Where

flow proportional dosing is required the variation of output shall be
achieved by varying the speed of the pump motor and not the pump
stroke length.
The normal operating range of dosing pump shall be not less than
6:1.
a.
Mechanical Diaphragm
the
drive
train.
Diaphragm rigidly coupled to
Single
suction
Pumps
and
discharge
valves.Glandless. Accuracy: 3% of stoke.
b.
Piston Diaphragm Pumps
Diaphragm hydraulically
operated by liquid displaced by a plunger and protected from

excess pressure via a relief valve. Accuracy: 2% of stroke.
Materials shall be selected to suit the chemicals being pumped. Liquid

ends shall be polypropylene, AISI 316 stainless steel, glass, or
Hastelloy C. Diaphragm materials shall be butyl rubber, PTFE, or
Hypalon and glands shall be PTFE or Neoprene.
Each pump shall be provided with inlet and outlet isolating valves
and where necessary, with pressure relief and non-return valves.
Dosing pumps shall be provided
with back pressure loading
valves
and pulsation dampeners in the delivery lines depending on the

downstream conditions.
relief valve shall be incorporated in
the
delivery lines under
conditions where the pump discharge pipe can be shut off or where
pressure may rise to an excessive point. The relief valve shall be
sized to handle the system pressure and to discharge maximum
pump output freely, and shall be located in the discharge
between the pump and
the case of
the
line
first downstream isolating valve or in
dosing pumps the back pressure loading valve. Relief
PAGE 61 of 70
861 of 2461
MMRDA
valves when used on pumps handling non-hazardous chemicals shall

discharge the vented liquid to waste.
When used on hazardous
chemicals the valve outlet shall be piped back to the suction supply
tank or bunded area. The open end of the return pipe shall be located
where it is visible, so that any relief valve leakage/operation can be
detected.
Pump transferring/dosing chemicals to systems under pressure shall

incorporate a pressure gauge on the pump delivery. Air cocks shall be
provided for release of air where necessary.
Unless otherwise specified flushing connections shall be provided at

each pump inlet and flushing shall be manual.
When flushing, water
shall be discharged either locally through a drain valve or to the point of

application of the chemical.
flushing
chemical
pump
Facilities shall also

suction
be provided
and delivery
manifolds
for
and
delivery lines to point of application.
Dosing pumps and motors shall preferably incorporate an integral

reduction gearbox drive which shall be totally enclosed and oil bath
lubricated.
The gear box
diaphragm drive and
shall incorporate
shall be
provided
the cams for the
with filling and
drain
connections and visible oil level indication.
3.13.8 Chemical Gravity Feeders
Gravity Feeders shall have material of construction corrosion resistant

to the chemical being dosed. The doser shall have a repeatable
accuracy with +3% of the set rate within the full operating range.
3.13.9 Sampling pumps
Centripetal type, self priming, monoblock pump set shall be suitable for
pumping water samples from various process units to the Laboratory
shall be provided. Pumpsets connected to a suction and delivery pipes
PAGE 62 of 70
862 of 2461
MMRDA
of 25NB size with necessary valves, unions, bends and tees shall be
provided. Piping shall be GI pipes.
3.13.10 Chemical Gravity Feeders
Gravity Feeders shall have material of construction corrosion resistant

to the chemical being dosed. The doser shall have a repeatable
accuracy with +3% of the set rate within the full operating range.
3.14
Air Blowers
Total four sets of Air blowers (Two working +two standby) shall be provided
for backwash of filter bed . The air blower shall be designed for required
quantity of air and pressure
for backwashing of filter beds of filter plant
considering water quality parameters with design output quantity of water of

403 Mld .
Compressor blowers shall be of the Roots type, each provided with inlet filter
and silencer, pressure reducing valve, pressure gauges, pressure relief valve,
drain, air flow indicator and acoustic bend or silencer in the delivery branch.
Bearing housings and gear boxes shall be separated from the blower
housings by air spaces. The units shall be complete with a self contained oil
cooling system for the bearings. The blowers shall be housed in a separate
sound proof room to reduce the noise level or inside acoustic enclosure. The
noise level shall not exceed 85 dBA at 1.86 metre from the Blower.
The bearings shall be generously designed to give long operational life.

Bearings at the drive end may be oil or grease lubricated. The gears and
bearings at the non-drive end shall be oil lubricated. Bearings shall be
provided with oil throwers to prevent leakage of oil. The blower shall be
arranged for horizontal inlet and vertical outlet, delivery velocity not exceeding
25 m/s and each blower shall be provided with following components but not
limited to:
a.
Common base frame for Blower & Motor
PAGE 63 of 70
863 of 2461
MMRDA
b.
inlet silencer and filter
c.
Discharge Silencer & non-return valve in delivery branch
d.
Butterfly valves in both inlet and delivery branches
e.
pressure relief valve or excess pressure safety device
f.
Bellows type couplings on inlet and delivery branches.
g.
Acoustics Enclosure
h.
Motor-Blower Direct coupling.
i.
Isolating valves, Pressure reducing valves & Pressure gauges
The interconnecting pipe work shall be flanged to BS EN 1092-1. A drain cock

shall be provided at the lowest point in the each delivery pipe work along with
reflux valve. Individual stop valves and safety valves shall be provided for
each unit.
Blowers shall be driven by squirrel cage motors through a direct coupling.

Blowers shall not run above 1000 rpm.
Each delivery branch shall include a drain at the lowest part and a reflux
valve.
3.14.1 General Design Requirements
The air blowers shall be of such design as to achieve energy efficient

operation continuously over the range of design airflow rates at the
discharge pressure that shall remain practically constant.
The sizing of the blower units shall ensure that the peak airflow
demand can be met by one duty blower with one unit on stand-by (two
duty and one 50% standby will also be considered). Each blower shall
be fitted with a motor and be capable of operating airflow demand.
The discharge pressure shall be calculated by the Contractor

dependent on the final design layout of the a filter plant system and of
the delivery manifold.
PAGE 64 of 70
864 of 2461
MMRDA
The blowers shall also be capable of supplying the design mass flow
rate at maximum ambient inlet temperature of 50C.
Each of the blowers shall be capable of operating without surge in

parallel with the other duty blower at the maximum mass flow against
designed maximum gauge pressure at the outlet pipe. The Contractor
shall demonstrate this during testing and commissioning. Performance
curves for the blower system shall be submitted. Standard certified
factory test sheets showing the results of each test shall be supplied in
triplicate to the Engineer prior to delivery of the blowers. The blower
unit shall be capable to operate at maximum duty for continuous
operation. The blower motor shall be having speed of 1500 rpm and
Blower General Arrangement
The blower arrangement shall have the following features:
The blowers shall be roots type units
Each blower shall be fitted with an acoustic enclosure;
The arrangement shall be such that all blowers are accessible

for operation and maintenance and the installation of additional
blowers in the future is possible;
The blowers shall be neatly arranged and housed in a sound

attenuated building.
The inlet air to the blower house shall be filtered to suit the
blowers and aeration diffusers selected;
A blower removal system shall be provided so that any one

blower can be removed as a single unit and loaded onto a truck.
The blower building shall be acoustically designed to minimize
both noise inside the building and noise breaking out of the
PAGE 65 of 70
865 of 2461
MMRDA
building. The building ventilation system shall be designed to

limit the temperature rise not more than 3 C above ambient
temperature.
3.14.2 Ancillary Equipment for Blowers
The blowers shall be provided with the usual ancillary equipment for
aeration duty, including:
Acoustic enclosure with fan cooling
Discharge pressure switch
Power actuated bypass valve or blow-off valve
Discharge pressure relief valve
Discharge check valve
Discharge isolation valves
Discharge silencer, designed to minimize noise propagation

along the pipework
Vacuum switch, pressure switch, oil level indicator and any other
monitoring device shall be mounted outside the acoustic
enclosure
Inlet and outlet pressure gauges shall be mounted outside the

acoustic enclosure
Vibration absorbing mounting pads.
3.14.3 Blower Noise limits

PAGE 66 of 70
866 of 2461
MMRDA
The blowers supplied under this Contract shall be quiet in operation.

The Contractor shall guarantee that the total sound power noise
emission for the filtration backwash system Y shall be broad band and
free from any tonal or intermittent components. Under any loading
condition from no load to full rated, the blower supplied shall comply
with the noise requirements.
3.14.4 Positive Displacement Blower
The air rotary positive displacement blowers (Roots type or equivalent)

shall consist of lobed rotors rotating designed for continuous operation
at the required pressures and flows. The blowers shall be controlled by
variable speed drives. The bowers shall be able to operate over a
speed range to deliver the range of airflow rates nominated above.
Rotors and shafts shall be of one-piece construction and shall be of

forged steel or shall comprise cast iron rotors on steel shafts. The
rotors shall have two or more lobes and shafts shall be geared together
with timing gears so that the lobes do not make contact during
operation.
Bearing housings and rotor shafts shall be fitted with suitable oil seals
to exclude dirt and moisture and to prevent oil carryover into the
discharge air. Where bearings are oil lubricated the housings shall be
fitted with effective oil level indicators.
The blower and motor shall be mounted on a base frame incorporating

an integral silencer, non-return valve, pressure relief valve, discharge
connection with flexible joint and flexible mounting pads (vibration
dampers shall be placed under blower mounts.
The complete assembly including drive motor and lubrication system

shall be mounted and aligned on a substantial galvanised sub-frame.
Heavy-duty anti-vibration mountings are to be located on the underside
PAGE 67 of 70
867 of 2461
MMRDA
of the sub-frame.
Materials of Constructions
Particulars
MATERIAL
Casings
Cast Iron
Base plate
Steel, Galvanised
Rotor/impeller
Manufacturers std
Shaft
Manufacturers std
Nuts and Bolts
Stainless Steel
3.14.5 Filters and Silencers
The blowers shall receive filtered air individual replaceable filter

elements suitable for the intended duty.
The filter elements shall be housed in an airtight housing which shall

allow easy replacement of the filter elements. Replacement of
elements shall be possible without the use of tools.
If the filter/silencer elements supplied are located out of doors a

weatherproof cover shall protect the filter element from rain.
The filter unit shall be fitted with suitable vacuum gauges to indicate the
suction pressure into each blower. The gauges shall be industrial
Bourdon of Schaffer type gauges with a nominal diameter of 150 mm.
The scale shall be suitably selected and shall include a red line to
indicate the point at which the filter elements require renewal.
Each blower intake shall be fitted with a differential pressure switch,

which shall indicate an alarm signal in the event of excessive pressure
drop in the blower intake.
3.14.6 Flexible Connections
PAGE 68 of 70
868 of 2461
MMRDA
The blower discharge shall be fitted with an approved flexible sleeve

with fixing clamps and a flanged outlet spigot for connection to site
pipework. If the blower inlet is via a common plenum the inlet pipe shall
be also fitted with a flexible connection.
Flanges shall be drilled to Table D and shall comply with the required
standard. Sleeves shall be manufactured from an approved nonmetallic material suitable for the duty and location in which the blowers
are to be installed.
3.14.7 Pressure Relief Valve
The pressure relief valve shall be sized and adjusted to allow the full
flow of the blower to be discharged in the event of a blockage or valve
closure in the downstream pipeline and without overloading the drive
motor.
Each blower shall be fitted with a suitable pressure switch, which shall
shut down the blower in the event of excessive discharge pressure.
The pressure setting shall be lower than the set pressure of the
pressure relief valves.
The pressure relief valve shall be installed at a height above 2m from

the floor and away from blower suction point. The pressure relief valve
shall be fitted with a silencer.
3.14.8 Non-Return Valves
A non-return valve shall be installed on the discharge pipework of each

blower, upstream of the blower isolation valve.
3.14.9 Isolating Valves
Isolating valves shall be installed on the delivery pipework of the

blowers, such that each blower and all associated pipework and valves
PAGE 69 of 70
869 of 2461
MMRDA
upstream of the common distribution manifold can be dismantled

without disruption to the normal operation of the plant
3.14.10 Temperature Measurement
Temperature sensor complete with gauge of an approved type shall be

supplied for each main distribution pipework and for the blower room.
3.14.11 Piping Vibration
If the blower type selected produces a discharge flow with a pulsating

characteristic, flow pulsation dampers shall be installed on the blower
intake and discharge, as required, to eliminate excessive noise or
vibration from this source.
3.14.12 Blower Discharge Pipework
The discharge pipework from each blower shall be connected to a

common manifold. Flexible connections shall be provided between the
blower assembly units and the discharge pipework to allow for any
differential movements. The design of the manifold pipe work shall
incorporate all components necessary to enable the easy connection to
the main distribution pipework.
PAGE 70 of 70
870 of 2461
SUB-SECTION 6B.4
SPECIFICATION FOR ELECTRICAL WORKS
871 of 2461
SUB-SECTION 6B.4-A: ELECTRICAL WORKS (AFTER POINT OF SUPPLY)
872 of 2461
MMRDA
Table of Contents
SUB-SECTION 6B.4-A: ELECTRICAL WORKS (AFTER POINT OF SUPPLY) .................... 1
4.1
General...................................................................................................................................... 1
4.1.1
Safety and Security .......................................................................................................... 9
4.1.2
Environmental Condition ............................................................................................... 10
4.1.3
Electrical Switchgear Room Environment .................................................................. 10
4.1.4
System Voltage............................................................................................................... 11
4.1.5
Voltage & frequency variations .................................................................................... 12
4.1.6
Phase Sequence ............................................................................................................ 12
4.1.7
Voltage drop criterion..................................................................................................... 12
4.1.8
Compatibility .................................................................................................................... 14
4.1.9
Enclosures ....................................................................................................................... 14
4.1.10
Identifications .................................................................................................................. 15
4.1.11
Harmonics ....................................................................................................................... 16
4.1.12
Surge protection ............................................................................................................. 16
4.1.13
Earthing System ............................................................................................................. 17
4.1.14
Lightning Protection ....................................................................................................... 18
4.1.15
HV System....................................................................................................................... 18
4.1.16
Polarity ............................................................................................................................. 19
4.1.17
Low Voltage and frequency .......................................................................................... 20
4.1.18
Units of measurement.................................................................................................... 20
4.1.19
Electricity supply ............................................................................................................. 20
4.1.20
Tools & Testing Equipments ......................................................................................... 21
4.1.21
Drawings .......................................................................................................................... 23
4.1.22
Personnel......................................................................................................................... 24
4.2
Scope of Work....................................................................................................................... 24
4.2.1
4.3
Submittals ........................................................................................................................ 29
132 kV Outdoor substation ................................................................................................ 32
4.3.1
Outdoor Lightning Arrestor............................................................................................ 32
4.3.2
Outdoor Isolator .............................................................................................................. 42
4.3.3
Outdoor Bus post insulator ........................................................................................... 51
4.3.4
Outdoor Current Transformers ..................................................................................... 54
4.3.5
Outdoor Voltage Transformers ..................................................................................... 67
4.3.6
Outdoor SF6 circuit breaker.......................................................................................... 75
873 of 2461
MMRDA
4.3.7
Power transformers ...................................................................................................... 116
4.3.8
Neutral Grounding Resistors ...................................................................................... 164
4.3.9
Outdoor substation structure ...................................................................................... 166
4.3.10
Overhead conductor .................................................................................................... 176
4.3.11
Protective Relays Demonstration .............................................................................. 177
4.3.12
Battery, Battery charger and DCDB .......................................................................... 192
4.3.13
Metal Enclosed HV Switchgear Panel....................................................................... 202
4.3.14
Electrical Motors ........................................................................................................... 221
4.3.15
Distribution Transformer .............................................................................................. 233
4.4
415V SWITCHGEAR ........................................................................................................... 236
4.4.1
General Specification of Low Voltage Switchgear .................................................. 236
4.4.2
Panel Construction Details.......................................................................................... 236
4.4.3
Equipment Requirement.............................................................................................. 239
4.4.4
Control Circuit ............................................................................................................... 246
4.4.5
Busbars / Cable Entry .................................................................................................. 248
4.4.6
Earthing:......................................................................................................................... 250
4.4.7
Terminals ....................................................................................................................... 251
4.4.8
General .......................................................................................................................... 251
4.4.9
Circuit Breakers ............................................................................................................ 255
4.4.10
Motor Starter ................................................................................................................. 257
4.4.11
Automatic Power Factor Control ................................................................................ 265
4.4.12
Other Requirements ..................................................................................................... 268
4.5
General Specification of Earthing and Lightning Protection ................................. 277
4.5.1
Earthing .......................................................................................................................... 277
4.5.2
Earth electrodes ........................................................................................................... 277
4.5.3
Conductors .................................................................................................................... 279
4.5.4
Earthing terminal .......................................................................................................... 280
4.5.5
Installation ..................................................................................................................... 280
4.5.6
Earthing of extraneous metalwork ............................................................................. 281
4.5.7
Instrumentation earthing system ................................................................................ 282
4.6
Lightning Protection.......................................................................................................... 283
4.6.1
Design ............................................................................................................................ 283
4.6.2
Materials ........................................................................................................................ 283
4.6.3
Dimensions of component parts ................................................................................ 283
4.6.4
Fittings ............................................................................................................................ 283
874 of 2461
MMRDA
4.6.5
Metallic building fabric ................................................................................................. 284
4.6.6
Bonds and clamps ........................................................................................................ 284
4.6.7
Conductor fixings .......................................................................................................... 284
4.6.8
Joints .............................................................................................................................. 285
4.6.9
Test joints ...................................................................................................................... 285
4.6.10
Earth electrodes ........................................................................................................... 285
4.7
General Specification of Cabling Installations ........................................................... 286
4.7.1
Cabling General Requirements ............................................................................. 286
4.7.2
Cables ............................................................................................................................ 288
4.7.3
Power cables................................................................................................................. 288
4.7.4
Control cables ............................................................................................................... 289
4.7.5
Mineral insulated cables .............................................................................................. 289
4.7.6
Use of proprietary cable types.................................................................................... 289
4.7.7
Cable glands, terminations and joints ....................................................................... 289
4.7.8
Cable termination, joints, sleeves and tape - general............................................. 290
4.7.9
Terminations ................................................................................................................. 291
4.7.10
Joints .............................................................................................................................. 291
4.7.11
Sleeves .......................................................................................................................... 292
4.7.12
Tape ............................................................................................................................... 292
4.7.13
Cable installation .......................................................................................................... 292
4.7.14
Arrangement of single-core cables in three-phase systems ................................. 293
4.7.15
Cable spacing ............................................................................................................... 294
4.7.16
Cable and core identification ...................................................................................... 294
4.7.17
Installation in buildings ................................................................................................ 295
4.7.18
Cable systems .............................................................................................................. 296
4.8
General Specification of Electric Generators ............................................................. 303
4.8.1
Diesel Generator Sets Diesel Engine................................................................... 303
4.8.2
Diesel Generator Sets Generator ......................................................................... 314
4.8.3
Diesel Generator Sets Control System ................................................................ 318
4.9
General Specification of Building Services ................................................................ 326
4.9.1
Building And External Services Power Distribution ........................................... 326
4.9.2
Building and external services roadway lighting................................................. 335
875 of 2461
MMRDA
SUB-SECTION 6B.4-A: ELECTRICAL WORKS (AFTER POINT OF SUPPLY)
4.1
General
a)
Regulations and Standards
The electrical installation shall comply with all relevant statutory

regulations and standards current at date of tender, unless otherwise
indicated within this Specification. In general, the following shall apply:-
(a)
Indian Electricity Act and rules 1956;
(b)
National Electrical Codes of Practice;
(c)
Fire Insurance regulations;
(d)
Rules laid down by the Chief Electrical Inspector of the

Maharashtra State;
(e)
ECBC (Energy Conservation & Building Code);
(f)
International
Electro-Technical
Commission
(IEC),
Standard, European Standard or CENELEC
British
Harmonized
Standards.
If no standard is specified, the relevant Indian Standard or, in the

absence of such standard, international standard shall apply.
b)
Reference Standards
Unless
otherwise
approved
motors,
transformers,
generators,
switchgear, control gear and associated equipment shall comply with

the relevant IEC, ISO, PD, HD, BS EN and BIS Standards. The
standards associated with the electrical installation and building
SECTION 6B.4: ELECTRICAL WORKS AFTER POINT OF SUPPLY
876 of 2461
PAGE 1 of 339
MMRDA
services shall be in accordance with the relevant Indian Standards and

regulations.
Reference is made in this section to the Standards listed below.
Standards Subjects
IS Codes
IS 732
Description
Code of practice for electrical wiring installations
(System voltage not extending 650 volts)
IS 900
Code of practice for installation and maintenance of

Induction Motors
IS 1271
Classification of insulting materials for electrical

machinery and apparatus in relation to their thermal
stability in service
IS 1646
Code of practice for fire safety of buildings (general)

Electrical Installations
IS 1866
Code of practice for maintenance of insulating oil
IS 1882
Code of practice for outdoor installation of public

address systems
IS 10028:
PART 2&3
Transformers
IS 1913
General and safety requirements of electric lighting

fittings
IS -2026
General requirements for Transformers

Part 2 Temperature-rise
Part 3 Insulation levels and dielectric tests
Part 4 Terminal markings, tappings and connections
877 of 2461
PAGE 2 of 339
MMRDA
IS Codes
Description
Part 5 Ability to withstand short circuit
Part 7 Loading guide for oil-immersed power
transformers
Part 8 Application guide
Part 10 Determination of sound levels
IS 2032
Graphical symbols used in electric technology
IS 2165
Guide for insulation coordination
IS 2309
Code of practice for the protection of buildings and

Allied structures against lightning
IS 3034
Code of practice for fire safety of industrial buildings

Electrical generating and distributing stations
IS 3043
Code of practice for earthing
IS-10118

switchgear (System voltage not exceeding 1000
volts)
IS 3638
Application guide for gas-operated relays
IS 3646
Code of practice for interior illumination
IS 3716
Application
guide
for
insulation
coordination
Equipment located in hazardous situations

IS 3842
Application guide for electrical relays for AC system
IS 15086
Application guide for non-linear resisted type lightning
Part 5
arrestors for AC system
IS 4146
Application guide for voltage transformers
IS 4201
Application guide for current transformers
IS 5571
Guide for selection of electrical equipment in

hazardous area
IS 5572
Classification of hazardous areas for electrical

installations
IS 5780
Intrinsically safe electrical apparatus and circuits
878 of 2461
PAGE 3 of 339
A.
MMRDA
EQUIPMENT
1.
Switchgear
(a)
General:
IS Codes
Description
IS 5578
Marking and arrangement for switchgear bus-bars,
11353
main connections and auxiliary winding
IS 694 - Part PVC insulated cables (for voltages up to 100v) with

1
copper conductors
IS 1248
Direct acting electrical indicating instruments
IS 13947
Degrees of protection provided for enclosures for low

voltage switchgear and control gear
IS 9224 part
HRC cartridge fuse links up to 650 V
2
IS 2705 - Part Current transformers
I, II & III
IS 3156 - Part Voltage transformers
I, II & III
IS 3202
Code of practice for climate proofing of electrical

equipment
IS 3231
Electrical relays of power system protection
IS 13947
Heavy duty air break switches and composite units of

air-break switches and fuses for voltages not
exceeding 1000 volts
IS 13947 part General requirements for switchgear and control gear

1
for voltages not exceeding 1000V
(b)
415 Volts:
IS / BS / IEC
Description
Codes
IS
AC electricity meters
879 of 2461
PAGE 4 of 339
MMRDA
IS / BS / IEC
Description
Codes
13010,13779
8530,14415
14372
IS 1951
PVC sleeving for electrical purposes
IS 13947
AC circuit breakers requirements and tests for
Part 1- sec.1
voltages not exceeding 1000V
PartII/Sec.2
IS 2419
Dimensions of electrical indicating instruments
BS 4752
Circuit breakers of rated voltage up to and including

1000 volts and 1200 volts dc
BS 6231
PVC insulated cables for switchgear wiring
IEC 157
Low voltage distribution switchgear circuit breakers
(c)
M.C.C.:
IS Codes
Description
IS 1554 -Part PVC insulated (heavy duty) electric cables for
2.
working voltages up to and including 1100 volts
IS 13947
AC motor starters of voltage not exceeding 1000 volts
IS 13947
AC contactors of voltage not exceeding 1000 V
Motors:
IS Codes
Description
IS- 9283
Submersible Motors
IS 325
Three phase induction motors
IS 4691
Degrees of protection provided by enclosures for

rotating electrical machinery
IS 4722
Rotating electrical machines
880 of 2461
PAGE 5 of 339
3.
MMRDA
Cables:
IS / IEC Codes
Description
IS 1554 -Part PVC insulated (heavy duty) electric cables for

I &II
working voltages up to and including 1100 volts and

for up to 33KV
IS 8130
Aluminum conductors for insulated cables
IS 3961 - Part Recommended current ratings for cables

II
IS 3975
Mild steel wires, strips and tapes for armoring cables
IS 5819
Recommended short-circuit ratings of high voltage

cables
IEC 60028 Ed. International standard of resistance for copper

-2.0 b: 1925
60034-1 Rotating electrical machines Part 1: Rating and
IEC
Ed.11.0
b: performance
2004
60034-11 Rotating electrical machines Part 12: Starting
IEC
IEC 60034-12 - performance

Ed.2.0 b: 2002
of
single-speed
three-phase
cage
induction motors
IEC 60034-14 - Rotating electrical machines Part 14: Mechanical

Ed.3.0 b: 2003
vibration of certain machines with shaft heights 56

mm
Higher Measurement, evaluation and limits of
vibration severity
IEC 60034-15 - Rotating electrical machines Part 15: Impulse

Ed.2.0 b: 1995
voltage withstand levels of rotating a.c. machines with

form wound stator coils
IEC 60034-16- Rotating electrical machines Part 16: Excitation

1
-Ed.1.0
1991
b: systems
for
synchronous
machines
Chapter1:
Definitions.
IEC 60034-18- Rotation electrical machines Part 18: Functional

1
Ed.1.0
1992
b: evaluation of insulation systems Section 1: General

guidelines & Section 21: Test procedures.
881 of 2461
PAGE 6 of 339
MMRDA
IS / IEC Codes
Description
IEC 60034-18- Rotating electrical machinery

31 Ed 1.0 b:
1992
IEC
60034-2 Rotating electrical machines Part 2: Methods for
Ed.3.0 b: 1972
determining l losses and efficiency of rotating

electrical machinery from tests (excluding machines
for traction vehicles)
IEC
60034-2A Rotating electrical machines Part 2: Methods for
Ed. 1.0 b: 1974
determining
Losses
and
efficiency
of
rotating
electrical machinery form tests (excluding machines

for
traction
vehicles)
First
supplement:
Measurement of losses by the calorimetric method

IEC
60034-3 Rotating electrical machines Part 3: Specific
Ed. 5.0 b: 2005
requirements
for
cylindrical
rotor
synchronous
machines
IEC
60034-4 Rotating electrical machines Part 4: Methods for
Ed.2.0 b: 1985
determining synchronous machine quantities from

tests
IEC
60034-5 Rotating electrical machines Part 5: Degrees of
Ed 4.0 b: 2000
protection provided by the integral design of rotating

electrical machines (IP code) Classification
IEC
60034-6 Rotating electrical machines Part 6: Methods of
Ed.2.0 b: 1991
cooling (IC code).
Standards Subjects
IEC Codes
IEC
Description
60076-2 Power Transformer
Ed.2.0 b: 1993
IEC
60079-0 Electrical apparatus for explosive gas atmospheres
Ed.4.0 b: 2004
Part 0: General requirements
IEC 60079-10
Electrical apparatus for explosive gas atmospheres
Ed.4.0 b: 2004
Part 10 Classification of hazardous areas
882 of 2461
PAGE 7 of 339
MMRDA
IEC Codes
Description
IEC GUIDE III
Selection of Rotating Machinery
IEC- 62026
Low Voltage Switchgear
IEC-60502
Power Cables Up to 30 kV-General Requirement,

Selection
IEC-60287
Calculation of permissible current in cables at steady

state rating
Power Cables Testing Requirements for Protective
IEC-60255
Relays
c)
Abbreviations of electrical terms
For
the
purpose
of
these
Requirements
the
following
abbreviations of electrical Terms have been used.
Symbol
Abbreviations
red phase
MCB
miniature circuit breaker
yellow phase
MCCB
moulded case circuit breaker
blue phase
ELCB
earth leakage circuit breaker
ac
alternating current
RCD
residual current device
dc
direct current
MCC
motor control centre
APFC
Automatic power factor correction
mA
Milliamp
PF
power factor
Volt
CP
control panel
kW
Kilowatt
LCP
local control panel
kVA
kilovolt amp
883 of 2461
PAGE 8 of 339
Symbol
MMRDA
Abbreviations
UPS
uninterruptible power supply
kWh
kilowatt hour
PLC
programmable logic controller
MVA
megavolt amp
I/O
input / output
Hz
hertz (cycles per second)
RI/O
remote input / output
SP
single pole
SCADA
supervisory control and data acquisition
SPN
single pole and neutral
HMI
human machine interface
DP
double pole
LAN
local area network
TP
triple pole
OS
operator station
TP&N
triple pole and neutral
PC
personal computer
SP&SwN
single pole and switched neutral
SPD
surge protection device
TP&SwN
triple pole and switched neutral
LED
light emitting diode
FOC
fiber optic cable
UHF
Ultra-High Frequency
ACB
Air Circuit Breaker
S/S
Soft Starter
4.1.1 Safety and Security
It is essential at all times to maintain a safe system of working and to

comply with all enactments, regulations and working rules relating to
safety, security, health and welfare of all persons who may be affected
by the work.
In particular, it has to be ensured that only persons who are properly

884 of 2461
PAGE 9 of 339
MMRDA
trained for their duties are employed, and that the correct tools and
procedures are used. Nothing which has been written into or omitted
from this document shall be taken to relieve the contractor from the
obligations under this clause. No clause in this specification shall
prevent the executing agency from drawing the attention of the Owner
to any feature of the works which is not consistent with normal safety
practices nor prevent him putting forward proposal sat any time which
would increase the safety of the installations.
The design should include all reasonable precautions and provisions

for the safety of Operating and maintenance personnel.
Electrical works design life shall be 20 years.
4.1.2 Environmental Condition
All equipment shall be designed for operation in tropical humid climate

having 50C ambient temperature and a humidity of 100 percent.
Maximum temperature and maximum humidity however are not likely
to occur simultaneously. The derating of the equipment shall be done
on the basis of the maximum ambient temperature of 50C.
Continuity of equipment operation is the first consideration and the

design shall be such as to provide facilities to simplify inspection,
testing, maintenance, and cleaning and general repairs at site.
4.1.3 Electrical Switchgear Room Environment
Electrical switchgear rooms are designed to provide a non-hazardous,

clean and dry location for the switchgear/motor control centres/power
control centres and associated equipment.
Rooms are be ventilated with air taken from non-hazardous and clean
areas.
885 of 2461
PAGE 10 of 339
MMRDA
No pipe work is routed in electrical rooms. If this cannot be avoided,

precautions taken to ensure that no liquid from a burst pipe or leaking
joint can enter the electrical room.
Vehicle access is provided to equipment doors.
Ventilation system shall be provided with minimum 5 air change in

Electrical switch gear room.
4.1.4 System Voltage
System Voltage/Incoming Power Supply of Pumping station is derived

based on Load Demand.
Based on Load requirement, 132 KV Power supply shall be received

through MSETCL from nearest MSETCL Substation.
Fault level has envisaged 40 kA for1 sec at 132 kV Supply from

MSETCL, however contractor has to design electrical equipment
confirming actual fault level at Project site.
Incoming Power supply & system Voltage for all equipment is derived
in table below:
System Voltage
S.
System Voltage Type
No.
1)
Incoming Voltage132 KV based on Load demand of Pumping

Station and WTP with CWPS from MSETCL
2)
Supply voltage for HV Pump Motors 6.6 KV, 3 phase, 3 wire,

50Hz
886 of 2461
PAGE 11 of 339
3)
MMRDA
LV system distribution network 415V 3 phase 4 wire neutral

solidly earthed
4)
Motors less than 250kW 415 V, 3 phase, 3 wire, 50 Hz
4.1.5 Voltage & frequency variations
Electrical equipment shall function satisfactorily during voltage

fluctuations within +10% and -10% of the stated voltage levels and at
frequencies within +/-5% of the stated frequency.
4.1.6 Phase Sequence
Phase sequence shall be specified in alphabetical order, each phase

reaching its maximum in time sequence in this order. Bus bars shall be
marked as R.Y.B. and N as seen from the front or operating side of a
switchboard or panel.
Cable terminals and apparatus which are to be connected directly or

indirectly to supply conductors shall be marked U.V.W. The neutral and
earth shall be marked as N, E respectively.
4.1.7 Voltage drop criterion
The steady-state voltage drop of each circuit shall be calculated on the

basis that the total load on the circuit is equal to the sum of the
nameplate full load amperes of all connected utilization devices that will
be in operation under normal conditions.
The normal steady-state voltage drops in the distribution system

between the secondary terminals of the supply transformer and the
utilization devices shall be limited to values that allow rated voltage to
be supplied to each energized and loaded device.
The most suitable setting for the power transformer tap changers shall
887 of 2461
PAGE 12 of 339
MMRDA
be established following consideration of the supply configuration and

resultant voltage drop conditions.
The actual distribution of the allowable overall steady-state voltage

drop across the different parts of the electrical system will depend on
the circuit configurations and distances between circuit components.
The voltages at all motors during start up shall be maintained at a

value which ensures that there is sufficient accelerating torque
developed by the motor to give a safe run up time.
The maximum system transient impedance shall be used in calculating

voltage drops relating to motor starting, restarting and re-acceleration
requirements.
Vendor requirements for special equipment requiring close voltage

regulation shall be taken into account when designing the overall
system to ensure that the voltage drops do not exceed those specified.
During starting or re-acceleration of a motor, either individually or in a

group, the voltage dip at the motor terminals shall not vary more than
15% from rated voltage when started direct online under the worst
operating scenario i.e. largest motor started with minimum number of
power sources and minimum fault level.
The above shall be achieved within the constraints imposed by the

electrical system and asfeasible with regard to process requirements,
safety and economic factors.
Under steady state conditions, the maximum voltage drop in various

sections of electricalsystem shall be limited to the following:
Cables/bus-bar ducting between transformer and switchboard

:0.5%
888 of 2461
PAGE 13 of 339
MMRDA
Cables/bus-bar ducting between generator and switchboard

:0.5%
Cables between LV switchboard and LV motor

:5%
Cables between LV switchboard and lighting panel

:1%
Cables between lighting panel and farthest lighting point

:4%
4.1.8 Compatibility
Components used with electrical switchgear, motor control gear and

control panels shall beuniform throughout the works in order to reduce
spare holdings. Electrical enclosures housingswitchgear, motor control
gear, control systems, terminations shall each be of similarconstruction
throughout the works in order to achieve a consistent appearance.
4.1.9 Enclosures
Enclosures shall be constructed to provide an adequate level of

protection form theenvironment. The following minimum standards
shall be applied unless otherwise specified:
Switchgear and control panels located in switchgear or control

rooms- IP 54
Switchgear and control panels located in plant rooms
- IP
55
Equipment located externally in sheltered locations

-IP 65
889 of 2461
PAGE 14 of 339
MMRDA
Equipment located externally in exposed locations
- IP
65
Equipment liable to be periodically submerged
-IP
68
The IP ratings are defined by IEC 529.
4.1.10 Identifications
Each main and auxiliary item of pumping station shall have

permanently attached to it in aconspicuous position a nameplate and
rating plate. Upon these shall be engraved, in English,
The manufacturers name, direction of rotation, type and serial number
of plant, details of theloading and duty at which the item of pumping
station has been designed. All indicating andoperating devices shall
have securely attached to them or marked upon them designations
asto their function and proper manner of use. Provision shall be made
to incorporate descriptivenumbering codes as indicated on the layout
drawings.Such nameplates, rating plates and labels shall be of a rigid
type, at least 3 mm thick,laminated and engraved plastic material, with
black block capitals on a white background. Thelabels shall be fixed by
non-ferrous or stainless steel screws.Warning labels shall be of similar
construction with black block capitals on a yellowbackground.
Weatherproof labels for use outside the buildings shall be rigid type
laminated plastic.
All field items shall be tagged with 50 25 mm engraved labels. The

label shall state the itemtag number and hazardous area classification
in case it falls under it and shall be attached bya corrosion resistant
ring to a fixed portion of the item. The ring shall retain the tag
securelybut shall allow transfer to a replacement item when
necessary.Warning labels shall be provided where necessary to warn
890 of 2461
PAGE 15 of 339
MMRDA
of dangerous circumstances orsubstances. Inscriptions or graphic

symbols shall be black on yellow background and tointernationally
recognized standards.
Instruction labels shall be provided where safety procedures such as

wearing of protectiveclothing are essential to protect personnel from
hazardous or potentially hazardousconditions.
These labels shall have inscriptions or graphic symbols in white on a

blue background.
4.1.11 Harmonics
The limits for harmonics in the power system as a result of non-linear

loads are to be limited tothose standards imposed by the power supply
company i.e. MSETCL.
No significant non-linear loads are proposed therefore the existing

background harmoniccontent of the supply will be unaffected. There is
no evidence of problems at present withharmonic content of the power
supply.
4.1.12 Surge protection
Surge protection shall be provided on power system equipment fed

from overhead linesystems. Usually this will apply to HV overhead
supplies feeding to sites. In this case thesurge protection shall be
provided by the contractor near to the point of common couplingSurge
protection shall be provided on at each end of long LV cables e.g. such
as thosefeeding the switchboards at longer distance.
Surge protection shall be provided at the main control panel end of

instrumentation cablingconnecting equipment located external to
buildings.
891 of 2461
PAGE 16 of 339
MMRDA
4.1.13 Earthing System
The electrical installation shall where required be connected to the

general mass of the earthby an earthing conductor as per IS 3043.
Where the earth electrode system is not provided by the power supply
authority or where arequirement for a standby or base load generator is
specified the installation shall compriseone or more earth electrodes,
earthing strip network, mesh or a combination of these in orderto obtain
the required earth electrode resistance.
Earth electrodes where used shall be of galvanized iron. The rod shall
penetrate a minimum ofthree meter below ground level. Where multirods are used they shall be separated by adistance of not less than the
driven length.
Earth rods shall have hardened tips and caps and be extendable. Bare
galvanized iron stripburied at a minimum depth of 600 mm shall be
used for interconnection of rods.
Where soil conditions make the use of rod type electrodes

impracticable a grid configurationmay be used comprising horizontally
buried bare galvanized iron strips as per IS 3043. Stripshall be buried
at a minimum depth of 600 mm.
Each earth electrode rod if used shall be provided with an approved

non-ferrous clamp for theconnection of the earthing conductor or tape
as required. These connections shall each behoused in individual
concrete inspection chamber set flush to the finished ground level
andshall allow disconnection for testing of individual electrodes.
All materials used for the earth electrode installation shall be purpose
made for the applicationand shall be suitable for the site and soil
conditions.
892 of 2461
PAGE 17 of 339
MMRDA
Unless otherwise stated all excavation of trenches for the installation of

the earth electrodesand the inspection pit shall be carried out by the
Contractor.
The Contractor shall demonstrate that the resistance of the electrodes

to earth and thecontinuity of the earth network are within the limits
specified. Any additional earth electrodesand test instruments required
for the tests shall be provided by the Contractor.
Marker posts and plates shall be provided to mark the route of buried
strip electrodes. Themarkers shall be similar to those provided for
cable routes.
4.1.14 Lightning Protection
Lightning Protection system shall be provided for protection against

atmospheric dischargeson the all new buildings. This shall consist of
an air termination network of horizontal and/orvertical conductors. The
air termination network shall be connected to earth electrodes by
anadequate number of down conductors. The earth electrodes shall be
connected to thepumping station earthing system.
The lightning protection system shall be designed and installed in

accordance with IS 2309and IEC 62305 Standards. The normal air
termination shall be tinned copper strip. Allmetallicducts, antennae,
hand railing, etc. shall be bonded to the air termination.
The earth electrode resistance of the lightning protection earth

electrode system alone shallnot be more than ten ohms. Each lightning
protection system should be bonded locally to thepower earth at not
less than two points
4.1.15 HV System
a)
Power Supply
893 of 2461
PAGE 18 of 339
Voltage
132
MMRDA
kV-nominal,Phases
3,
Frequency
50
Hz,
Connection 3 wire 132 kV overhead line,maximum fault level

(breaking capacity) 40kA/1sec
b)
Supply of HT Motors: Voltage 6.6/7.2kV, frequency 50Hz,

3phase 3 wire system
c)
Auxiliary Supply
Voltage 415 V nominal Frequency 50 Hz Connection 3phase 4

wire Offload transformer voltage 433 V System earthing TN-S
All Plant shall, unless otherwise specified, be capable of

continuous operation at a voltage level in the range of 90% to
110% of the relevant nominal voltage and a frequency variation
of plus 5 % minus 5% with a maximum combined tolerance of
10%.
4.1.16 Polarity
The polarity of all apparatus used for the Works specified shall be
arranged as follows:
For two pole apparatus the phase or `live' pole at the top (or left hand
side) and the neutral or èarthed' pole at the bottom (or right hand
side), For three or four pole apparatus the phases in order, red, yellow,
blue and neutral reading from top to bottom or left to right in the case of
vertical and horizontal layouts, respectively, as viewed from the front.
All cables shall be so connected between main switchboards,
distribution boards, plant and accessories so that the correct sequence
or phase colours are preserved throughout the system.
All cable cores shall be identified with phase colours for three and four
wire circuits. Single phase circuits shall be red and black.
894 of 2461
PAGE 19 of 339
MMRDA
The neutral shall always be black. Where more than one phase is
incorporated on a common system in one room then the live cores
shall be red, yellow, and blue as appropriate. All fittings and switch
accessories shall be permanently labelled and segregated.
4.1.17 Low Voltage and frequency
Unless otherwise specified, all apparatus and wiring shall be suitable

for use with a three-phase, four-wire, 240/415 volt, 50Hz solidlyearthed neutral supply having a nominal sinusoidal waveform.
Supplies for circuit-breaker control, circuit-breaker spring-charging

motors, protection relay, tripping coil, closing coil, alarm and indication
functions shall, unless otherwise specified. Supplies for transformer
tap-changing motors and switchboard anti-condensation heaters shall,
unless otherwise specified, be 240V ac / 415 V ac.
Supply for low voltage motor-starter control circuits, contactor coils and
relays shall, unless otherwise specified, be 240V ac.
During construction and installation of the Works, all portable electric

tools shall operate from 240V ac. supply.
4.1.18 Units of measurement
All information shall be in SI units in accordance with ISO 1000:1992.

Where plant designs exist in Imperial units, the dimensions and
tolerances of layouts and terminal points shall be presented in SI units
to a degree of accuracy which permits the precise matching of existing
components.
4.1.19 Electricity supply
Not less than two months prior to the power supply being required, the
895 of 2461
PAGE 20 of 339
MMRDA
Contractor shall arrange for the electricity supply authority to undertake

any testing and inspection necessary for the electricity supplies to be
connected when required. On completion of the tests and inspections,
the Contractor shall supply to the Engineer a copy of his Electrical
Installation Completion Certificate and of the electricity supply
authoritys test certificates.
The Contractor shall be responsible for liaison with supply authority

and Electrical Inspectorate via Engineer/Owner
4.1.20 Tools & Testing Equipments
The work shall be performed using tools and testing equipment

designed and approved for the purpose.
The following tools and testing equipments are recommended for
carrying out the electrical installation work. The contractor shall bring
tools and equipment which may be necessary to carry out / complete
the work, in addition to the tools and equipment suggested hereunder,
if asked for by Owner.
1. 5000 volts constant pressure type motorized insulation tester

(megger)
2. 1000 volts constant pressure type insulation tester (megger)
3. 500 volts constant pressure type insulation tester (megger)
4. Relay testing kit
5. High voltage test kit
6. Universal Earth Tester
7. Welding Sets
896 of 2461
PAGE 21 of 339
MMRDA
8. Cutting Tools
9. Derricks, if required
10. Jacks
11. Electric Blower
12. Drilling Machines (different sizes)
13. Grinding Machine
14. Cable Crimping Tool
15. H.V. and L.V. Cable termination and jointing kits.
16. Tong Tester
17. Portable Voltmeter
18. Pipe bending machine
19. Phase sequence indicator
20. Portable test lamps with prongs
21. Tachometer (0-1500 r.p.m.)
22. Constant pressure type continuity tester
23. Wiremen kits

24. Fitters tools
897 of 2461
PAGE 22 of 339
MMRDA
25. Vices
26. Die sets with difference dies
27. Ladders (different sizes)
28. Cable laying tools
Cutting, patching and excavation
The Contractor shall do all excavation and cutting required for the
installation work and shall be responsible for any damage that may be
caused to the work of others. He shall, where possible, keep the
excavation, cutting and patching to a minimum. If the contractor fails to
perform his work in the proper manner or at proper time and due to
this, additional excavation, cutting and patching is required, the
Contractor shall do such additional cutting and patching without any
extra cost.
4.1.21 Drawings
The Contractor shall submit four prints of the each drawing after award
of contract for approval.
One set of drawings shall be kept as record drawings. All deviations of

the actual proposed installations as shown on the drawings should be
marked in red on these drawings. On completion of the project, as-built
drawings shall be prepared by the contractor in co-operating these
changes and four sets of such drawings shall be handed over to the
Owner at the time of final handing over.
The contractor shall also submit one set of CD each to Owner

containing all drawings.
Sketches
etc.
in
AutoCAD
2009/2010
898 of 2461
and
data
in
MS
PAGE 23 of 339
MMRDA
Office/WINDOWS 2010 or latest.
4.1.22 Personnel
All work shall be performed by contractor under the direct supervision

of a qualified person appointed by him and regularly engaged in the
installation of electrical equipment. The contractor shall place in charge
of the work at all the times during the construction. A qualified and
experienced Contractors Electrical Engineer who shall be responsible
for keeping liaison and coordination between Owners personnel and
his own men at site. He shall also submit progress reports every fifteen
days. Anyone not deemed capable shall be replaced immediately upon
such advice.
4.2
Scope of Work
This section covers the particular requirements for the provision of all
necessary electrical site works for the 132 kV outdoor substations Raw
Water Pumping Station at Kawadas and Water Treatment Plant with
Clear Water Pumping Station at Suryanagar including MSETCL
switching Station at Both Substattion.
MSETCLs requirement for Switching Station at 132 kV
substations at Kawdas&Suryanagar up to point of Supply are as
under
Establishment of 132 kV substations as per MSETCL requirements,

supervision and Technical specification up to point of supply comprising:
Incoming bay steel structure for two lines
Lightning arresters
Coupling capacitor
Wave traps
899 of 2461
PAGE 24 of 339
MMRDA
Isolator with earth blade
Current transformer for metering and protection
SF6 Circuit breakers
Isolators
Single bus bar system with 3 isolator and Bus P.T complete with bay
steel structures, insulator ACSR Conductor etc.,
Earthing and lightning protection
Control and relay panels. Control and power cable etc.
All civil works including metering room
Metering C.T.,P.T (main & check), insulator, support structure,

conductors etc.
ABT metering with connectivity and allied equipments
PLCC terminal (Twin channel carried set) at Suryanagar substation

and Kawdas substation
SCADA System for remote monitoring of switchyard to be installed at

Kawdas, Suryanagar and at existing 132 kV Dahanu substation.
All equipments materials etc., required for above works shall be as per
supply
companies
specifications
and
requirements.
Supervision,
approval of design calculations and drawings shall be done by supply

companies representatives.
Contractor shall be responsible for
coordination and installation of works in consultation with supply

companies representative and MMRDA. Works shall be executed by
900 of 2461
PAGE 25 of 339
MMRDA
contactor having similar 132 kV substation installation experience

preferably with MSETCL.
O & M of above works shall be done by MSETCL after successful

commissioning of above works..
The detail specifications for the above mentioned work is enclosed in

Standard Specification, Section 6B (Electrical Works under MSETCL
supervision).
The Contract shall include the design, manufacture, testing at

manufacturers' works, delivery to Site, off-loading, storage, erection,
testing, commissioning and setting to work the complete electrical site
works for all sites including but not limited to:
(a)
132 kV outdoor substation Equipments after point of supply with

transformers;
(b)
High voltage switchboards, motor control centres and
motor
starters;
(c)
HT motors
(d)
Low voltage switchboards and motor control centres, motor

starters;
(e)
Power factor correction equipments
(f)
Emergency
stop
push-buttons/local
start/stop
push-button
stations;
(g)
Battery units for switchgear operation;
(h)
Battery and Battery charger Panel;
901 of 2461
PAGE 26 of 339
(i)
Power,
control,
MMRDA
instrumentation
and
telephone
cabling
installations;
(j)
Interface with electrical & ICA plant to be provided;
(k)
Earthing and lightning protection installations;
(l)
All Cabling, termination and cable containment works;
(m)
Ventilation systems, fire fighting and alarm system, DG sets etc.
(n)
All Architectural and Civil work comprising equipment and

substation structure foundation, soil treatment, fencing, gates,
Gravels, cable trenches, Storm water drain system, drainage
system, approach road, buffer wall, RCC pipe etc.
The electrical Plant, cabling and earthing installations shall comply with
Standard Specifications and the following clauses herein. Where there
are discrepancies among the Standard Specification, the Particular
Specification and the Drawings, the latter shall take precedence.
Outdoor street illumination using lamps as per site requirement

complying IS 3646 Part-II.
Switchyard Lighting before point of supply shall be as per MSETCL

requirement.
132kV Relay and metering auxiliary supply shall be taken from 415V
Power Distribution Board.
Reactive power compensation, Harmonic mitigation, Switching surge

protection in line with utility norms, OEM recommendation and
confirming to Indian Standards and latest IE Rules.
Supply and delivery of Personal Protective Equipment (PPE) in line

902 of 2461
PAGE 27 of 339
MMRDA
with utility norms andconfirming to Indian Standards and latest IE

Rules.
Air-conditioning of panel room and SCADA room; ventilation of

electrical panel building and Pumping station as per National Building
Code.
All work to be performed and supplies to be effected as a part of

contract shall requirespecific review and approval of Client/Consultant
or his authorized representative as per vendor data requirement.
Design, supply, transport, storage, installation, testing (Factory

Acceptance Test (FAT) and Site AcceptanceTest (SAT), precommissioning, commissioning and operation and maintenance of DG
set of415V, of required KVA capacity complete with AMF panel.
To obtain clearance for energizing the complete electrical facilities

covered under this tenderand approval of installation / drawings and
documents from Central Electrical Authority /Maharashtra state
electricity Inspectorate and any other concerned approving authority
and follow up with Electricity board for getting power approved by
Client. Any other requirements as necessary by the statutory
regulations which are not shown in typical installation shall be complied
by the contractor.
To supply and deliver commissioning spares
To make the provision of all testing instruments / kits for testing and
commissioning of the system.
The contractor shall arrange technical experts of equipment for O & M

as and when necessary until the commissioning and guaranteed run of
the plant is completed.
The Contractor shall also include in the project any other work/activity
903 of 2461
PAGE 28 of 339
MMRDA
which is not specifically listed but is necessary for completeness of

electrical system.
4.2.1 Submittals
Following submittals shall be part of scope of work but not limited to

following list.
1. Design Calculations
2. Equipment Lists covering list of Bearings and Seals
3. Equipment Data Sheets
4. Electrical Single Line Diagrams
5. Schematic and Control Diagrams

6. General Arrangement Drawings of all electrical equipments
7. Earthing Layout
8. Illumination layout
9. Lightning Protection layout
10. Equipment Dimensional Drawings
11. Electrical Equipment Weights
12. Cable Schedules and Cable Routing Drawings
13. Transformer, Motor, switchgear etc. Performance Curves
14. Noise and Vibration Test Certificates

904 of 2461
PAGE 29 of 339
MMRDA
15. Factory Test Reports and Performance test Certificates at the time
of testing
16. Construction Power Supply Requirements
17. Protection co-ordination Settings
18. Interface or Inter-connection Diagrams / Lists
19. Quality control document
20. Submit to Inspection Authority and the Power Supply Authority the
required copies of
(a)
Relevant drawings and specifications for examination and

approval prior to commencement ofwork.
21. Neatly assemble and submit operating and maintenance data

containing booklets, ASBUILT drawings, instruction sheets, etc.,
issued by the suppliers and relating to theequipment intended to be
installed under this section and necessary or desirable for
themaintenance, repair or operation of the equipment along with
AS BUILT drawing
22. The contractor shall submit to the department such as QAP / data
sheets / drawings /catalogues etc. and any other supporting
documents (each 3 sets) of equipment / items ofelectrical system
before start of manufacturing and approval of Engineer-in-charge to
beobtained. Before shipping of such items, the contractor shall
obtain inspection release note /dispatch clearance from the
Engineer-in-charge
23. Contractor has to submit drawings of all Electrical 132kV equipment

before point of supply for MSETCL approval.
905 of 2461
PAGE 30 of 339
a)
MMRDA
Specific Requirement
Design Considerations
The Contractor shall design the Electrical Installation taking into

consideration the following:-
(a)
Location and Power Demand of each Load Centre
(b)
Provision of duplicate supplies to each main load centre
(c)
Prospective Short Circuit current
(d)
Environment in which electrical plant is located
(e)
Ambient temperature, humidity and its effect on the rating

of
switchgear, transformers, cables and generating
plant
(f)
Method of cable installation
(g)
Cable transient and steady state volt-drop on motor

starting
(h)
Transient volt-drop on motor starting at point of supply
(i)
Electrical protection discrimination
(j)
Ground earth Resistivity
(k)
Basis of Transformer sizing/rating required. Largest Motor

starting requirement and Voltage drop criteria to be
specified
906 of 2461
PAGE 31 of 339
(l)
MMRDA
Design Criteria for Transformer sizing, motor sizing, cable

sizing, Earthing System, illumination levels for Indoor and
Outdoor, APFC shall include Voltage Drop criteria for
Transient and Steady state shall be specified
(m)
DG Set Sizing criteria for which Electrical critical loads to

be connected on DG bus
4.3
132 kV Outdoor substation
4.3.1 Outdoor Lightning Arrestor
4.3.1.1
Scope
This specification covers the design, manufacture,

assembly, testing at manufacture's works, delivery &
commissioning of outdoor type, heavy duty station class
lightning arrestors, complete in all respects, confirming to
modern
design
and
practice
for
protection
of
transformers, sub-station equipment's and overhead

lines.
4.3.1.2
Standards
The lightening arrestors covered by this specification

shall comply with the requirements of latest, edition of
IEC publication No. 60099 4, except specified,
otherwise in the specification.
4.3.1.3
Drawings &Documents
The contractor shall furnish one set of following drawings

after award of work:
1.
General outline drawings of the complete arrester
907 of 2461
PAGE 32 of 339
MMRDA
with technical parameters.
2.
Drawing showing clearance from grounded and

other live objects and between
adjacent poles of
surge Arresters, required at various heights of

surge Arresters.
3.
Drawing showing details of pressure relief devices.
4.
Detailed drawing of discharge counters along with

the writing and schematic drawing of discharge
counter and meter.
5.
Outline drawing of insulating base.
6.
Details of grading rings, if used.
7.
Mounting details of Surge Arresters.
8.
Details of line terminal and ground terminals.
9.
Details and dimensions of ZnO block.
10.
Volt-time characteristics of Surge Arresters.
11.
Details of galvanizing being provided on different

ferrous parts.
12.
Details of Master name plate and individual unit

name plate.
The detailed dimensional drawing of porcelain housing

such as ID, OD thickness and insulator details such as
height, profile of petticoats, angel of inclination and gap
between successive petticoats, total minimum creep age
908 of 2461
PAGE 33 of 339
MMRDA
distance etc.
Contractor shall submit above drawings for owners
approval.
The contractor shall submit the routine test certificates of

bought out items and raw materials at the time of routine
testing of the fully assembled arrester.
4.3.1.4
Type
The metal oxide type lightning arrestors shall be designed

to provide maximum possible protection against lightning
and switching surges. Supporting insulators, terminal
connectors and other components as specified hereafter,
shall be provided with arrestors. The metal oxide type
lightning arrestors shall be of class A pressure relief
device and long duration Class-II.
4.3.1.5
Description
i)
Design & Construction
Arrestors shall be without series gaps as per the

requirement along with characteristic ofelements.
The non-linear resistor blocks shall have nonageing characteristic and stable thermalproperties.
The blocks shall preferably be metallized on the

flat surface for ensuring good electricalcontact.
The arrestors shall be complete with suitable

grading devices, wherever necessary and shall be
provided with an insulating base at the bottom.
909 of 2461
PAGE 34 of 339
MMRDA
The clamps required to fix the surge counter shall

have to be provided with the surge counter.
Braided flexible copper jumper shall be provided
for bypassing surge counter, whenever required.
Each individual component unit of the arrestor

stack shall have its arrestor elements hermetically
sealed under dry inert air and fully protected
against ingress of moisture into the arrestor. The
details like material, cross section/thickness etc.
shall be indicated in cross-sectional drawing.
The arrestor, when energized at rated operating

voltage, shall not exhibit any visible corona, when
viewed in complete darkness.
All arrestor units shall be provided with pressure

relief class 'A' devices, to limit the internal arrestor
pressure to obviate explosion or violent shattering
of porcelain housing.
ii)
Porcelain Housing
All porcelain used in or with each arrestor shall be

manufactured by the wet process, be freefrom
lamination, cavities or other flaws, affecting
mechanical & dielectric strength and shall be
vitrified property and non- porous. The creepage
distance along with external surface shall belarge
enough to ensure that surface contamination
which is possible under site condition willnot
adversely affect the performance of arrestors.
iii)
Pressure Relief Device
910 of 2461
PAGE 35 of 339
MMRDA
The arrestors shall be provided with efficient

pressure relief device so as to check bursting
oflightning arrestors, in case, excessive gas
pressure is built up and in case, it losses its
abilityto effectively dissipate the energy due to any
operation.
The
contractor
shall
submit
detailedinformation and literature on pressure relief

class A device of lighting arrestors.
iv)
Terminal Connectors
Each lightning arrestor shall be supplied with

compression joint type terminal connectorsuitable
for ACSR 'PANTHER' Conductor. The bolt and
nuts shall be of stainless steel 2 SSwasher and 2
SS nuts (including lock nut) for each bolt shall be
supplied. Each terminalconnector shall be suitable
for vertical / horizontal take-off.
v)
Galvanizing
All metal parts exposed to weather and likely to be

subjected to corrosion, shall be hot dipgalvanized
as per IS: 2629 (latest edition). Bolts, Nuts and
Washers shall be electro zincplated.
vi)
Name Plate
Each arrestor shall have non-corrosive nameplate,

legibly and indelibly marked and securelyfixed to it.
They shall be provided with the information as
required by relevant standard. Thewords 'RIPC'
shall, also, be punched on it after inspection of
lightning arrestor is over.
911 of 2461
PAGE 36 of 339
vii)
MMRDA
Surge Counter
Each lightening arrestors shall be provided with a

recording
type
surge
counter
with
vertical
mounting. The installation of surge counter shall

have practically no effect on the operation. The
number of discharges recorded by the counter
shall be visible through inspection window.
The connection of LA to Surge Monitor shall be

made from bottom of surge monitor and there shall
not be any opening on top of surge monitor.
viii)
ix)
System voltage
i.
Nominal system voltage - 132 kV
ii.
Highest System Voltage - 145 kV
Rated Arrestors Voltage
i.
ii.
x)
Normal System Voltage - 132 kV
Arrestor Voltage - 120 KV
Nominal Discharge Current
The arrestor shall have a nominal discharge

current of 10 kA (8/20 microsec) and shall be of
heavy-duty station class type with long duration
Class 3.
xi)
Maximum residual Voltage
The
maximum
residual
912 of 2461
voltage
at
nominal
PAGE 37 of 339
MMRDA
discharge current of 10 kA with 8/20 micro-second

current wave shall not exceed 355 kV (Peak).
Maximum Continuous Operating Voltages:
The maximum continuous operating voltages shall

be as per IEC60099-4.
Energy absorption capability shall be 6.5 in kJ/ kV.
xii)
System Neutral Connection
The system is an effectively earthed neutral

system.
xiii)
Outdoor Installation
All the lightning arrestors shall be suitable for

outdoor installation.
xiv)
Special Condition
Maximum temperature for a few days, in a year, is

likely to go to 45 C and humidity duringmonsoon
is likely to reach the value of 95%. The arrestors
offered must withstand theseclimatic conditions
without deteriorating effects.
The lightning arrestors shall be suitable for 1.2/50

micro-sec lightning impulse voltage of 650kV peak
and one minutes power frequency withstand
voltage of 275 kV rms.
xv)
Impulse withstand voltage
913 of 2461
PAGE 38 of 339
MMRDA
The BIL of transformer and circuit breakers is 650

kV (Peak).
xvi)
Overhead Earth wire:
Solidly grounded overhead Earth wire/s shall be

provided for the substation andTransmission
Lines.
xvii)
Physical data
Technical and guaranteed particulars shall be

furnished
in
datasheet.
Drawings
showing,dimensions, (actual figures), arrangement

and clearances (actual figure) required shall,
alsobe furnished after award of work.
All fittings and accessories which may not be

specifically mentioned in this specificationbut
which are useful or necessary for lightning
arrestors shall be deemed to be includedin the
specifications and shall be furnished by the
contractor without extra charges.
xviii)
Creepage Distance
In case the lightning arrestors are installed in

highly polluted atmosphere i.e. near theindustrial
area or near the sea shore. The total minimum
creepage distance shall be 25 mm/kV that
commensurate
with
the
highly
polluted
atmosphere.
All necessary accessories and earthing connection

leads between the bottom of the arresterand the
914 of 2461
PAGE 39 of 339
MMRDA
discharge counter shall be in the contractors

scope. The discharge counter shall beso designed
that the readings of discharges recorded by the
counter and the readings ofmilliamp meter shall be
clearly visible through an inspection window to a
person standing onground. The minimum height of
support shall be 2.5 M. The live part to plinth level
clearanceshall be maintained as 4600 mm.
mounting bolt, Nut, washers etc shall be supplied
witheach LA.
The mounting of LA shall be suitable to structure

on which it is to be mounted. If requirednecessary
MS, HDG 8 mm thick adaptor plate with both PCD
drilled in, shall be supplied as apart of supply.
xix)
Type Test
All the Lightning Arrestors shall be fully type tested

from accredited laboratory (accreditedbased on
ISO/IEC Guide 25 /17025 or EN 45001 by the
National accreditation body of thecountry where
laboratory is located), as per IEC / IS / technical
specification. The Contractorshall furnish two sets
of type test reports for the complete Lightning
Arrestors along withthe test reports of porcelain
housing of the type and Design offered by him
after award of work.
The Type test reports shall not be older than FIVE

years and shall be submitted for ownersapproval.
The following type test reports shall be submitted

after award of work.
915 of 2461
PAGE 40 of 339
MMRDA
In case of non-submission of some of the type test

reports, the contractor shall confirm thesubmission
of same before commencement of supply, without
affecting delivery schedule,from NABL accredited
laboratory, at his own cost.
S. No.
List of Type Test Reports
Tests on metal oxide blocks
Steep Current Impulse Residual Voltage

test
Lightning impulse Residual voltage test
Switching impulse Residual voltage test
Long duration current impulse withstand

test
Operating duty test

- High Current Impulse operating duty test
- Switching Surge Operating Duty test
P. F. voltage v/s time characteristic
Reference voltage test
Accelerated ageing test
10
Tests on Arrester Housing
11
Impulse voltage withstand test on

insulator
12
P.F. (Dry) voltage withstand test on

insulator
13
P.F. (Wet) voltage withstand test on

insulator
14
Bending test on assembly
15
Tests on Arrester
16
Artificial pollution test
17
Seismic test
18
High current pressure relief test

(High current short circuit test)
19
Low current pressure relief test - General
20
STC on Terminal connector (25 kA for 3
916 of 2461
PAGE 41 of 339
MMRDA
S. No.
List of Type Test Reports

sec)
21
Degree of Protection test on counter/surge

monitor
22
xx)
Uniformity of Zinc coating
Routine Test
Routine tests shall be carried out by the contractor

on all complete arrestors and also onproportionate
prorated sections as per IEC recommendations.
Certified copies of routine testreports shall be
submitted to the Owner for approval along with the
acceptance testreports.
S. No.
List of Routine Test Reports
Measurement of reference voltage
Lightning Impulse Residual voltage test
Seal Leakage check test
Partial discharge test
Tests on discharge counter
Visual / Dimensional check
Special Seal leakage test for a duration of

24 hrs to check the waterpenetration, on
any one randomly selected sample from
every 50 (Fifty) or below nos.of LA offered
for inspection, shall be carried out and
report shall be submitted.
4.3.2 Outdoor Isolator
4.3.2.1
Scope
This specification covers design, manufacture, assembly,

testing, Supply, installation &commissioning of high
917 of 2461
PAGE 42 of 339
MMRDA
voltage isolators and earthing switches suitable for

4.3.2.2
Standards
Unless otherwise specified, equipment shall conform to

the latest applicable Indian Standardsin particular to
following:
IS Code
Description
IS : 1818(1972)
Specification for alternating current

isolators (Disconnector) andearthing
switches
IS : 2544(1973)
Specification for porcelain post

insulators (3.3 KV and above)
IS : 2099(1986)
High voltage bushing
IS : 9921(1981)
Alternating
current
isolator
and
earthing
(Disconnector)
switchesfor voltage above 1000V
4.3.2.3
Description
Isolators shall be off load type but shall be able to make

and break the magnetizing on line/buscharging currents.
Isolators shall be suitable for horizontal mounting as

specified in the datasheet.
Isolators shall be designed for a normal current rating and

the system voltage indicated on thedata sheet.
All similar parts shall be interchangeable.

Base channels and all other structural steel members
manual operating rod, bolts nuts etc.shall be hot dip
918 of 2461
PAGE 43 of 339
MMRDA
galvanized or metallized. All castings, except current

carrying parts shall bemade of malleable cast iron or cast
steel. Grey iron shall not be used in the manufacture
ofany part.
Each pole of the isolator shall be provided with two

earthing pads at opposite ends.
The isolators and earth switches shall be designed to

withstand stresses corresponding toshort circuit duties
specified in the data sheet and shall withstand seismic
forces.
Bottom bearing assembly of base frame shall be sealed

such that there cannot be ingress ofdust/dirt water etc.
Whole assembly shall be lubricated for life long service.
Terminal head of isolator arms where conductor will be

terminated shall be strong and robust.
It should have 360 degree freedom of rotation and should

have built-in cover to eliminated position of dust or foreign
particles.
i)
Contacts
The construction shall be such that it ensures

permanent pressure and liberal contact area.
Contacts shall be fully self-aligning and floating

type
with
self-cleaning
and
wiping
action
withcentral blade rotating type.
Contacts, current carrying parts, shall be of nonferrous material such as copper or copperalloy and
919 of 2461
PAGE 44 of 339
MMRDA
all contact surfaces shall be silver faced.
Construction of Make-Break contacts of main

blade shall be such that no external springs
areused to achieve contact pressure.
ii)
Insulators
Insulators shall conform to IS: 2544 & IS: 2099.
Insulators shall be post type, glazed vitreous

porcelain.
Insulators of the same rating and type shall be

interchangeable.
Insulator shall be suitable for heavily polluted

atmosphere.
Provision of continuous adjustment/alignment of

insulator
shall
be
there
which
is
required
tocompensate permitted tolerances of insulator

and structure or base frame assembly.
Adjustment/alignment using shim washers are not

allowed.
iii)
Operating mechanism
The isolators shall be electrical motor operated

and manually operated. The earthing switchesshall
be manually operated. The mechanism shall
provide quick, simple & effective operation.
Single person shall be able to operate the isolator,

920 of 2461
PAGE 45 of 339
MMRDA
earthing switch without undue effort. Theheight of

the handle above the plinth shall be 1000 mm.
Motor drive:
a.
Design of operating mechanism shall be

such that angular travel of output shaft shall
not altereven if motor over-runs due to any
eventuality like failure of limit switch etc.
b.
Requirement
of
Auxiliary
contacts
for
signaling/interlocking shall be as per IEC

129.
Signaling/Interlocking of the closed

position of disconnector shall not
take place unless it iscertain that the
contacts will reach a position in which
the
rated
normal
current,
the
peakwithstand current and the shorttime withstand current can be carried

safely
Signaling/Interlocking
of
open
position shall not take place unless

the movable contactshave reached a
position such that the clearance
between contacts is at least 80% of
thegap or the isolating distance, or
unless it is certain that the movable
contacts will reach theirfully open
position
c.
It is required that all auxiliary contacts shall

be individually adjustable and convertible
921 of 2461
PAGE 46 of 339
MMRDA
fromNO to NC or vice-versa even at site.

Rupturing
capacity
of
auxiliary
switch
contacts shall beindependent of speed of

operating mechanism. It should be possible
to replace individualcontact.
d.
Operating mechanism box shall be made of

at least 3mm thick Aluminum sheet to
avoidrusting and damage during handling.
e.
It is required to have PMDC or DC

Compound Motor to achieve best speedtorqueCharacteristics.
Power supply for
motor operation shall be 1 phase 230V AC

or 220V DC.
Hand drive:
f.
Requirement
of
Auxiliary
contacts
for
signaling/interlocking shall be as per IEC

129.
Signaling/Interlocking of the closed

position of disconnector shall not
take place unless it iscertain that the
contacts will reach a position in which
the
rated
normal
current,
the
peakwithstand current and the shorttime withstand current can be carried

safely.
Signaling/Interlocking
of
open
position shall not take place unless

the movable contactshave reached a
position such that the clearance
922 of 2461
PAGE 47 of 339
MMRDA
between contacts is at least 80% of

thegap or the isolating distance, or
unless it is certain that the movable
contacts will reach theirfully open
position.
g.
It is required that all auxiliary contacts shall

be individually adjustable and convertible
from NOto NC or vice-versa even at site.
Rupturing
capacity
of
auxiliary
switch
contacts shall beindependent of speed of

operating mechanism. It should be possible
to replace individualcontact.
h.
Operating mechanism box shall be made of

at least 3mm thick Aluminium sheet to
avoidrusting and damage during handling.
i.
The operating mechanism shall be such

that isolators cannot be dislodged from
theiropen or closed position by gravity,
vibration, wind pressure etc.
j.
The operating mechanism shall provide a

quick,
simple
and
effective
operation.
Oneman shall be able to operate the

isolator/earthing switches without undue
effort.
k.
The operating mechanism shall be so

designed that all the three phases are
openedor closed simultaneously.
l.
The length of the operating handle for

horizontal mounting type isolatorsshall be
923 of 2461
PAGE 48 of 339
MMRDA
with respect to mounting height specified in

the data sheet.
m.
The operating handle shall have provision

for
padlocking
in
both,
open
and
closedposition.
n.
A weatherproof (IP 55) galvanised sheet

cabinet
with
gasketed
hinged
door
andpadlocking facility shall be provided to

house
driving
mechanism
auxiliary
switchesfor electrical interlocks, if specified

in the data sheet.
o.
Suitable means for mechanical `Castle type

or electromagnetic type interlockingshall be
provided. Details of type of interlocking shall
be as specified in the datasheet.
p.
position
provided
indicating
for
each
device
shall
be
isolator/earthing
switch,irrespective of whether the isolating

distance is visible or not.
q.
Adjustable stops shall be provided to

prevent over travel of isolator blades in
eitherdirection.
r.
All joint in link mechanism exposed directly

to
external
environment
shall
have
suchmaterials that they do not call for any

periodic lubrication and will not create
jamming or excessive play which can result
into loss of setting of complete isolator
ordeformation in links and levers.
924 of 2461
PAGE 49 of 339
s.
MMRDA
Isolators and Operating mechanisms, which

do
not
require
lubrication/adjustments
any
periodic
in
linkages,
bearings, bush-pins, and hinges, are only to

be used.
Supplier shall enclose test reports for

additional
extended
mechanical
endurancetest, which justifies that there are

no undue wear & tear and loss of
adjustment afterlarge number of operations.
t.
Link mechanism shall have Dead center

interlocking to prevent any change in
endposition of disconnector due to external
forces on the arm (e.g. Earthquake, Short
line fault, Wind etc.) even when the drive is
de-coupled from disconnector.
4.3.2.4
Earthing switch
i.
When specified, earthing switch shall form an

integral part of each pole of the isolator.
ii.
Two independent earth terminations with flexible

braids and switches connectors shallbe provided.
iii.
Isolator and earthing switch shall be mechanically

interlocked such that it will not bepossible to close
the earthing switch when the isolator is closed or
vice versa.
iv.
Suitable name plate shall be provided for isolators

and earthing switches.
925 of 2461
PAGE 50 of 339
v.
MMRDA
Clamps and connectors shall be supplied as part

of the isolator, wherever called for inthe data
sheet. The direct delivery of insulators from
insulator
manufacturers
works
willnot
be
accepted. Isolators shall be completely assembled

at the works to ascertain thatall parts fit correctly.
Contractor
shall
structures
for
switches,
furnish
isolators
supporting
and
earthing
detaileddimensioned
drawings
indicating weights and all fixing details and

relative
locations
of
chassis,operating
mechanism box and operating handles. The

mounting will be confirmed at the time of
drawing approval
Routine tests shall be carried out as per IS:

1818
in
the
presence
of
the
Ownersrepresentatives
Four copies of type and routing tests

certificates of insulators isolators shall be
submitted
forthe
Owners
record
and
approval before dispatch
4.3.3 Outdoor Bus post insulator
4.3.3.1
Scope
This specification covers design, manufacture, assembly,

testing
at
manufacturers
works,supply,
delivery,
Installation & commissioning of &132 kV solid core post

insulators required for 132 kV sub-station.
926 of 2461
PAGE 51 of 339
4.3.3.2
MMRDA
Design
The post insulator required for sub-station shall be of

outdoor
type
suitable
for
operation
undertropical
conditions with high temperature, humidity and rainfall.
The insulation level should be as under:
1.
Power frequency withstand value-1 min(dry)/wet in

kV(rms) - 275 kV
2.
Impulse withstand strength-kV(peak) - 650 kV

Peak
All malleable iron steel work, steel bolts and nuts and
flanges shall be hot dip galvanized inaccordance with IS:
2629/1966 with the latest amendment thereof.
Insulators shall be of Post Type and the metal fitting
cemented by insulator manufacturers.
4.3.3.3
Testing
All the acceptance tests shall be carried out as IS 25441973
(latest
amendments).
PowerFrequency
(dry)
withstand test shall be carried out on selected samples at

the time ofAcceptance Test.
List of Type Tests:
1. Visual Examination
2. Verification of dimensions
3. Visible discharge (Corona extinction ) test

927 of 2461
PAGE 52 of 339
MMRDA
4. Lightning Impulse Voltage withstand test
5. Lightning Impulse 50% flashover Voltage test
6. Dry Power frequency voltage withstand test
7. Wet Power frequency voltage withstand test
8. Dry Power frequency flashover voltage test
9. Wet Power frequency flashover voltage test
10. Temperature Cycle test
11. RIV test
12. Corona inception & extinction
13. Switching Impulse voltage test
14. Mechanical Strength test
Compression Test
Tensile Test
Torsion Test
Cantilever Strength test and
Bending test
15. Porosity Test

16. Puncture Test ( for Insulators type B only ) and,
17. Galvanizing test
The contractor shall furnish documents & drawings for owners
approval after award of work
928 of 2461
PAGE 53 of 339
MMRDA
4.3.4 Outdoor Current Transformers
4.3.4.1
Scope
This section covers this design, manufacture, assembly,

testing
at
manufacturers
works,
supply,delivery,
Installation & commissioning of outdoor, dead tank type,

oil impregnated paper, singlephase, 50 Hz, oil immersed,
self-cooled, current transformer. The current transformers
shall becomplete in all respects.
4.3.4.2
Standards
Unless otherwise specified, equipment shall conform to

the following latest applicable IndianStandards:
IS / IEC
Description
Codes
IS:2165
Insulation co-ordination for equipment of

100 KV and above
IS:2705
(I to IV) Instrument Transformers
IS:2099
High voltage porcelain bushings
IS:3347
Dimensions
of
porcelain
transformer
bushings
IS:2071
Method of high voltage testing
IS:335
Insulating
oil
for
transformers
and
switchgears
IS:2147
Degree
of
protection
provided
by
enclosures for low voltage switchgear and

control.
IEC-60044-1
Instrument Transformers
IEC-270
Partial discharge measurement
929 of 2461
PAGE 54 of 339
MMRDA
IEC-44(4)
Instrument transformer measurement of

PDs
IEC-171
Insulation co-ordination
IEC-60
High voltage testing techniques
IEC-8263
Method for RIV test on high voltage

insulators
Indian Electricity Rules 1956
The
Instrument
Transformers
covered
by
this
specification shall comply with the requirementof the

latest edition of IEC Publication No. 60044-1 &/ or Indian
Standard No. 2705 Parts I toIII (as amended up to date)
but the Instrument Transformers for the accuracy class
PS shallconfirm to Part - IV of IS : 2705 except where
specified otherwise in the specification.
The core shall be high grade, non ageing, silicon
laminated
steel
of
low
hysteresis
loss
andhigh
permeability. The core material used in case of metering

core shall be stated in thedatasheet.
4.3.4.3
Description
The core shall be high grade, non ageing, silicon laminated

steel of low hysteresis loss andhigh permeability. The core
material used in case of metering core shall be stated.
The current transformers shall be hermitically sealed to

eliminate breathing and entering of airand moisture in the tank.
Provision of pressure releasing device is not permitted.
For compensation of variation in volume of oil due to

temperature variation, stainless steelbellows/ Nitrogen gas
cushioning shall be provided. The contractor shall have to
submitcalculations of volumetric expansion and contraction.
930 of 2461
PAGE 55 of 339
MMRDA
These calculations shall be submittedalong with the basic

parameters of SS bellow/ Nitrogen gas cushioning used in CT.
The current Transformers provided with stainless steel bellows/

Nitrogen gas cushioning for compensation of oil volume
variation shall be provided with a suitable oil level indicator at
suitable location to enable an observer to see the oil level of the
C.T. from the ground level. Oil level indicator shall be provided
with fluorescent green colored floating ball of non-oil reacting
material. All parts of bellow shall be of stainless steel/ Nitrogen
gas cushioning only.
The core of current transformers to be used for metering and

instrumentations shall havesaturation factor, low enough to
avoid damage to the instruments, in the event of maximumshort
circuit current.
The C.T. core, to be used for protective relays shall be of

accuracy class, specified orappropriate class suitable for back
up, over current and earth fault, differential and busbarprotection.
The contractor shall ensure that sealing of current transformer is

properly achieved. In thisconnection, the arrangement provided
by the contractor at various locations including thefollowing ones
shall be described supported by sectional drawings.
a. Location of emergence of primary and secondary terminals.
b. Interface between porcelain housing and metal tank.
c. Cover of the secondary terminal box.
d. G.A. drawing complete with details of primary and secondary

windings overall dimensions,weight, nameplate, porcelain
931 of 2461
PAGE 56 of 339
insulator,
MMRDA
primary
&
secondary
terminals,
terminal
connectors,etc.
Nuts and bolts (or screws used for fixation of interfacing

porcelain bushings for taking outterminals) shall be provided
on flanges, cemented to the bushing and not on the
porcelain i.e. Flange type 132 KV bushing for CT, shall be
provided.
For gasket joints, wherever used, Nitrile Butyl rubber NBR or

Viton shall be used. No CORKgaskets shall be used. All
gaskets or O rings shall be fixed in a machine groove. The
gasketsshall be securely fitted for perfect sealing.
The bolts required for fitting the dome shall be of stainless

steel of minimum 6 mm dia.
The outer surface of metal tank shall be Hot Dip Galvanized,

whereas, the inner portion shallbe painted with oil resistive,
insoluble paint. The Owner reserves right for stage
inspectionduring manufacturing process of tank or CT. The
galvanizing shall be as per applicablestandard IS: 2629 and
minimum thickness of zinc coating shall be 610 gm/sqmt.
The tank of CT shall be provided with pressboard of 2 mm

thickness inside and at bottom.
Provision of drain valve for sampling / draining of oil purpose

at the bottom of tank are notpermitted.
The minimum thickness of flange & gasket provided on tank

shall be as follow:
i. Flange thickness of tank - 8 mm
932 of 2461
PAGE 57 of 339
MMRDA
ii. Top plate thickness - 5 mm
iii. Gasket thickness - 6 mm
The current transformers shall be suitable for mounting on steel

structures or concretepedestals
i) Winding & Terminals
The rating of the secondary winding shall be suitable as per

transformer rating. Ratio changing arrangement shall be
provided on secondary winding for multiratio design, either
anumber of identical secondary winding may be provided to
achieve desired ratios by series /parallel connection for the
secondary winding or the secondary winding may be tapped.
However, identical secondaries
for tapped
secondary
winding shall meet requirement asspecified.
Primary and secondary windings shall be of electrolytic

grade copper and shall havecontinuous thermal rating as
specified for all ratios. The primary winding is to be designed
forcontinuous extended primary current at 120 % of rated
primary current. The secondarywinding wherever tapped,
shall
be
adequately
reinforced
to
withstand
normal
handlingwithout damage.
The primary terminals shall be of standard size of 30 mm dia

x 80 mm length for all CTs ratedup to 1200 Amps. For higher
values of primary current, each primary terminal shall be
madeout of two such rods of 30mm dia x 80 mm length in
parallel. The primary terminals shall be ofheavily tinned
electrolytic copper. The maximum thickness of tinning shall
be 15 microns.
933 of 2461
PAGE 58 of 339
MMRDA
The secondary terminals shall be brought out in a

compartment for easy access.
Secondary terminal studs shall be provided with at least

three nuts and adequate plain andspring washers for fixing
the leads. The studs, nuts and washers shall be of brass,
duly nickelplated.
The minimum outside diameter of the studs shall be 6mm.

The length of at least15mm shall be available on the studs
for
inserting
the
leads.
The
horizontal
spacing
betweencenters of the adjacent studs shall be at least 1.5

times the outside circum dia. of the units.
The current transformer shall be provided with suitable test

tap for measurement ofcapacitance, tan delta as well as
partial discharges, in factory as well as at site. Provisionshall
be made of a screw on cap for solid and secured earthing of
the test tap connection,when not in use. A suitable caution
plate shall be provided duly fixed on the cover of the
secondary terminal box, indicating the purpose of the test tap
and necessity of its solidearthing as per prescribed method,
before energizing the CT.
ii) Terminal box of current transformer
The exterior of the secondary terminal box shall be hot dip

galvanized. A cable box alongwith necessary glands for
receiving control cables suitable for mounting on bottom
plate of theterminal box shall be included in the scope of
supply. A door with locking arrangement shallbe provided on
the front of the terminal box. The secondary terminals shall
be taken outthrough composite epoxy or FRP mould having
single gasket packing & shall be provided bysuitable link with
dummy secondary leads. For control cable connections,
934 of 2461
PAGE 59 of 339
MMRDA
separate terminalconnector block to be provided. Secondary

jumpers shall be terminated at one side of thisterminal
connector block. The secondary terminal box shall comply
with Degree ofProtection (IP-55) standards and type test
report shall be furnished with for ownersapproval.
iii) Temperature rise
The maximum temperature rise of the current transformer

and its oil, winding and externalsurface of the core and other
parts shall be as specified in Table I of IS: 2705 (Part I).
iv) Bushing & insulators
The porcelain hollow insulator used shall be homogenous,

free from lamination cavities andother flaws or imperfection
that might affect the mechanical or dielectric qualities. The
hollow insulator shall conform to the latest edition of IS:
5621. The puncture strengths of the hollow insulator shall be
entirely free from external and internal corona. The total
creepage distanceof the hollow insulator shall be suitable for
heavily polluted atmosphere i.e. the total creepagedistance
shall be 25mm/kV mm (minimum).
Suitable means shall be provided to accommodate conductor

expansion and there should notbe any undue stress on any
part of the equipment due to temperature changes.
The contractor may provide packing between insulator and

tank. This packing shall bepreferably Nylon Bush of minimum
3 mm thickness.
The exterior, upper and lower joints of insulator bushing shall

be sealed with suitable sealant.
935 of 2461
PAGE 60 of 339
MMRDA
The hollow porcelain bushings conforming to the latest

edition of IS: 5621 shall be used forcurrent transformers. The
insulation of bushings shall be coordinated with that of
theinstrument transformer such that the flashover, if any, will
occur only external to the currenttransformers. The bushings
should not cause radio interference, when operating at
ratedvoltage.
The oil shall conform to the requirements of latest edition of

IS: 335.
v) Terminal connectors &earthing terminals
Compression joint type bimetallic terminal connectors

suitable for ACSR PANTHERconductors (with 510 amps.)
shall be supplied for CTs having ratio from 50-100 / 1-1-1
Ampup to 800-1000 / 1-1-1 Amp.
The terminal connectors shall be suitable for 25 kA for 3 sec.

They shall be suitable for vertical& horizontal connections of
the transmission line conductors or station bus bar. The bolt
andnuts shall be of stainless steel and one SS washer and
two SS nuts (including lock nut) foreach bolt shall be
supplied. Two grounding terminals suitable for receiving
connections forgrounding shall be provided for the current
transformers.
vi) Galvanising
All ferrous parts of current transformers including bolts, nuts

etc. Shall be hot dip galvanized as per IS: 2629 with (latest
edition) and the minimum thickness of zinc coating shall be
610gr/sqmt.
vii) Test &Test Reports

936 of 2461
PAGE 61 of 339
MMRDA
Equipment offered shall have Type Test Certificates from

accredited laboratory(accredited based on ISO/IEC Guide 25
/17025 or EN 45001 by the National accreditationbody of the
country where laboratory is located), as per IEC / IS /
technicalspecification. The type test reports shall not be older
than FIVE years.
The type test reports for the type tests carried out as per IS:
2705 (latest edition) & IEC60044-1 for specified CTs and
those for offered insulator shall be submitted.
Following test reports shall be submitted for owners
approval.
i.
Lightning chopped Impulse voltage withstand test on

Primary winding
ii.
High voltage power frequency wet withstand test on

Primary winding
iii.
High voltage power frequency dry withstand test on

primary winding
iv.
Temperature rise test
v.
Short Time Current withstand test
vi.
Determination of Errors & other characteristics
vii.
Measurement of dielectric dissipation factor
viii. Degree of protection IP55 for secondary terminal box
ix.
STC test on primary terminal connector
937 of 2461
PAGE 62 of 339
MMRDA
x.
Mechanical Load test on primary terminal
xi.
Thermal stability test
xii.
Thermal coefficient test
The type test reports for offered terminal connectors

(confirming to IS: 5561 (latest edition), butnot older than five
years and those for offered insulators confirming to the
applicable standardshall, also, be submitted after award of
work.
Routine tests as per the latest edition of IS: 2705 for current
transformers shall be carried outon each current transformer
(in presence of Owners representative, if desired by the
Owner).
Following tests shall be performed:
i.
Verification of terminal marking and polarity
ii.

primary winding
iii.

secondary winding
iv.
Over Voltage inter turn test
v.
Measurement of Partial Discharge test
vi.
vii.
Measurement of dielectric dissipation factor
938 of 2461
PAGE 63 of 339
MMRDA
(0.3%max) & Capacitance at 10 kV and atVm/3.
In case of non-submission of some of the type test reports,

the contractor shall confirm thesubmission of same before
commencement
of
supply,
without
affecting
delivery
schedule,from NABL accredited laboratory, at his own cost.
If contractor has submitted all valid type / special / additional

test reports as per requirement oftechnical specifications
then the same are not required to be repeated. However,
those testswhich are covered under acceptance/ additional/
routine tests will be required to be carried outduring the
inspection, which is not a repetition.
viii)General points
The manufacturer shall use 5 kV motorized megger for

measuring IR values of CTs.
The manufacturer shall carry out Partial Discharge test

and tan delta test as per relevant IS,and shall keep
record of the same.
The manufacturer shall offer CTs for routine tests /

inspection in line with the requirement asper delivery
schedule.
Record
of
each
manufacturing
process
shall
be
maintained by the manufacturers,and shall be shown to

the inspector, on demand at the time of inspection.
ix) Quality Assurance plan
The contractor shall invariably furnish following information

after award of work; Informationshall be separately given for
939 of 2461
PAGE 64 of 339
MMRDA
individual type of instrument transformer.
Statement giving list of important raw materials, including but

not limited to:
i.
Primary Conductor
ii.
Insulator Bushing
iii.
Core
iv.
Oil
v.
Sealing material
vi.
Secondary wire
Names of sub-suppliers for the raw materials, list of

standards; according to which the rawmaterials are tested,
list of tests normally carried out on raw materials in presence
ofcontractors representative, copies of test certificates.
Information and copies of test certificates as in (i) above, in

respect of, bought outaccessories
List of manufacturing facilities available. In this list the

contractor
shall
specificallymention
whether
lapping
machine, vacuum drying plant, air conditioned dust free room

withpositive air pressure for provision of insulation, oil
leakage testing facility, facility for testing tan delta of
insulation at rated voltage etc. are available.
Levels of automation achieved and list of areas where

manual processing still exists.
940 of 2461
PAGE 65 of 339
MMRDA
List of areas in manufacturing process, where stage

inspections are normally carried out forquality control and
details of such tests and inspections.
Special features provided in the equipment to make it

maintenance free.
List of testing equipment available with the contractor for final

testing of instrumenttransformer and test plant limitation, if
any
for
the
type,
special
acceptance
and
routine
testsspecified in the relevant standards. These limitations

shall be very clearly brought out inschedule of deviations.
The following testing equipments shall be available for
testing at OEM/Third party NABLaccredited laboratory works.
i.
Partial Discharge test set up
ii.
Tan delta and capacitance test set up
iii.
Minimum Sensitivity of high voltage laboratory- 2.5pC

for PD measurement.
i.
All test set up shall be calibrated at NABL accredited

laboratory and report shallbe submitted with inspection
report.
OEM (Original equipment manufacturer) shall have ISO

certification.
x) Completeness of equipments
Any fittings, accessories or apparatus which may not

have been specifically mentioned inthese specifications,
but which are usual or necessary for the equipment of
941 of 2461
PAGE 66 of 339
MMRDA
similar plant shallbe deemed to be included in the

contract and shall be supplied by the contractor without
extracharges. All plant and equipment shall be complete
in all details whether such details arementioned in the
specification or not.
4.3.5 Outdoor Voltage Transformers
4.3.5.1
Scope
This specification is intended to cover the design,

manufacturing,
assembly,
testing
at
manufacturers
works, supply, delivery, Testing & commissioning of

outdoor voltage transformers.
4.3.5.2
Type & rating
The voltage transformers shall be of outdoor, dead tank

type, oil impregnated paper, singlephase, oil immersed,
self-cooled suitable for operation in 3 phase,132 kV
solidly groundedsystem.
4.3.5.3
Standards
The voltage transformers shall conform in all respects to

the latest issue of IEC,recommendations publication No.
60044 or British Standards No. 81 & 2046, and IS:
3156(latest issue) except wherein specified otherwise,
where the equipment conforms to any otherstandard, the
salient points, differences between the standards adopted
and the BritishStandards shall be clearly brought out
datasheet.
Equipment meeting any other authoritative standard,

which ensures an equal or better qualitythan the standard
942 of 2461
PAGE 67 of 339
MMRDA
mentioned above, is also acceptable.
4.3.5.4
Description
The voltage transformers shall be outdoor, oil immersed

and self-cooled type suitable for theservices indicated
conforming to the modern practice of design and
manufacture.
The core shall be of high grade, non-ageing, electrical

silicon laminated steel of low hysteresis less and high
permeability to ensure high accuracy at both normal and
over voltage.
The voltage transformers shall be hermitically sealed to

eliminate breathing and entering of air and moisture in the
tank. Provision of pressure releasing device is not
permitted.
For compensation of variation in volume of oil due to

temperature variation, stainless steel bellows/ Nitrogen
gas cushioning shall be provided. The contractor shall
have to submit calculations of volumetric expansion and
contraction. These calculations shall be submittedalong
with the basic parameters of SS bellow / Nitrogen gas
cushioning used in PT.
The Voltage Transformers provided with stainless steel

bellows/ Nitrogen gas cushioning forcompensation of oil
volume variation shall be provided with a suitable oil level
indicator atsuitable location to enable an observer to see
the oil level of the C.T. from the ground level. Oillevel
indicator shall be provided with fluorescent green
coloured floating ball.
943 of 2461
PAGE 68 of 339
MMRDA
All parts of bellow shall be of stainless steel / Nitrogen

gas cushioning only.
The bolts required for fitting the dome shall be stainless

steel of minimum 6 mm diameter.
The outer surface of metal tank shall be Hot Dip

Galvanized, whereas, the inner portion shallbe painted
with oil resistive paint. The OWNER reserves right for
inspection duringmanufacturing process of metal tank.
The tank of PT shall be provided with pressboard of 2

mm thickness inside and at bottom.
The contractor shall provide packing between insulator

and tank. This packing shall bepreferably Nylon Bush of
minimum 3 mm thickness.
The exterior, upper and lower joints of insulator bushing

shall be sealed with suitable sealant.
The provision of drain valve for sampling / draining of oil

purpose at the bottom of the tank isnot permitted.
The minimum thickness of flange & gasket provided on

tank shall be as follow:
i.
Flange thickness of tank-8mm
ii.
Top plate thickness-5 mm
iii.
Gasket thickness-5 mm
The primary winding shall be of electrolytic grade copper.

All primaries of potentialtransformers will be connected in
944 of 2461
PAGE 69 of 339
MMRDA
phase to neutral with the neutral point solidly earthed.

Theneutral of the system is also solidly earthed.
The primary terminal shall be of heavily tinned electrolytic

grade copper and shall be ofstandard size 30 mm dia. x
80 mm long and tinning shall be adequate.
The secondary winding shall be of electrolytic grade

copper. Secondary terminal shall be nickel-plated brass.
The secondary terminals shall be taken out through

composite epoxy or FRP mouldhaving single gasket
packing & shall be provided by suitable link with dummy
secondary leads. Forcontrol cable connections, separate
terminal
connector
block
to
be
provided.
Secondaryjumpers shall be terminated at one side of this

terminal connector block.
All potential transformers for phase to ground connection

shall be provided with two separatewindings rated for 110
V and 63.5 V for connection in star and delta winding
respectively. Thestar winding, to be used for metering
and relaying (distance relays) shall be of accuracy
classspecified or appropriate class. The rated burden of
this winding shall not be less than thatspecified above.
The delta winding to be used for synchronizing and

relaying (directional relays) shall be ofaccuracy class
specified or appropriate class and its rated burden shall
not be less than thatspecified above.
4.3.5.5
Insulation
The
potential
transformer
shall
withstand
1.2/50
microsecond lightning impulse with stand voltage of 650

945 of 2461
PAGE 70 of 339
MMRDA
kV peak.
They shall withstand power frequency withstand voltage

of 275 kV (rms) (dry & wet) for oneminute.
4.3.5.6
Temperature rise
The potential transformers shall be designed to limit the

temperature of windings and otherparts as specified in
the IEC Standards / relevant standards when corrected or
the differencesbetween the temperature prevailing at site
and
temperature
specified
by
the
standards.
Thetemperature rise, at 1.2 times rated primary voltage

when applied continuously at ratedfrequency and at rated
burden, shall not exceed the limits specified above and
thetemperature rise at 1.5 times rated primary voltage
when applied for 30 seconds, starting fromprevious stable
operating condition at rated frequency and rated burden
shall not exceed theabove temperature limits by more
than 10 degree C.
The insulating oil shall conform to the requirements of

latest edition of IS: 335.
The manufacturer of PT shall measure the PPM value of

oil before filling inside the PT andshall keep record of the
same.
The voltage transformers shall be suitable for mounting

on steel structures or concretepedestals. The necessary
flanges, bolts etc. For the base of the voltage transformer
shall besupplied and these shall be galvanized. Nuts and
bolts shall be provided on flanges,cemented to the
bushing and not on the porcelain. i.e. flange type bushing
to be provided.
946 of 2461
PAGE 71 of 339
4.3.5.7
MMRDA
Terminal box of voltage transformer
The exterior of the secondary terminal box shall be hot

dip galvanized.
A cable box along with necessary glands for receiving

control cables suitable for mounting onbottom plate of the
terminal box shall be included in the scope of supply. A
door with lockingarrangement shall be provided on the
front of the terminal box. The secondary terminals shallbe
taken out through composite epoxy or FRP mould having
single gasket packing & shall beprovided by suitable link
with
dummy
secondary
leads.
For
control
cable
connections,separate terminal connector block to be

provided. Secondary jumpers shall be terminated atone
side of this terminal connector block. The secondary
terminal box shall comply withDegree of Protection (IP55) standards and type test report shall be submitted for
ownersapproval.
The
porcelain
hollow
insulator
used
shall
be
homogenous, free from lamination cavities andother flaws

or imperfection that might affect the mechanical or
dielectric qualities. The hollow insulator shall conform to
the latest edition of IS: 5621. The puncture strengths of
the hollow insulator shall be entirely free from external
and internal corona. The total creepage distanceof the
hollow insulator shall be suitable for heavily polluted
atmosphere i.e. the total creepagedistance shall be
25mm/kVmm (minimum).
Suitable means shall be provided to accommodate

conductor expansion and there should notbe any undue
stress on any part of the equipment due to temperature
947 of 2461
PAGE 72 of 339
MMRDA
changes.
The contractor may provide packing between insulator

and tank. This packing shall bepreferably Nylon Bush of
minimum 3 mm thickness.
The exterior, upper and lower joints of insulator bushing

shall be sealed with suitable sealant.
The hollow porcelain bushings conforming to the latest

edition of IS: 5621 shall be used forcurrent transformers.
The insulation of bushings shall be coordinated with that
of theinstrument transformer such that the flashover, if
any, will occur only external to the currenttransformers.
The bushings should not cause radio interference, when
operating at ratedvoltage.
For gasket joints, wherever used, Nitrile Butyl rubber

NBR/Viton gaskets shall be used. NoCORK gaskets shall
be used. All gaskets/O rings shall be fixed in a
machinegroove. The gaskets shall be securely fitted for
perfect sealing.
4.3.5.8
Terminal connections
The compression joint type terminal connector suitable

for ACSR PANTHER conductor shallbe supplied.
Suitable terminal earth connector for connections for
earthing shall also besupplied.
The terminal connectors shall be suitable for 40kA for

1sec or 25 KA for 3 seconds. They shall be suitable
forvertical & horizontal connections of the transmission
line conductors or station bus bar. Thebolt and nuts shall
be of stainless steel and one SS washer and two SS nuts
948 of 2461
PAGE 73 of 339
MMRDA
(including locknut) for each bolt shall be supplied. Two

grounding terminals suitable for receivingconnections for
grounding shall be provided for the voltage transformers.
4.3.5.9
Type tests
The type test report for all the type tests as stipulated in
IS: 3156 (Part I latest edition) but not older than FIVE
years and shall be submitted for owners approval. The
type
test
reports
foroffered
terminal
connectors
(confirming to IS: 5561 (latest edition), but not older than

five years.
Lightning chopped Impulse voltage withstand test

on Primary winding
High voltage power frequency wet withstand test

on primary winding
High voltage power frequency dry withstand test

on secondary winding
Degree of protection IP55 for secondary terminal

box
4.3.5.10
STC test on primary terminal connector
Mechanical load test on primary terminal
Routine tests
949 of 2461
PAGE 74 of 339
MMRDA
Each voltage transformer shall be subject to routine tests

as stipulated in IS: 3156 (latestedition) in presence of
Owners representative. All the type test reports shall be
submitted andgot approved from the Owner before the
dispatch of potential transformer.
Following tests shall be performed:
Verification of terminal marking & polarity test

on primary winding

on secondary winding
Measurement of Partial Discharge test
Measurement of dielectric dissipation factor (0.3%

max) & Capacitance at 10 kV and atVm/3.
4.3.6 Outdoor SF6 circuit breaker
4.3.6.1
Scope
This section covers the design, manufacture, testing,

inspection, supply, delivery, testing &commissioning of
132 kV SF6 gas Circuit Breakers SPRING operated,
along with associated accessories and complete in all
respects.
4.3.6.2
Applicable Standards
950 of 2461
PAGE 75 of 339
MMRDA
The equipment to be supplied under this specification

shall conform to the latest issue ofstandards, rules and
codes some of which are mentioned below.
IEC / IS Codes
IEC-62271/
Description
Specification for alternating current Circuit breaker
IS13118
IEC-60376
Specification and acceptance of new Supply of

sulphurHexafluoride
IS: 2147
Degree of protection provided for Enclosures for

lowvoltage switchgear and control gear
IS: 375
Marking and arrangement for switchgear busbar,

mainconnections and auxiliary wiring
IS: 325
Specification for 3ph induction motor
IS: 2516
Specification for circuit breaker
IS: 2099
High voltage porcelain bushing
IS: 2629
recommended practice for hot dip galvanizing of

iron and steel
The components & accessories to be used in the

manufacture of circuit breaker shall conformto relevant
Indian Standards/the standard specified under respective
clause in thisspecification.
However, in the event the offered breakers confirming to

any other standard, salient points ofdifferences between
the standard adopted and the specified standards shall
be clearlyindicated in the offer.
4.3.6.3
Drawings/documents
The contractor shall furnish the drawings in triplicate

incorporating the following particulars.
a.
Drawing showing the general outlines dimensions
951 of 2461
PAGE 76 of 339
MMRDA
of circuit breakers, with clearidentification of parts /

items.
b.
Drawing showing control cabinets and circuit

diagrams
for
operating
mechanism
of
circuitbreakers.
c.
Drawing showing the complete operation cycle of

the circuit breaker with description.
d.
Compression type terminal connectors for the

breakers.
The contractor shall submit the following drawings after

award of work.
a.
Outline dimensional drawings showing all parts /

items, transport weight etc. of circuit breaker & its
support structure.
b.
Detailed drawings of operating mechanism of

circuit breakers.
c.
Wiring and control diagram.
d.
Drawings of foundation details, mounting

structures, spacing of bolts etc.
e.
Compression type terminal connectors, with STC

rating, bill of materials, etc., complete withall
dimensions.
f.
4.3.6.4
Erection, operation & maintenance manuals.
General Design Features of Circuit Breakers
952 of 2461
PAGE 77 of 339
MMRDA
The circuit breakers shall be capable of rapid and smooth

interruption of currents underall conditions completely
suppressing all undesirable phenomena even under the
most severeand persistent short circuit conditions or
when interrupting small currents or leading orlagging
reactive currents. The circuit breakers shall be RestrikeFree under all operating conditions. The details of any
device incorporated to limit or control the rate of rise
ofrestricting voltage across, the circuit breaker contacts
shall be stated.The over voltagescaused by circuit
breaker while switching inductive or capacitive loads shall
not exceed 2.5times the highest phase to neutral voltage.
The actual make and break times for the circuitbreakers
throughout the ranges of their operating duties shall be
stated and guaranteed.
The arc quenching chambers shall have devices to

ensure almost uniform distribution of voltage across the
interrupters.
4.3.6.5
Breaking Capacity
The interrupting capacity of the breaker for kilometric

faults (short line faults) shall be equal toits interrupting
capacity as per IS: 13118 / IEC 62271. The details of
tests conducted forconfirming the capability of the
breakers under kilometric fault conditions shall be
furnished.
The circuit breakers shall be designed for interrupting line

charging currents without unduerise in the voltage on
supply side and without any restrike and without showing
signs ofundue strain. The guaranteed over voltage which
shall not be exceeded while interrupting theline charging
953 of 2461
PAGE 78 of 339
MMRDA
currents.
The circuit breakers shall be capable of interrupting small

inductive currents (occurring whileswitching off unloaded
transformer) without giving rise to undue over voltage and
without restrikes.
Re-striking Voltage:
The circuit breakers shall be capable of interrupting the

rated power when the restrikingvoltage has a frequency
of not less than 400 Hz and with a restriking voltage
havingfrequency of 2000 Hz. The circuit breakers shall be
capable of interrupting at least 50% ofnominal breaking
capacity
The measures adopted for ensuring proper operation at

high rate of rise of restriking
Voltage and for limiting the actual voltage values across

the breaks shall be described. Thetype characteristics
and rating of the resistor used, if any, to shunt the
breaker contacts andof the auxiliary switching devices
used for interrupting the resistor current shall be
clearlystated.
Recovery voltage and power Factor:
The circuit breaker shall be capable of interrupting the

rated power with recovery voltageequal to the rated
maximum line to line service voltage at rated frequency
and at apower factor not exceeding 0.15.
The circuit breakers shall also be capable of satisfactory

operation even under conditions ofphase opposition that
954 of 2461
PAGE 79 of 339
MMRDA
may arise due to faulty synchronizing. The maximum

power which thebreaker can satisfactorily interrupt under
phase opposition shall be stated in the datasheet.
The operating duty of the circuit breaker shall be as

specified
in
the
specific
technicalrequirement
for
breakers.
4.3.6.6
Temperature Rise
The temperature rise and the maximum temperature on

any part of the breaker when inservice under continuous
full load conditions and exposed continuously to the direct
sun-raysshall not exceed the permissible limits as per
relevant IS. When the standard specifies thelimits of
temperature rise, this shall not be exceeded when
corrected for the differencebetween ambient temperature
at site and the ambient temperature specified in the
relevantspecification. The correction proposed shall be
stated in datasheet and shall be subject to theapproval of
the Owner.
4.3.6.7
General Features of Circuit Breakers
The circuit breakers shall be suitable for outdoor

operation under the climatic conditionsspecified in this
specification.
The circuit breakers operating mechanism shall have two

nos. of tripping coils and one no. ofclosing coil for both
132 kV SF6 Gas CB for better reliability. There shall be
separate contactorfor each coil.
Exposed live parts shall be placed high enough above

ground to meet the requirements oflocal safety codes.
955 of 2461
PAGE 80 of 339
MMRDA
All similar parts, particularly removable one and shall be

interchangeable with one another.
4.3.6.8
Insulation of the Circuit Breaker
The insulation to ground, the insulation between open

contacts and the insulation betweenphases of the
completely assembled circuit breaker shall capable of
withstanding
satisfactorilydie-electric
test
voltages
corresponding to BIL specified in this specification.
The minimum clearances in open air shall be as under in

case of SF-6 Breakers:
Minimum clearance between phase: As per

relevant IS.
Minimum clearance between live parts: As per

relevant IS. And groundedobjects.
Adequate clearance in air shall be provided between

phase and from phase to ground. Theclearance shall be
such that the breaker shall withstand the BIL specified in
the specification.
The minimum clearance from live parts to ground level

shall not be less than 4600 mm including plinth height
as 300 mm
4.3.6.9
Contacts of Circuit Breaker
The main contacts shall have adequate area and contact

pressure for carrying the ratedcurrents and the short time
rated
breaking
currents
956 of 2461
of
the
breaker
without
PAGE 81 of 339
MMRDA
excessivetemperature rise. Contacts shall be easily

replaceable and shall have a minimum of movableparts
and adjustments. The main contacts shall be first to open
and last to close so thatburning of the contact may be
negligible.
4.3.6.10
Operating Mechanism of Circuit Breakers
Circuit breakers shall be power operated by a motor

compressed spring charging mechanism;the mechanism
will be trip-free electrically and mechanically. The
mechanism shall be strong,quick in action and shall be
removable without disturbing other parts of the circuit
breakers. Allthe working parts in the mechanism shall be
of corrosion resistant materials and all bearingswhich
require greasing, shall be equipped with pressure grease
fittings. The mechanism andbreaker shall be such that
the failure of any spring will not prevent tripping and will
not causetripping or closing.
The circuit breakers shall be designed for remote control

from the control room and there shallbe provision for
manual operation of circuit breakers during maintenance
and for local trippingand closing by normal means.
The circuit breaker shall have a mechanical ON-OFF
indicator in addition to facilities forremote electrical
indicator.
The operating mechanism along with its accessories shall

be suitable for electrical operationand shall be mounted in
a weather proof cabinet with hinged doors located near
the breakers.
The cabinet shall be suitable for IP 55 degree of

957 of 2461
PAGE 82 of 339
MMRDA
protection. The operation shall be possiblefrom ground or

necessary
HDG
stand/platform
of
suitable
height
maintaining all safetyclearance with live parts shall be

supplied as a part of breaker. The local control switch
andthe breaker position indicator shall be provided in this
cabinet, which shall be free standingand supported by
suitable arrangement. The control circuit shall be
designed to operate onD.C. as specified in section-II of
this specification. The closing and opening coils shall
bedesigned to operate satisfactorily at any control voltage
from 85% to 110% & 70% to 110% ofthe normal voltage,
respectively.
heater
of
adequate
capacity
with
thermostat shall beprovided in the cabinet to avoid

moisture condensation
The terminal block shall of 1.1 kV voltage grade & shall

be with stud type connectionsinstead of with screw types
connections.
4.3.6.11
Auxiliary switches
A minimum number of 6 NC + 6 NO Auxiliary switches

contacts shall be provided on eachcircuit breaker for use
in remote indication control scheme of the circular
breakers and forsafety interlocking. Special contacts for
use with trip coils and auto reclosing operation shallalso
be provided. Provision shall be made for adding more
auxiliary switches, if required.
Auxiliary switches shall be placed in weatherproof

galvanized casing & current rating ofswitches shall be
furnished.
4.3.6.12
Bushing & Insulators
958 of 2461
PAGE 83 of 339
MMRDA
The porcelain insulator used in manufacturing the

bushings shall be homogeneous, free fromlaminations,
cavities and other flaws or imperfection that might affect
the mechanical or dielectric qualities. All bushings of
identical ratings shall be interchangeable. The insulators
shall conform to the latest edition of IS: 3447 or other
equivalent standard. The puncture strengths of the
bushings shall be greater than their flashover values. The
bushings shall be entirely free from external and internal
corona. The protected and total creepage distance of the
bushings
shall
be
suitable
for
heavily
polluted
atmosphere. The minimum creepagedistance of the

insulator shall be 25mm/kV mm suitable for heaving
polluted atmosphere. The compressive and cantilever
strength shall conform to the relevant IS.
4.3.6.13
Terminal Connectors and Earthing Terminals
Compression joint type terminal connectors suitable for

single or twin ACSRpanther/zebra/Moose shall be
supplied and they shall be suitable for both vertical
andhorizontal connections of the Transmission line
conductor or station bus bar. Suitable terminal earth
connectors (two Nos.) for earthing connections shall also
be supplied. The drawings for these connectors shall be
submitted. SS bolt for connector shall be provided with
two Nos. of SS nuts (including lock nut & one SS
washer.)
4.3.6.14
Tropicalisation
All control wiring, electric motors and accessories shall be

protected against fungus growthand other harmful effects
due to tropical environments
959 of 2461
PAGE 84 of 339
4.3.6.15
MMRDA
Galvanizing
All ferrous parts of breakers and bolts, nuts etc. shall be

hot-dip galvanized as per latest edition of IS: 2629.
Support structures galvanizing shall be done as per IS
4843 (latest edition). Electro galvanized bolts nuts, &
washers are also acceptable.
4.3.6.16
Painting
Interior and exteriors of tanks, mechanisms, enclosures,

cabinets and other metal parts shall be thoroughly
cleaned to remove all rust scales, corrosion and other
adhering foreign matter, steel surfaces in contacts with
insulation oil, as far as possible shall be painting with not
less than two coats of heat resistant, oil insoluble,
insulating varnish light-grey paint shade 631 as per IS: 5
shall be selected to withstand tropical heat and extremes
of weather
4.3.6.17
Test and Test Reports
Reports of following type tests carried out in NABL / Govt.

approved laboratory & as per IS:13118 / IEC 62271-100
for A C circuit breakers shall be submitted for owners
approval:
1.
Lightning impulse withstand voltage test
2.
Power frequency voltage withstand voltage test.

(Dry as well as Wet)
3.
Temperature rise test.
4.
Measurement of resistance of main circuit
960 of 2461
PAGE 85 of 339
5.
MMRDA
Short time current withstand and peak current

withstand Test
6.
Mechanical endurance test
7.
Duty cycle & Single phase short circuit test.
8.
Out of phase making and breaking current test.
9.
Capacitor current switching test for isolated neutral

capacitor banks.
10.
Line charging current switching test
11.
Cable charging current switching test
12.
Short line fault duty test
13.
Degree of protection test on cubicles
Equipment offered shall have Type Test Certificates from

accredited laboratory (accreditedbased on ISO/IEC Guide
25 / 17025 or EN 45001 by the National accreditation
body of thecountry where laboratory is located), as per
IEC / IS / technical specification. The type testreports
shall not be older than FIVE years.
In case of non-submission of some of the type test

reports, the contractor shall confirm thesubmission of
same before commencement of supply, without affecting
delivery schedule,from NABL accredited laboratory at his
own cost.
Routine tests as per the latest edition of IS: 13118/IEC

961 of 2461
PAGE 86 of 339
MMRDA
62271 for circuit breakers shall becarried out on each

circuit breaker. All the acceptance tests in presence of
Ownerrepresentative shall be carried out on circuit
breakers selected from offered lot.
In addition to above, speed curves for each breaker shall

be obtained with the help of asuitable operation analyzer
to determine the breaker contact movement during
opening,closing, auto-re-closing and trip free operations
under normal as well as limiting operatingconditions (of
control voltage) The tests shall show the speed of
contacts directly at variousstages of operation, travel of
contacts, opening time, closing time, shortest time
betweenseparation and meeting of contacts at makebreak
operation
and
dynamic
contactresistance
measurement (DCRM) etc.
The test reports for type tests and routine tests in respect
of associated items such asspring charging motors,
instruments,
pressure
switches,
relays,
terminal
connectors, etc. asper the latest edition of the relevant IS

shall be supplied by the contractor. All the routine
testreports for all the breakers and for all the insulators
utilized shall be submitted withinspection report.
All tests reports for acceptance / routine tests shall be

submitted in spiral bound volume and got approved from
the Owner before dispatching the breaker
4.3.6.18
Earthquake & wind design load
Each circuit breaker including its supporting structure

shall be designed to withstand required earthquake
acceleration of 0.08 x 2 g and with wind loads of 150
Kg/m2 on the projected area (non- simultaneous) without
962 of 2461
PAGE 87 of 339
MMRDA
damage to component parts and without impairment of

operation.
4.3.6.19
General design feature of circuit breaker
SF6 Gas Circuit breaker shall consist of three identical

single phase units with common spring operating
mechanism suitable for specified duty. Separate SF6 Gas
Cylinder along with suitable gas system, incorporating
required gas stop valves, copper piping of suitable size
shall be provided. Required pressure switches as stated
shall be provided. Gas pressure gauge shall be fitted on
the common feed pipe to monitor the pressure of SF6 gas
in the interrupter.
Absorbent shall also be provided in each interrupting unit

to keep the SF6 gas dry & absorb the decomposed
product of SF6 gas, formed during arcing.
Contractor shall give complete constructional details for

SF6 gas circuit breaker offered bythem. The insulation
level of porcelain of the circuit breaker shall be so
coordinated with that of the breaker that flashover shall
occur externally to the breaker.
In case of SF6 circuit breaker, it shall be possible to

arrange for either automatic tripping of the circuit breaker
or tripping of circuit breaker on fault and will be
automatically locked when the pressure in the individual
interrupter reaches below the limit value. Arrangements
shall be made to prevent closing of the breaker due to
leakage of gas passing through the closingvalve without a
positive impulse from the closing coil.
The SF6 gas used in the circuit Breaker shall comply in

963 of 2461
PAGE 88 of 339
MMRDA
all respect with the provisionsof the latest edition of

relevant standard.
Inter Locks:
Pressure switches with the required pressure fitting must

be incorporated to ensure safetyof breaker operation
when SF6 gas pressure goes below the specified
pressure range dueto leakage, the trip coil circuit &
closing coil circuit must be cut-off. The pressure
switchshall generally be temperature compensated gas
pressure switch having two micro switches,operating at
different pressures one for low pressure alarm and other
for lowpressure cut-out.
Additional dedicated pressures switch with 4 poles for

Normal, Low gas, Lockout, etc. shallbe provided for
SCADA remote operations. L/R switch shall have spare
contacts.
Limit switch for motors shall be provided with 4 NO and 4

NC contacts
4.3.6.20
ABT Metering
The
specification
covers
the
design,
engineering,
manufacture, assembly, testingsupply and delivery of

Electronic HT tri vector meters suitable for ABT
(AvailabilityBased Tariff), Four Quadrant, Bi-Directional
power flow, solidly earthed system withbalanced and unbalanced loads for a power factor range from zero to
unity(lagging and leading), with accuracy class 0.2s. The
meter as a self-containeddevice for measurement of
active, apparent and reactive energy and certainother
parameters as described in subsequent paragraphs of
964 of 2461
PAGE 89 of 339
MMRDA
this specification shallbe suitable for being connected

directly to voltage transformers (VT)/capacitivevoltage
transformers (CVT) having a rated secondary line-to-line
voltage of 110vand to current transformers (CTS) having
a rated secondary current of 1A, 3element 4 wire. The
reference frequency shall be 50 Hz. The energy meter
shall besuitable for rack/ panel/ metal box mounting.
4.3.6.21
Standards
Unless
otherwise
specified
elsewhere
in
this
specification, the meter shallconform in all respects

including
performance
and
testing
thereof
to
the
followingIndian/ International Standards to be read with

up-to-date
and
latestamendments/
revisions
there
ofMeters matching with requirements of other national or

international standardswhich ensure equal or better
performance than the above mentionedstandards shall
also be considered. When the meters offered by the
bidderconforms to standards other than those specified
above, salient points ofdifference between standards
adopted and the standards specified in thisspecification
shall be clearly acceptance brought out in the relevant
schedule.
IS / IEC Codes
Description
ISS:14697/1999
AC static transformer operated watt-hour and
Reaffirmed
VARHour.
meters, class 0.2s, 0.5 S and 1.0 S
2004
CBIP
Manual on Standardization of Ac static electrical
publication No
energy meters
304, July 2008

IEC 62052-11
Electricity metering equipment (AC) General

requirements , tests and test conditions
965 of 2461
PAGE 90 of 339
IEC 62053-22
MMRDA
Static meters for active energy (class 0.2 S and 0.5

s)
The standard for Electricity metering Data
IEC 62056
exchange for meter reading, tariff and load control
A copy of such standards along with their English

translation shall invariably befurnished along with the
offer.
4.3.6.22
Environmental conditions
a)
Climatic Conditions:
The
meters
specification
to
be
shall
be
supplied
against
this
suitable
forsatisfactory
continuous operation under the following climatic

conditions.
S.
Parameter
Range / Value
No.
i.
Max. ambient air temperature (Deg.
55
C)
ii.
Min. ambient air temperature (Deg.
-10
C)
iii.
Average
daily
ambient
air
35
temperature (Deg. C)
iv.
Max. Relative Humidity (%)
v.
Max. altitude above mean sea level
95
1000
(m)
vi.
Average Annual rainfall (mm)
925
vii.
Max. wind pressure (kg./sq.m)
200
viii.
Isoceraunic level (days per year)
50
ix.
Seismic
level
(Horizontal
0.3 g
acceleration)
966 of 2461
PAGE 91 of 339
x.
Average
MMRDA
No.
of
thunderstorms
40
days/years
xi.
Average number of rainy days/years
90
xii.
Average number of months/tropical
monsoon condition per year

xiii.
Noise level
45 dB
Moderately
hot
and
humid
tropical
climate,
conducive to rust and fungusgrowth. The climatic

conditions are also prone to wide variations in
theambient conditions. Smoke is also present in
the atmosphere. Heavy lightningalso occurs during
June to October.
4.3.6.23
Electrical Specifications
Class of accuracy: 0.2S for KWH and KVARH (Active

Energy and ReactiveEnergy)
Type of Meter: 3 Element, 4 Wire. (3 Phase, 4 Wire)
Supply Voltage and Range (PT Secondary): 3 Phase,
Phase to Phase 110V
with variation -30% to 20%
Reference Frequency and Range: 50 Hz, +/- 5%
Power factor Range: Zero lagging through Unity to Zero
leading
Basic Current (Ib): 1A
Maximum Current (I max): 120% of Ib
Starting Current (Is): 0.1% of Ib at UPF
Power Loss:
Voltage Circuit: Shall not exceed 1W and 4 VA per Phase
Current Circuit: Shall not exceed 1VA per Phase
Clock Time Accuracy: +/- 2 minutes per year drift or
better
4.3.6.24
Technical/Functional Requirements
967 of 2461
PAGE 92 of 339
a)
MMRDA
Meter case
The meter shall be made out of high quality

materials to ensure higher reliabilityand long life
with a polycarbonate meter casing. It should be
compact and ofreliable design to make it immune
to vibrations and shocks in normal serviceand
transportation
and
should
be
capable
of
withstanding several stresses likelyto occur in

actual service. The latest state of the art
technology of surfacemounting of components
etc., may be used for the purpose. The soldering
ifany shall be perfect without dry solders. The
components shall be of highquality and comply
with international industrial standard practices.
Theconstruction of the meter shall be such as to
permit sealing of the meter cover,terminal cover
etc. independently to ensure that the internal parts
are notaccessible for tampering etc. without
breaking the seals. The meter windowshall be
transparent and made out of UV Stabilized
material so that the windowdoes not turn yellow
after some years.
The meter case and meter terminal block and

cover shall meet the IS 14697 inall requirements
like shock, dust proof, creepage distances and
insulation etc.The meter shall be totally sealed and
tamper proof.
b)
Type of installation: Indoor
Energy Measurement
968 of 2461
PAGE 93 of 339
(a)
MMRDA
The active energy (Wh) and reactive

energy(Varh) measurement shall becarried
out on 3-phase, 4-wire principle, with an
accuracy as per class 0.2 S ofIS 14697, the
energy shall be computed directly in CT and
VT secondaryquantities, and indicated in
watt-hours/varh. The harmonics shall be
filteredout while measuring Wh, Var and
VArh,
and
only
fundamental
frequencyquantities
shall
be
measured/computed.
(b)
The 15-minute Wh shall have a +ve sign

when
there
is
net
Wh
export
fromsubstation busbars, and a ve sign

when
there
is
net
Wh
import.
Theintegrating (cumulative) registers for Wh

and Varh shall move forward whenthere is
Wh/Varh export from substation busbars,
and backward when thereis an import.
(c)
There shall be exclusive separate reactive

energy registers in addition to allother billing
parameters, one for the period when
average RMS voltage isabove 103% and
the other for the period the voltage is below
97%.
c)
Immunity to External Factors
The meters shall be immune to external influences

like
magnetic
induction,vibration,
electrostatic
discharge, switching transients, surge voltages,

obliquesuspension
confirm
to
the
969 of 2461
and
harmonics
standards
and
mentioned
shall
inthis
PAGE 94 of 339
MMRDA
specification.
The meter accuracy shall not be affected by AC /

DC magnetic field up to 0.2Tesla on all the sides of
meter i.e. front, sides, top and bottomof the meter
as per CBIP publication No. 304 with latest
amendments.Under influence of any magnetic field
(AC / DC / Permanent) above 0.2Tesla, if the
accuracy of the meter gets affected, then the same
shall berecorded as magnetic tamper event with
date & time stamping. Theenergy recorded during
such tamper shall be registered in a separate
registerin addition to main register.
d)
Sealing Points
Sealing provision shall be made available to the

following:
e)
(i)
Meter body or cover
(ii)
Meter terminal cover
(iii)
MD reset button
(iv)
Communication ports
Auxiliary power
The auxiliary power supply shall be drawn from

V.T circuit from all thethree phases, preferably
equally, so as to ensure meter supply even if
any/two ofthe three phases of the potential supply
is lost at a time.Name plate and Marking of meter.It
shall be as per IS 14697.
f)
Instantaneous parameters
970 of 2461
PAGE 95 of 339
MMRDA
The meters shall display the following parameters

on demand (by pressing the pushbutton) and
automatically. In automatic display each parameter
shall bedisplayed for at least 10 sec. Both forward
and backward scroll provision shall beavailable in
on demand display.
Parameters:
1.
Unique identification number of the meter
2.
Date
3.
Time
4.
Current - IR
5.
Current - IY
6.
Current IB
7.
Voltage - VRN for 3 / 4W
8.
Voltage VYN for 3 / 4W
9.
Voltage VBN for 3 / 4W
10.
Signed Power Factor R phase
11.
Signed Power Factor Y phase
12.
Signed Power Factor B phase
13.
System Power Factor PF
14.
Frequency
15.
Signed Active Power kW (+ Forward, backward)
16.
Signed Reactive Power kVAr (+ Lag, Lead)
17.
Apparent Power kVA
18.
Cumulative Energy export kWh
19.
Cumulative Energy Import kWh
20.
Cumulative Energy kVAh export
21.
Cumulative Energy kVAh import
22.
Kvarh Quadrant 1
23.
Kvarh Quadrant 2
24.
Kvarh Quadrant 3
971 of 2461
PAGE 96 of 339
MMRDA
25.
Kvarh Quadrant 4
26.
Maximum demand (kVA)export
27.
Maximum demand (kVA)import
28.
Cumulative MD (MVA)export
29.
Cumulative MD (MVA)import
30.
Date and Time of Last MD reset
31.
Cumulative MD reset count
32.
Raising demand(KVA) and elapsed time
33.
Average frequency of the previous 15minute block
34.
Net Wh transmittal in the previous 15minute block, with +/-sign
35.
Average percentage voltage
36.
Voltage-high VArh register reading
37.
Voltage-low VArh register reading.
38.
Cumulative
Power
Down
Time
in
DD:HH:MM
39.
Total Voltage Harmonic Distortion VTHD
40.
Total Current Harmonic Distortion ITHD
41.
Cumulative tamper count
42.
Cumulative programming count
43.
Demand Integration Period
44.
Programmed external CT and PT ratios set

in the meter
4.3.6.25
Load Survey Parameters
The following parameters for load survey purpose and

shall be logged with a blockperiod of 15 minutes. The
data storage required for the load survey parametersshall
be 45 days in nonvolatile memory with life time of the
meter.
1.
Average Frequency (Coded 00-99 for 49.00-5 1.00

Hz)
972 of 2461
PAGE 97 of 339
MMRDA
2.
Average Power factor (Export)
3.
Average Power factor(Import)
4.
Net active energy
5.
Active Energy (KW/kwh) Import
6.
Active Energy (KW/kwh) Export
7.
Apparent Energy (KVA/kvah) import
8.
Apparent Energy (KVA/kvah) export
9.
Kvar/ Kvarh Lag Export
10.
Kvar/ Kvarh Lead Export
11.
Kvar/ Kvarh Lag Import
12.
Kvar/ Kvarh Lead Import
13.
Percentage Voltage unbalance
14.
Total harmonic distortion of voltage in percentage

of fundamental
15.
Total harmonic distortion of current in percentage

of fundamental
16.
Phase wise voltages and currents also shall be

made available.
17.
Date and time shall also be included
18.
Serial number must be 10 digit only.
The Sample Load survey data download format is

attached to this specificationas an excel sheet named
Load survey dataSample format, which is present
database format for Energy billing. During Engineering
modifications as required shall becarried out.
4.3.6.26
Billing Parameters
The parameters listed below for billing purpose and are

logged at each daymidnight (00.00Hrs) and stored in nonvolatile memory for 45 days.
1.
Cumulative Active Energy (kWh) Import up to

two decimal
973 of 2461
PAGE 98 of 339
2.
MMRDA
Cumulative Active Energy (kwh) Export up to two

decimal
3.
Cumulative Apparent Energy (kvah) Import
4.
Cumulative Apparent Energy (kvah) Export
5.
Cumulative Reactive Energy (kvarh) (Lag/Lead) While KW is Import
6.
Cumulative Reactive Energy (kvarh) (Lag/Lead) While KW is Export
7.
Kvarh during low voltage <97%
8.
Kvarh during high voltage >103% *
9.
T.O.D Parameters:
10.
Kwh and kvah- Export
Kwh and kvah Import
MD in KVA
Power Factor for programmed periods.
Power Down Time or Power Off Data (DD:HH:MM)
Note: Scale MF shall be One (1) invariably
Historical Data Recording: Meter shall be capable of

recording
in
its
Non-Volatile(NVM)
historical
data
consisting of billing energy, demand, TOD registers,

minimumof six such data sets shall be stored and it
should be possible to retrieve these datathrough
communication
port
on
common
meter
reading
instrument (CMRI) orRMR.
4.3.6.27
Programmable Parameters
1.
Real time clock
2.
Demand integration Period
3.
Block Capture Time
4.
Billing Date/MD reset date
5.
Time Zones (1 to 8)
6.
External CT/PT ratios
7.
events/tampers
974 of 2461
PAGE 99 of 339
MMRDA
Provisions shall be made to program the above

parameters at sight usingCMRI, Laptop or using Base
computer
software
propersecurity
from
system.
remote
Logging
of
station
with
programmable
parameter changed event (date &time) along with display

of the same under On Demand Display Parameters
&snapping of billing data at that time shall be stored and
can be retrievable withCMRI and RMR and Laptop.
4.3.6.28
Name Plate Details
1.
Manufacturer name
2.
Meter serial number

The Meter serial Number must be in 10 digit Order
only.
3.
Firmware version for meter
4.
Firmware version of communication software
The above parameters shall be displayed on demand
4.3.6.29
Display
The meter shall have a display of liquid crystal display

(LCD) for measured valueswith one digit indicating
legend.
The
characters
shall
be
clearly
visible.
Provisionshall be made to read consumption in either

whole units or decimal multiples orsubmultiples of one
unit. The display shall be continuously with backlight
digital typeand with non-destructive read out.
In case of multiple values presented by a single display it

must be possible to displaythe contents of all relevant
memories. When displaying the memory, identificationsof
each tariff/parameter shall be available.
975 of 2461
PAGE 100 of 339
MMRDA
The register shall be able to record and display starting

from zero, for a minimum of
1500 h, the energy corresponding to rated maximum
current at reference voltage
and unity power factor. Register should not rollover in
between this duration.
RESOLUTION:
1. Voltage
0.1V
2. Current
0.001A
3. P.F.
0.001
4. Energy
0.001 MWH
5. Demand
0.1 KVA / KW=0.001 MVA/MW.
Maximum Demand(MD) Recording:
The maximum demand is to be monitored during each

demand interval set with30/15 minutes integration and
the
maximum
of
these
in
month
shall
be
stored.Whenever MD is reset the maximum demand

value so registered shall be storedalong with date and
time. Under the current integration period, the rising
demandshould be displayed continuously along with the
elapsed time. The registereddemand and the number of
times the MD is reset up to 10 shall be stored in
thememory.
4.3.6.30
MD Reset
The meter shall have the following provisions regarding

MD reset.
a)
Manually by operation of a button, which is to be
976 of 2461
PAGE 101 of 339
MMRDA
covered and sealingprovision available for such,

cover.
b)
Resetting shall also be possible through a hand

held common meterreading instrument (CMRI),
Widows based Laptop capable ofcommunicating
with the meter.
c)
Provision for automatic resetting at the end of

certain period may bemade available and it should
be possible to invoke this through CMRI,Widows
based Laptop with date and time.
Time Of Day Tariff (TOD)/Time of Use(TOU):
The meter shall contain provisions for differential pricing

of energy and/ormaximum demand. The meter shall be
capable of being set in to minimum of6 time zones (00:00
to 06:00 Hrs, 06:00 to 10:00 Hrs, 10:00 to 14:00 Hrs,
14:00 to18:00 Hrs, 18:00 to 22:00 Hrs, 22:00 to 24:00
Hrs) optionally more time zones canbe offered).The entire
hours of one day or seven days of one week or 365days
of one year shall be grouped in specific time slots, each
slot beingassociated with specific metered register(s).
The meter shall have a real timeclock based on a quartz
crystal with a battery totally independent of powersupply.
It should be possible to change the time period for the

TOD
recordingthrough
CMRI,
Laptop/remote
communication using a proper securitysystem. Meter

shall be capable to log such changes with date and
timestamping. The main control for this change shall be
available in the basecomputer system.
4.3.6.31
Communication Capability
977 of 2461
PAGE 102 of 339
MMRDA
The meter may be provided with two ports for communication of

themeasured / collected data, i.e. hardware ports. The meter
shall have agalvanically isolated optical communication port as
per IEC 1107/ANSI andadditional communication port RS
232/RS 485 should be provided for remotemeter reading
purpose
with
open
standard
protocols.
Both
the
ports
shallcommunicate simultaneously. Both the ports shall be of

universal typeconforming to relevant standard so that these can
be easily connected to aDCD, CMRI, MODEM (e.g. GSM,
GPRS, CDMA, PLCC, Microwave, Radio, VSAT,Leased Line,
PSTN, VPN, Ethernet etc.), Laptop, PC, GPS Time device for
datacommunication/ time synchronization etc. The ports shall be
integral part ofbody and sealable. All of the parameters available
in the register of the metershall be user selectable through
CMRI and also with laptop.
The manufacturer shall supply the meter compatible software,

Protocolsoftware required for Windows based Laptop, CMRI,
Base Computer, RMR. It isthe responsibility of the meter
manufacturer to provide the required softwareand all the
facilities required by the APTRANSCO to use the Windows
basedLaptop, DOS based hand held CMRI for reading and
retrieving the data from the meter or to retrieve the available
data through P&T lines, GSM, VSAT tothe central computer
station and regenerating appropriate reports requiredby the
APTRANSCO. After loading the software in the purchasers
basecomputer station/ central computer station, the meter
manufacturer shalldemonstrate the data transfer through hand
held CMRI, Windows basedLaptop, P & T lines, GSM, VSAT
and regeneration of appropriate reports to thepurchaser.
The data element size and its over head speed of transmission
shall be suchthat the entire billing data can be transferred within
maximum time of 5minutes. The baud rate preferable is 9600. It
978 of 2461
PAGE 103 of 339
MMRDA
should not possible to change software configuration and

recorded dataedit in the meter by any means except for
programmable parametersagreed.
The successful bidder need to supply required APIs to read
meters datathough GSM/GRPS to AMR project implementers to
collect the online MRI dataof all boundary meters.
a)
Communication cable
The Energy meter communication cable of 1500mm

length for communicatingwith Energy meter and Windows
based Laptop (Optical to USB). The cableshould be
flexible shielded and the two ends of the cable shall be
stressrelieved.
b)
Tamper Events Records
The following shall be captured when event occurrence

and
restoration
andfor
each
of
event
captured
Cumulative tamper count value shall beincremented.
Tamper Information: Minimum 100 events (occurrences

and restoration) with dateand time of event shall be
recorded. The Information shall be logged on first in
firstout basis and total number of tamper events during
the period. All these informationshould be available in
simple and easily understandable format i.e. slot wise
(i)Voltage tampers (ii)Current tampers (iii)Other tampers.
Events
1.
Description
R-Phase PT link Missing (Missing Potential)

Occurrence
2.
R-Phase PT link Missing (Missing Potential)

Restoration
979 of 2461
PAGE 104 of 339
3.
MMRDA
Y-Phase PT link Missing (Missing Potential)

Occurrence
4.
Y-Phase PT link Missing (Missing Potential)

Restoration
5.
B-Phase PT link Missing (Missing Potential)

Occurrence
6.
B-Phase PT link Missing (Missing Potential)

Restoration
7.
Phase R CT reverse Occurrence
8.
Phase R CT reverse Restoration
9.
Phase Y CT reverse Occurrence
10.
Phase Y CT reverse Restoration
11.
Phase B CT reverse Occurrence
12.
Phase B CT reverse Restoration
13.
Phase R CT Open - Occurrence
14.
Phase R CT Open - Restoration
15.
Phase Y CT Open - Occurrence
16.
Phase Y CT Open - Restoration
17.
Phase B CT Open - Occurrence
18.
Phase B CT Open - Restoration
19.
Influence of AC / DC or permanent magnet Occurrence
20.
Influence of AC / DC or permanent magnet Restoration
c)
21.
Power failure Occurrence
22.
Power failure Restoration
Self Diagnostics Features
The meters shall have indications for unsatisfactory/nonfunctioning of the following.
1.
Time and calendar
2.
Real Time clock(RTC)
3.
RTC battery
980 of 2461
PAGE 105 of 339
d)
MMRDA
4.
Non-Volatile Memory
5.
All display segments
Pulse Outputs
The meter shall have a test output (pulses) accessible

from the front and becapable of being monitored with
suitable testing equipment. The operationindictor must be
visible from the front. The resolution of the test output
shall besufficient to conduct satisfactorily accuracy test at
the lowest load in less than 5minutes and starting current
test in less than 10 minutes. Test outputs are required for
both kwh, and kvarh.
e)
Calendar
30-year calendar with automatic leap year adjustment
4.3.6.32
Tests
Type tests:
Two copies of Type test reports shall be furnished with

the Bid for metersmanufactured with same voltage and
current reference of thisspecification. The type tests must
have been conducted not earlier than 2years from the
date of opening of the Bid. The Bids received without
typetests reports will be treated as non-responsive.
Acceptance and Routine Tests:
a)
Acceptance Tests
The acceptance tests as stipulated in IS 14697 shall be carried

out by thesupplier in the presence of purchasers representative.
981 of 2461
PAGE 106 of 339
MMRDA
No of samplesand criteria for conformity from each lot offered for

inspection is also asper IS14697.
ACCEPTANCE TESTS FOR CONFIRMATION OF ABT FEATURE:
1.
15 minutes block average frequency registration.
2.
15 minutes block net active power registration.
3.
Net kVArh High registration in all four quadrants when voltage is

above 103% ofVREF.
4.
Net kVArh registration in all four quadrants when voltage is at

VREF.
5.
Net kVArh Low registration in all four quadrants when voltage is

97% of VREF.
6.
Net kVArh Low registration in all four quadrants when voltage

isbelow 97% of VREF.
7.
Test for confirmation of midnight energy banking in power ON &

power OFFconditions.
b)
Routine Tests
The routine tests as stipulated in IS 14697 shall be carried out

by the supplierfor 100% meters supplied and test certificates,
technical leaflet shall beenclosed along with each and every
meter.
c)
Inspection
The inspection may be carried out by the purchaser at any stage

ofmanufacture. The manufacturer shall grant free access to the
982 of 2461
PAGE 107 of 339
MMRDA
purchasersrepresentative at a reasonable time when the work is

in progress. Inspectionand acceptance of any equipment under
this specification by thepurchaser, shall not relieve the supplier
of his obligation of furnishing theequipment in accordance with
the specification and shall not preventsubsequent rejection if the
equipment is found to be defective.
The supplier shall keep the purchaser informed in advance,

about themanufacturing program so that arrangement can be
made for inspection.
The purchaser reserves the right to insist for witnessing the

routine testing ofthe bought out items. The supplier shall give 15
days for local supply/30 days(in case of foreign supply) advance
intimation to enable the purchaser todepute his representative
for witnessing the acceptance and routine tests.
In the event of order, Supplier shall have to get type tests

conducted as per therequirement of relevant standards on one
sample Energy meter against eachlot quoted without any
additional cost to APTRANSCO at CPRI/NABL. TheEnergy
meter to be type tested is selected at random by inspecting
officer 1No. for each Lot. Type testing is to be conducted even if
the bidder submitsType test reports of similar equipment done
earlier along with bid.Material shall be despatched only after
approval of these test reports andgranting of despatch
clearance. After completion of Type testing andacceptance by
MAHA Transco, payment for the delivered consignment
againstdespatch instructions of the Lot will be made.
As described above, the bidder shall offer one additional Energy

meter foreach lot free of cost. Out of which One No. Energy
meter will be randomlyselected to arrange Type testing at the
Suppliers cost.
983 of 2461
PAGE 108 of 339
4.3.6.33
MMRDA
Training of Personnel
The Supplier shall provide necessary facilities for training

of personnel ofpurchaser at their works/Principal Works
relating to design, manufacture,assembly, testing and
operation
&
maintenance
of
static
meters
for
personnelfree of cost including boarding and lodging.

However travel and incidentalcharges of the personnel
will be borne by the Purchaser.
4.3.6.34
Documentation
All drawings shall conform to International Standards

Organization (ISO) Àseries of drawing sheet India
Standards Specifications IS: 656. All drawings shallbe in
ink and suitable for micro filming. All dimensions and data
shall be in S.I.Units. Also a soft copy of Drawings shall be
submitted.
List of drawings and documents:
The bidder shall furnish the following along with bid.
u.
Two sets of drawings showing clearly the general arrangements,

fitting details,electrical connections etc.,
ii.
10 sets of Technical leaflets (users manual) giving operating

instructions.
The manufacturing of the equipment shall be strictly in

accordance with theapproved drawings and no deviation shall
be permitted without the writtenapproval of the purchaser. All
manufacturing and fabrication work inconnection with the
equipment prior to the approval of the drawing shall be atthe
suppliers risk.
984 of 2461
PAGE 109 of 339
MMRDA
Approval of drawings/work by purchaser shall not relieve the

supplier of hisresponsibility and liability for ensuring correctness
and correct interpretation ofthe Drawings for meeting the
requirements of the latest revision of applicationstandards, rules
and codes of practices. The equipment shall conform in
allrespects
to
high
standards
of
engineering,
design,
workmanship and latestrevisions of relevant standards at the

time of ordering and purchaser shall havethe power to reject any
work or materials which, in his judgment is not in fullaccordance
therewith.
The successful bidder shall, within 2 weeks of placement of

order, submit threesets of final versions of all the drawings as
stipulated in the purchase order forpurchasers approval. The
purchaser shall communicate his comments/approvalon the
drawings to the supplier within two weeks. The supplier shall, if
necessary,modify the drawings and resubmit three copies of the
modified drawings for theirapproval. The supplier shall within
two weeks of intimation of approval submit 10prints and two
good
quality
report
copies
of
the
approved
drawings
forpurchasers use.
4.3.6.35
Packing &Forwarding
The equipment shall be packed in crates suitable for

vertical/horizontal transportas the case may be, and
suitable
to
withstand
handling
during
transport
andoutdoor storage during transit. The supplier shall be

responsible for anydamage to the equipment during
transit, due to improper and inadequatepacking. The
easily damageable material shall be carefully packed
andmarked
with
the
appropriate
caution
symbol.
Wherever necessary, properarrangement for lifting, such

as lifting hooks etc., shall be provided. Anymaterial found
985 of 2461
PAGE 110 of 339
MMRDA
short inside the packing cases shall be supplied

immediately bysupplier without any extra cost.
Each consignment shall be accompanied with a detailed

packing listcontaining the following information.
a.
Name of the consignee
b.
Details of consignment
c.
Destination
d.
Total weight of consignment
e.
Handling and packing instructions
f.
Bill of material indicating contents of each package
The contractor shall ensure that the packing list and bill of
material areapproved by the purchaser before dispatch.
The packing shall be done as per the manufacturers
standard practice.
However, he should ensure the packing is such that, the

material should notget damaged during transit by
Rail/Road.
The marking on each package shall be as per the

relevant Standards andshall also contain MSETCL, P.O.
ref, name of the supplier, make, metertype and number.
SUPERVISION SERVICES: NIL
The Manufacturer shall arrange for unloading of the

consignments.
MANDATORY SPARES & TOOLS:
The bidder shall give the list of spares required for the
986 of 2461
PAGE 111 of 339
MMRDA
equipment along withprice list for them & shall keep a

reasonable stock of the same during the warrantyperiod.
The bidder shall indicate the sources of spares like
battery, interfacing cablesin India and also mention the
service agencies.
4.3.6.36
Guarantee
The meters should be guaranteed for satisfactory

operation for a period of 5 yearsfrom the date of receipt of
material at destination stores by the consignee in
goodcondition. During the guarantee period if the meter
while in its normal operation isfound defective, it shall be
replaced by the supplier with a new meter free of costwith
in 15 days. if the meter is not replaced within 30 days of
intimation the suppliershould note that the guarantee
period will be extended to that extent by thenumber of
days delayed beyond 30 days. If the tenderer does not
replace within180 days the cost of the meter(s) will be
recovered from the existing bills / future bills/ Bank
Guarantees available with the MSETCL.
For the purpose of ensuring 5 years guarantee, meter

may
be
sealed
atmanufacturers
premises
after
inspection by the MSETCL representative anddispatched

in sealed condition.
Other information:
a.
Principle of operation of the meter, outlining the

methods and stages ofcomputation of various
parameters
starting
from
input
voltage
and
currentsignals including the sampling rate if

applicable shall be furnished by thebidder.
987 of 2461
PAGE 112 of 339
b.
MMRDA
The bidder shall indicate the method adopted to

transform the voltage andcurrent to the desired low
values with explanation on devices used such
asCT, VT or Potential divider as to how they can
be considered superior inmaintaining ratio and
phase angle for variation of influence quantities
duringits service period.
c.
The bidder shall furnish details of memory used in

the meter.
d.
Details of testing facilities:
The
manufacturer
laboratory
must
be
well
equipped for testing of the meters.They must have

computerized
standard
power
source
and
standardequipment calibrated not later than a year

(or as per standard practice). Thedetails of testing
facilities available for conducting (a) The routine
tests and (b)Acceptance tests shall be furnished in
a statement. Bids without these detailswill be
treated as Non responsive.
SCHEDULES:
The Bidder shall submit the following schedules

(as per Standard Format),which is part and parcel
of the Specification.
1.
Schedule - A : Guaranteed Technical

Particulars
2.
Schedule-B:
Specific
confirmation
to
clauses given in the technical specification
988 of 2461
PAGE 113 of 339
MMRDA
SCHEDULE A
GUARANTEED TECHNICAL PARTICULARS FOR

HT ELECTRONIC TRIVECTOR METER suitable for ABT
S.
Description
Required in Specification
No.
To
befilledby
theBidder
Name of the Manufacturer
To be filled by the Bidder
andOrigin
2
Type of meter/model
3phase,4wire
Accuracy class
0.2S
Meter case
polycarbonate
Battery life for clock
Parameters in meters
a) Instantaneous parameters
As per clause 5.8
b) Load profile
As per clause 5.9
c) Billing parameters
As per clause 5.10
P.F. Range
0 Lag-unity- 0 Lead
Basic Current (Ib)
1A
Maximum Current
> 120% of Ib
10
Minimum starting current
0.1% of Ib
11
Rated Voltage
Ph-N : 110/3 V Phase to Phase

110 V
12
Variation of voltage atwhich - 30% to + 20% of Vref

meter functions normally
13
Reference
Frequency
and 50Hz,+/- 5%
range
14
Power
Loss
&Currentcircuits
in
Voltage Voltage Circuit - Less than 1 W

and 4 VA perphase Current
Circuit - Less than 1VA perphase
15
Dynamic range
989 of 2461
PAGE 114 of 339
S.
MMRDA
Description
No.
To
befilledby
theBidder
16
MD reset Provisions
a) Manually
b) Through authenticated CMRI

or
remotecommunication
command
c) Automatic resetting at present

date & time
17
No.
of
digits
of
display Liquid Crystal Display (LCD) with
andheight of character
backlit
Character height and number of
characters tomentioned
18
Non-volatile
memory 45 days
storagecapacity
19
Principle of operation
20
MD Integration
15 Minutes/30minutes
period(Programmable)
21
Weight of meter
22
Dimensions
23
Warranty
5 years from dateof supply in the

stores
24
Outline drawings & Leaflets
25
a)
Remote
meter-readout RS232/RS485
facility
b)
Communication
protocol Open protocol
used
c) Sealing provision
As per clause 5.5
d) Baud rate of data Transfer Preferable 9600

frommeter to CMRI/RMR
990 of 2461
PAGE 115 of 339
S.
MMRDA
Description
To
No.
befilledby
theBidder
e) Manufacturers Seal
26
Shall be provided
Base Computer Software works To be filled by the Bidder

onwhich operating system
27
Type Test Certificates
28
Time
of
To be furnished by the Bidder
Day
Zones Minimum of 6 time zones (00:00
(programmable)
to 06:00Hrs, 06:00 to 10:00 Hrs,

10:00 to 14:00 Hrs,14:00 to 18:00
Hrs, 18:00 to 22:00 Hrs,22:00 to
24:00 Hrs)
29
Whether meter measuresboth Fundamental

fundamental &Harmonic Energy (energy
to
energy
required
recordingcorresponding
50hz
duly
filtering
outHarmonics)
30
Real Time Clock Accuracy
+/- 2min for per annum
31
Anti-Tamper Features
As per clause 5.17
32
Data
retention
withoutbattery
by
backup
NVM Life time of the meter

and
unpowered
Condition
33
Self Diagnostic Feature
As per clause 5.18
34
Programmable Parameters
As per clause 5.11
35
Name plate details
As per clause 5.12
4.3.7 Power transformers
4.3.7.1
Scope
This specification
manufacture,
covers the
assembly,
design, construction,
testing
of
performanceof
transformers packing, supply delivery & commissioning of

132 kV class power Transformerscomplete with all
fittings, accessories and associated equipments which
991 of 2461
PAGE 116 of 339
MMRDA
are required for efficient& trouble free operation.
4.3.7.2
Standards
Unless otherwise specified equipment shall conform to

the following latest applicable Standards
IS Codes
Description
IS 2026 Part I
Specification of Power Transformers
IS 2026 Part
Temperature Rise
2
IS 2026 Part
Insulation levels and Dielectric Tests
3
IS 2026 Part
Terminal Markings, Tapping and connections
4
IS 2026 Part
Transformer / Reactor Bushings - Minimum External
clearance in AirSpecification
IS 6600
Guide for Loading of Oil Immersed Transformer
IS 335
Specification for New Insulating Oil for Transformers

and Switchgears
IS 3639
Specification for Fittings and Accessories for Power

Transformers
IS 2099
Bushings for alternating voltages above 1000 Volts
IS 3637
Specification for gas operated relays
IS 1666
Copper conductors for transformer Windings
IS 3347
Dimensions for Porcelain and transformer bushing
IS 1271
Thermal evaluation and classification of electrical

insulation
IS 2026 Part I
Specification of Power Transformers
IS 2026 Part
Temperature Rise
2
IS 2026 Part
Insulation levels and Dielectric Tests
992 of 2461
PAGE 117 of 339
4.3.7.3
Service condition
i)
S. No.
MMRDA
Climatic condition
Parameters
Maximum Altitude above sea level less than 1000M
Service conditions
a)
Maximum ambient air temperature (C) 50
b)
Average daily air temperature.(C) 35
c)
Maximum yearly air temperature(C) 50
d)
Minimum ambient air temperature (C) -5
Maximum relative humidity (%) 95
Average annual rainfall (mm) 1000
Maximum wind pressure kg/m2 150
Seismic level (Horizontal acceleration) 0.3 g

(i)
Auxiliary Power supply
Auxiliary electrical equipments shall be suitable for

operation on the following supplysystem.
b.
Power Devices
415V, 3 Phase; four wire 50 Hz, neutral grounded AC

supply
c.
240V, single phase, 2 wire 50 Hz, AC supply
Alarm, Control 220 / 110 DC supply
Protective device
Variation in AC supply Voltage: 10 %
Frequency: 5 %
993 of 2461
PAGE 118 of 339
4.3.7.4
MMRDA
Variation in DC supply voltage: -15 % to + 10 %
General Technical requirement
The transformer and OLTC should be suitable for

unidirectional flow of rated power HVto LV.
The transformers and all its accessories shall be

designed to withstand without injury thethermal &
mechanical effects of any external short circuit to earth &
of short circuits at theterminals. The short circuit duration
for conforming thermal limit shall be three seconds.
Theshort circuit apparent power of the HV System to
which the HV of transformer will beconnected is 40 kA.
The thermal ability to withstand short circuit for duration
of 3 secondsshall be demonstrated by calculation. The
calculation of dynamic ability to withstand shortcircuit
shall also be submitted after award of work.
The Transformer shall be capable of being operated

without danger on any tapping, at therated MVA, with
voltage variation of 10% corresponding to the assigned
voltage of tapping.
The transformer shall be of oil and natural cooling.
Transformer shall be capable of withstanding thermal &

mechanical stress caused by
Symmetrical and asymmetrical faults due to external
short circuits, on any winding.
All materials used shall be new and is of best quality & of

the best class, most suitable forworking under the
conditions specified and shall withstand variation of
temperature &atmospheric condition without distortion or
994 of 2461
PAGE 119 of 339
MMRDA
deterioration, or setting up of undue stress in anypart and

also, without affecting the strength and stability of the
various parts for the work whichthey have to perform.
Exposed parts shall not leave pockets where water can

collect.
Internal design of the transformer shall ensure that air is

not trapped in any location.
Materials in contact with oil shall be such as not to

contribute to the formation of acid in oil.
Surface in oil shall not be galvanised or cadmium plated.
Labels indelibly marked shall be provided for identifiable

accessories / parts.
Centre line of transformer shall be marked on top plate.
The GM valves shall conform to IS: 778.
i)
Transformer Losses
The transformers No Load Losses, No load

Current and full load losses shall be specified and
guaranteed
The above losses shall bemaximum, without any

positive tolerance.
The measurement of losses shall be carried out

with 3 (Three) Watt meter method only andCTs,
PTs and meters used for these measurements
shall be of class of accuracy of 0.2.
995 of 2461
PAGE 120 of 339
ii)
MMRDA
Construction details
The feature & construction details of power

transformer
shall
be
in
accordance
with
therequirement stated hereunder.
2.
Transformer Tank
The tanks shall be made from good commercial grade steel &
shall be of weldedconstruction. The structural steel material
used for fabrication of tank shall be as per IS: 2026 (latest
edition). All joints shall be hot oil tight & no bulging shall take
place while inservice. All the oil tight joints shall be made with
suitable flanges, treated cork or otherapproved type of packing.
The tanks shall be so designed that the core and winding can
belifted freely from the case with as little dismantling as
possible.
Suitable guide may, also, be provided for positioning of cores.

External lugs or eyes for liftingthe core with windings, as also,
the complete transformer with oil shall be fitted with asubstantial
under carriage and mounted on four bi- directional flanged,
wheels for rail trackgauge of 1436 mm. The main tank body
excluding tap changer compartment and radiatorsshall be
capable of withstanding vacuum of 500mm of hg. The tank shall
be
designed
towithstand
mechanical
shock
during
transportation, vacuum filling of oil. It shall also with standthe

pressure for one hour corresponding to twice the normal head of
oil or to the normal.
Pressure plus 35KN/m2 (5 Lbs/Inch2) whichever is lower,

measured at the base of thetank.
Dimensions of turret for provision of bushing shall be such that

996 of 2461
PAGE 121 of 339
MMRDA
requiredclearances are maintained and there will not be any

discharge or high field stressdeveloped.
3.
Axle & Wheels
a.
The transformer shall be provided with flanged bidirectional wheels & axle.
b.
These shall be designed not to deflect excessively to

interfere with the movementof the transformer.
c.
The wheels are required to swivel and they shall be

arranged so that they can be turnedthrough 900, when
the tank is jacked up to clear of rail, Means shall, also,
beprovided for locking the swivel movements in positions
parallel & right angle to thelongitudinal axis of tank. The
anti-earth
quake
clamps
should
be
provided
for
protectionagainst earth quake.
d.
The rail track gauge shall be 1436mm along longer axis

as well as shorter axis.
4.
Core
The transformer shall be of three legged core type with inter

leafed /step lap, core joints. On no account, interleaved step
down butt joints shall be offered. The core shall be bolt less
&built of non-ageing prime grade CRGO laminations having high
permeability and lowhysteresis loss and with hot oil proof
insulation. The core material shall be prime CRGO,shall be
procured directly from manufacturer or through accredited
marketing organization ofreputation. It shall be properly clamped
together to the frame & bonded by application ofaraldite tightly
to prevent undue vibration or noise. The complete design of the
core mustensure permanency of the core losses with continuous
997 of 2461
PAGE 122 of 339
MMRDA
working of the transformer.
The thickness of lamination shall be 0.27 mm or less. Surface

insulation of laminations shallbe rust resistant and have high
interred laminar resistance. Insulation shall withstand annealing
temperature as high as 850 C. Insulation shall be resistant to
hot cooling medium.
Laminations are not to be punched.
Contractor should have in house core cutting facility for proper

monitoring & control on quality& also to avoid any possibility of
mixing of prime material with defective/second grade material.
This should be indicated invariably in the QAP. The Owner may

witness the core-cuttingprocess. In case the in-house core
cutting facility is not available, then the same shall becarried out
in the presence of the representative of Owner.
Contractor will offer the core for stage inspection and get
approval
from
Owner
duringmanufacturing
stage.
The
Contractor has to produce following documents at the time of

stageinspection for confirmation of use of prime core materials.
i.
Invoice of supplier
ii.
Mills approved test certificates
iii.
Packing list
iv.
Bill of lading
v.
Bill of entry certificate by custom.

To avoid any possibility of mixing of Prime material with
998 of 2461
PAGE 123 of 339
MMRDA
any other second grade/ defectivematerial, the imported

packed slit coils of CRGO materials shall be opened in
the presence ofthe Owners representative. Only after the
inspection and approval from Owner, the corematerial will
be cut in-house OR sent to external agency for cutting
individual laminations. Incase the core is sent to external
agency for cutting, the Owners representative will have
fullaccess to visit such agency for the inspection of the
cutting of core.
After having sheared, the laminations shall be treated to

remove all burrs and shall be re-annealed in a nonoxidizing atmosphere to remove all residual stresses and
restore theoriginal magnetic properties of CRGO sheets.
The insulation of the lamination shall be inert tothe action
of hot transformer oil. Paper and varnish insulation will is
not accepted.
The core shall be rigidly clamped to ensure adequate

mechanical strength and to preventvibration during
operation. The clamping structure shall be so constructed
that eddy currentswill be minimum. The insulation of bolt
less core to clamp plates shall be such as to with
stand2000 V A.C. for one minute.
The design of magnetic circuit shall be such as to avoid

static discharges, development ofshort circuit paths within
itself or to the earthed clamping structure and production
of fluxcomponents at right angles to the plane of the
laminations which may cause local heating.
The core shall be provided with lugs suitable for lifting the
complete core and coil assembly ofthe transformer.
The core and the coil assembly shall be so fixed in the

999 of 2461
PAGE 124 of 339
MMRDA
tank that shifting will not occur andcause any damage

when the transformer is moved shifted, or during a short
circuit.
The core shall not be earthed at multiple locations.

Terminal shall be brought on top oftank and earthed
through link. Core and Frame terminals should be
brought out ontransformer top so as to enable megger.
5.
Winding
The winding shall be of electrolytic grade copper conductors.

The arrangement of windingsmust be such that there is good
electrical and magnetic balance under all loading & shortcircuit
conditions. Oil ducts shall be provided to ensure uniform
temperature gradients andabsence of hot spots. All similar coils
shall be interchangeable.
It is essential that the windings shall be subjected to thorough

shrinking &seasoning process, so that no further shrinkage of
winding occurs, even during service. However adjustable
devices shall be provided for taking up any possible shrinkage of
coils, while in-service. The general design and construction of
the transformer and the bracing of the windings shall be such
that no mechanical movement of the coils is possible with dead
short circuit on either side.
The insulation paper shall be of high quality and the value of

degree of polymerization shall not be less than 1100 Pv and the
necessary test certificate shall be submitted along with the stage
inspection report. Provision shall be made for taking sample of
paper for testing purpose and location shall be easily accessible
and indicated on the transformer tank by affixing special caution
plate.
1000 of 2461
PAGE 125 of 339
MMRDA
The material used in the insulation and assembly windings shall

be insoluble, non- crystallite and chemically inactive in the hot
transformer oil and shall not soften or otherwise, be affected
under the operating conditions.
Transformers shall be capable of withstanding dynamic &

thermal forces, due to three phase symmetrical faults at the
terminals, without considering any system impedance. The short
circuit duration for conformity of thermal limit shall be three
seconds. Current density of windings shall be stated. The
calculations of Thermal stability and dynamic ability to withstand
short circuit shall also be submitted after award of work. Ampere
turns shall be balanced at various heights of windings for HV, LV
and tapping winding. Contractor shall justify for the same by
submitting details.
Special attention shall be given for the provision of adequate

insulation and clearance between& LV windings. All clearance of
widening & other live parts must be adequate, for the maximum
voltage of operation, plus 10 %. The minimum required
clearance of windings in oil shall be stated.
The HV winding shall be interleaved / disc type. Disc winding

shall be with the static end rings at both ends. The winding shall
be suitable for chopped wave & full wave impulse voltage. The
wave shape of the impulse voltage shall be in accordance with
IS 2026 (Part III) & relevantIEC standard for high voltage Tests.
LV winding shall be continuous disc type / Layer type.
The impulse strength of HV and LV winding for 1.2 / 50 micro

sec., wave Full description of thewindings for the transformer,
offered, shall be furnished in datasheet.
Contractor shall indicate in the DATASHEET, the cross sectional

area of all windings withrespect to the current density adopted.
1001 of 2461
PAGE 126 of 339
MMRDA
All threaded connections shall be provided with locking facilities.

All leads from the windingshall be duly brazed for proper contact
to the terminal board and bushings shall be rigidlysupported to
prevent injury from vibration.
The guaranteed minimum IR value should be indicated in

DATASHEET. The measured IRvalue with 5 kV motorized
megger during acceptance test shall not be less than
guaranteedminimum value.
6.
Fittings & Accessories
a.
Standard fitting as described in IS: 2026 (latest issue)

and stated below shall beprovided for each transformer.
b.
Main conservator shall have air cell type constant oil

preservation
system
to
preventoxidation
and
contamination of oil due to contact with moisture.

Conservator for main tankshall fitted with oil filling flange
& cap, isolating valve, drain valve, 150mm magnetic oil
levelgauge with low level alarm potential free contacts.
Conservator shall be at right angle to theaxis of HV
bushing. The conservator shall be provided with separate
compartment forOLTC. No separate conservator tank
shall be provided for OLTC.
c.
Prismatic oil level gauge shall, also, be provided on

conservator tank. The backgroundshall be so painted that
the oil level can be seen from ground level also. The
threepositions of oil level shall be indicated viz.
Minimum
Normal
1002 of 2461
PAGE 127 of 339
d.
MMRDA
Maximum
Silica gel dehydrating breather of acrylic seamless body

with clear view design. Thecapacity of breather for main
conservator
tank
should
be
such
that
it
can
containminimum 5 kgs. Silica gel and minimum 1 kg. for

OLTC conservator compartment. TheGI pipe connecting
breather with conservator should be seam less and no
joint ispermitted. It will be located below conservator tank
opposite to HV side of transformer.
e.
Pressure Relief valves should be provided one each for

main tank and OLTC ofminimum size of T6 and T3
respectively. Necessary pressure operation test will have
toshow during acceptance testing of transformer. It shall
operate before reaching the testpressure specified in
transformer tank pressure test. The operating pressure
shall berecorded. The device shall seal off after excess
pressure has been released. Theterminal box of PRV
should conform to degree of protection as per IP 55 of
IS: 13947.
f.
One drain valve (gate) of 75mm diameter, with flange.

Two Nos. Oil sampling valves, of25mm size-each at top &
bottom of main tank with the provision for fixing PVC
pipe. Allthe necessary flanges with adopter suitable to
connect piping for oil tanking and filtrationprocess.
Necessary guiding cover must be provided to these
valves.
g.
Two Nos. Oil filter valves (gate) of 50mm size, on

diagonally opposite corners of thetransformer tank with
flange and adopter for connection of (30mm) hose pipe
for filtrationof oil.
1003 of 2461
PAGE 128 of 339
h.
MMRDA
Rating and diagram plate of Brass / stainless steel with

details engraved.
i.
Jacking lugs.
j.
Minimum Two Nos. of inspection covers on tank cover.

No inspection cover shall beprovided on any of the sides,
of transformer.
k.
Four nos. of earthing pads each with four nos. of tapped

holes (M 12 Bolts,) with M12bolts, plain & spring washers
suitable for connection of 50 x 6 mm GS earthingflats.
Theseearthing pads should be provided one each on
each side of transformer at centre.
l.
All the gaskets to be provided shall be of RC70C or

RC80C grade. It shall not be olderthan one year.
Necessary tests certificates from manufacturer shall be
submitted alongwith acceptance test report. Flat gasket
material will be SRBC (Synthetic rubber bondedcork) with
minimum joints. When chords are used it shall be
provided in fabricatedgroove. It shall be of Nitrile rubber.
In fabricated groove the inner strip shall be weldedfor its
full length.
m.
Four nos. of anti-earth quake clamps should be provided

along with the required sizedfoundation bolts.
n.
HV and LV terminal connectors shall be supplied along

with the transformer
o.
150mm dial temperature indicator of mercury switch

contacts
with
pointer
reading
Maximum',
suitable
resetting device, set of electrical contacts for 'alarm' and

1004 of 2461
PAGE 129 of 339
MMRDA
'trip' alongwith necessary length of capillary tubing to be

provided one each for Oil &Winding temperature
monitoring. The contact rating shall be at least 2 Amp
continuous at 250 VAC or DC. The range shall be from
0C to 150C.
p.
Double float buchholz relay with 'alarm' & 'trip' contacts.

The oil connection from transformer tank to conservator
vessel shall be arranged at rising angle of 6 to 9degrees
to horizontal up to the Buchholz relay and shall consist of
suitable pipe of inside diameter (heavy gauge) as per IS:
3639.
q.
Marshalling Box, housing the temperature indicators and

auxiliary contacts.
r.
Air release plugs
s.
Detachable pressed steel radiators shall be provided with

two butterfly valves, one for inlet& the other for outlet
connection. The nos. of radiator to be provided shall be
arrived from the cooling calculation submitted after award
of work.
t.
Two isolating GM valves of 50mm dia shall be provided

for Buchholz relay on either side.
u.
Skids.
v.
Additional thermometer pockets to be provided other than

for Oil and winding temperature measurement. The
capillary so provided for both pockets shall be only
ofBrass and having same diameter and threads suitable
to interchange.
1005 of 2461
PAGE 130 of 339
w.
MMRDA
Flanged bi-directional rollers suitable for 1436mm rail

track gauge with anti-earth quake clamps.
x.
Terminal marking plates of Brass/ Stainless steel should

be provided and it should be legible from ground level
also.
y.
Lifting lugs.
z.
Oil surge relay with trip contacts for OLTC, with 25mm
GM gate valve on either side should be provided.
aa.
Bushing with metal parts & gaskets as specified
bb.
Neutral earthing GI bar of size 50 x 6 mm thick along with

22 kV class Epoxy support insulators shall be provided.
7.
Cooling Arrangement
All the transformers covered by this specification shall have

'ONAN' cooling. The cooling shall be effected by pressed steel
radiators conforming to IEEMA. The radiators fins provided shall
have sufficient surface to limit temperature rise. The tubes shall
be so arranged as to admit scrubbing without trouble when
necessary. It will be so designed that any scale forming inside
will flake off and pass to the bottom of the tank by gravity. Oil
leak proof butterfly valves (positive operated) shall be provided
to facilitate taking out any of the radiators without disturbing the
transformer. Necessary gaskets in required nos. for fixing
radiators and butterfly valve operating keys shall be provided.
The space between the bottom of tank and mounting rail shall
be maintained to minimum of 350 mm, for free air circulation.
8.
Oil
1006 of 2461
PAGE 131 of 339
MMRDA
The insulating oil for transformer shall, generally conform to IS:

335 (latestedition).Sufficient quantity of oil for the first filling of
complete transformer (withaccessories) plus 10% extra oil shall
be supplied by the vendor in non-returnable 210 litrecapacity
drums. The quantity of oil for transformer (including accessories)
and OLTC shouldbe indicated separately in the rating plate.
9.
Terminal Arrangement
a.
Bushing
The electrical & mechanical characteristic of

bushing shall be in accordance with IS: 2099 &(IS
3347 (Part III / Section I respectively, and
bushings shall be suitable for heavilypolluted
atmosphere
145 kV bushing shall be oil filled condenser type &

hermetically sealed. 24 kV bushing tobe used for
LV side shall be solid porcelain
Condenser type bushing shall be provided with Oil

level glass
Tap for capacitance / tan delta test
Bushing
of
identical
ratings
shall
be
interchangeable
Porcelain used in the manufacture shall be

homogeneous, free from lamination,cavities &
other flows or imperfection that might effect the
mechanical or dielectric qualityand
shall be
thoroughly vitrified tough and impervious to

moisture
1007 of 2461
PAGE 132 of 339
MMRDA
Glaze of porcelain and bushing shall be of uniform

brown colour, free from blisters burrs &other
defects
Clamps & fittings shall be hot dip galvanised steel
For neutral, the bushing of the same rating shall be

used as those to be used for LVterminals
Special Adjustable coordinating gaps shall be

provided
as
per
relevant
IS,
on
all
bushingterminals and the gap setting shall be fixed

with
reference
to
the
impulse
strength
of
thewindings. The contractor shall state the impulse

flash over values of the bushings & thecalibration
with settings for coordinating gap shall be given for
the arrangement of theterminals. All the required
type test reports as per relevant IS stated above
for the bushings tobe used shall be submitted after
award of work. The height of live part shall be so
arrangedthat minimum clearance up to plinth shall
be maintained as follow:
10.
145 kV - 4600 mm, 6.6 kV - 3600 mm
Foundation
The transformers shall be erected on concrete foundations,

which shall be laid by contractor intime to have the foundations
ready before the Transformers arrive at site. The foundation
shallbe of concrete masonry with reinforced steel as per
requirement.
The
OEM/supplier
shallfurnish
complete
information regarding loading and maximum stress in the

foundations etc.and the Contractor will design the foundations
1008 of 2461
PAGE 133 of 339
MMRDA
as per site conditions.
11.
Completeness of contract
All fittings, accessories, or apparatus, which may not have been

specifically mentioned butwhich are useful or necessary for the
efficient working of the transformer shall be deemed tobe
included in the contract and shall be provided by the supplier
without any extra charge. Thetransformer with accessories shall
be complete with all details whether such details are statedin the
specification or not.
12.
Tools
The contractor shall also, quote the prices for one set of special
tools, if any. The Ownerreserves the right to order for any
quantity of tools, as may be deemed fit.
13.
Interchangeability
All similar parts of the various transformers shall be interchangeable as far as possible.
14.
Flexible separator (Air cell)
This section covers the design, manufacture, assembly, testing

at manufacturers works,supply and delivery of the Flexible
Separator (Air cell), complete with all accessoriesrequired for
satisfactory and trouble free operation of the equipment.
a.
Construction
The construction of Flexible Separator (Air cell) shall be

of Polyamide/nylon fabric coated onboth side with
synthetic rubber and meeting the complete requirement
1009 of 2461
PAGE 134 of 339
MMRDA
of this specification.
Adhesives used shall be compatible with air and

transformer oil at 100oC. All the joints shall beproperly
designed
&
suitably
vulcanized.
Further,
Flexible
Separator (Air cell) shall bereinforced at bottom face to

avoid damage due to contact with magnetic oil gauge
float. Thereshall not be any patch work in Flexible
Separator (Air cell). Adaptor used shall be made
fromstructural steel confirming to Fe-410-S to IS: 226.
Adaptor
and
bolts
shall
be
cadmium
platedand
passivated (CD-8 of IS: 1572) or Zinc plated and

passivated. (Fe Zn 12.5 of IS: 1573).
The width of the overlap at the joints shall be such that

there is no possibility of joint openingand leakage.
Minimum width shall be 75 mm.
b.
Functional requirements
The function of Flexible Separator (Air cell) is to line the

inside of the conservator tank intransformer, allowing for
changes in volume, while protecting the oil from any type
ofcontamination or external corrosive agents like ozone,
nitrogen, humidity etc.
Flexible Separator (Air cell) shall be suitable for

continuous use in transformer oil at -20C to100 C.
Inside coating shall be very good enough to resist

weather and ozone.
Outside coating shall be transformer oil resistant.

Compounds used for coating shall notdeteriorate during
service.
1010 of 2461
PAGE 135 of 339
MMRDA
Flexible Separator (Air cell) shall be suitable for inflation

and deflation due to change in oilvolume in the
conservator. Further, Flexible Separator (Air cell) shall be
designed to collapseslowly as oil level rises in the
conservator.
Flexible Separator (Air cell) shall not develop cracks even

at -20oC.
Fixation lugs and adaptor shall be provided on the

Flexible Separator (Air cell).
Flexible
Separator
(Air
cell)
shall
have
excellent
impermeability to oil, gases and water vapor.
Flexible Separator (Air cell) shall have high mechanical

resistance. ix) Flanges provided shallmeet any of our
requirements indicated.
c.
General
The Flexible Separator (Air cell) shall be suitable for

conservator of diameter, length & shapein the datasheet.
The suitability & size of Flexible Separator (Air cell) to be
provided shall besupported by necessary calculation for
given size and shape of conservator.
The Flexible Separator (Air cell) conform to relevant IS or

international standards shall beindicated in the datasheet.
The type tests and routine/acceptance tests shall be
carried outaccordingly and report shall be submitted after
award of work for owners approval.
The work of providing and fixing shall be carried out as

1011 of 2461
PAGE 136 of 339
MMRDA
per availability of shut down ofparticular transformer at

site. Necessary tools tackles, accessories, manpower,
etc. requiredshall be managed by Contractor.
15.
On load tap changing gear
General requirements
The details of the method of diversion of the load current during

tap changing; the mechanical construction of the gear and the
control features for OLTC gear shall be submitted with
thedatasheet. Information regarding the service, experience on
the gear and a list of importantusers shall be furnished. The tap
changer shall change the effective transformation ratiowithout
producing phase displacement.
a.
The current diverting contacts shall be housed in a

separate oil chamber notcommunicating with the oil in
main tank of the transformer.
b.
The contacts shall be accessible for inspection without

lowering oil level in the main tankand the contact tips
shall be replaceable.
c.
The Contractor shall indicate the safeguards in order to

avoid harmful arcing at thecurrent diverting contacts in
the event of operation of the OLTC gear under overloadconditions of the transformer. Necessary tools and
tackles shall be furnished formaintenance of OLTC gear.
d.
The OLTC oil chamber shall have oil filling and drain
plug, oil sampling valve, relief vent and level glass. It shall
also be fitted with oil surge relay; with the trip contacts.
The outletof which shall be connected to a separate
conservator tank.
1012 of 2461
PAGE 137 of 339
e.
MMRDA
The diverter switch or arcing switch shall be so designed

as to ensure that its operationonce commenced shall be
completed
independently of
the
control relays or
switches,failure of auxiliary supplies etc. To meet any

contingency which may result in incompleteoperation of
the diverter switch, adequate means shall be provided to
safeguard thetransformer and its ancillary equipment.
f.
Tap changer shall be so mounted that TOP cover or

transformer can be lifted withoutremoving connections
between windings and tap changer.
g.
Drive mechanism chamber shall be mounted on the tank

in accessible position. It shouldbe adequately ventilated
and provide with anti-condensation metal clad heaters.
Allcontactors, relay coils and other parts shall be
protected
against
corrosion,
deteriorationdue
to
condensation, fungi etc.
h.
The control feature shall provide the following :
i)
Local / remote selector switch mounted in the local

control shall switch control ofOLTC in the following
manner :
When the selector switch is in LOCAL position, it shall be

possible to operate the RAISE /LOWER control switches
specified under sr. NO. (ii) below. Remote control of
RAISE /LOWER functions shall be prevented.
When the selector switch in REMOTE position the local

control cubicle mounted RAISE /LOWER switches
specified under Sr. No (ii) shall be inoperative. Remote
control of theraise lower function shall be possible from
1013 of 2461
PAGE 138 of 339
MMRDA
the control panel.
The LOCAL / REMOTE selector switch shall have at least

two spare contacts per positionwhich are closed in that
position but open in the other position.
ii)
A RAISE / LOWER CONTROL SWITCH shall be

provided in the Local ControlCubicle. The switch shall be
spring loaded to return to the centre 'OFF' position
andshall require movement to the RIGHT to raise the
voltage of the transformer.
Movement to the left shall lower the voltage. This switch

shall be operative onlywhen 'local / remote, selector
switch is in "local" position. As an alternative to theraise /
lower Control switch, push button shall be provided for
the said purpose.
iii)
An OFF-ON tap changer control switch shall be provided

in the OLTC local controlcabinet for transformer. The tap
changer shall be inoperative in the OFF positioning.
Also the OFF-ON switch shall have at least one spare

contact per position which isclosed in that position but
open in the other position.
iv)
Operating mechanism for on load tap changer shall be

designed to go through onestep or tap change per
command. Subsequent tap changes shall be initiated
onlyby a new 'ON' repeat command.
v)
On load tap changer shall be equipped with a time delay

incomplete STEP alarmconsisting of a normally open
contact which closes, if the tap changer fails to makea
complete tap change. The alarm shall not operate for
1014 of 2461
PAGE 139 of 339
MMRDA
momentary loss of auxiliarypower.
i.
Limit switches shall be provided to prevent overrunning of

the mechanism and shall bedirectly connected in the
circuit of the operating motor. In addition, a mechanical
stopshall be provided to prevent over running of the
mechanism under any condition.
j.
Limit switches may be connected in the control circuit of

the
operating
motor
providedthat
mechanical
declutching mechanism is incorporated.
k.
Thermal device or other means shall be provided to

protect the motor and control circuit.
All relays, switches, fuses etc. Shall be mounted in the

drive mechanism chamber andshall be clearly marked for
the purpose of identification.
l.
A permanently legible lubrication chart shall be fitted

within the driving mechanismchamber.
m.
A five digit counter shall be fitted to the tap changing

equipment to indicate the numberof operations
completed.
n.
All relays and operating devices shall operate correctly at

any voltage between the limitsspecified.
o.
It shall not be possible to operate the electric drive when

the manual operatinggear is in use.
p.
It shall not be possible for any two controls to be in

operation at the same time.
1015 of 2461
PAGE 140 of 339
q.
MMRDA
The equipment shall be suitable for supervisory control

and indication with make beforebreak multi-way switch,
having one potential free contact for each tap position.
Thisswitch shall be provided in addition to any other
switch / switch which may be requiredfor remote tap
position.
r.
Operation from the local or remote control switch shall

cause one tap movementonly until position between
successive operations.
s.
All electrical control switches and the local operating gear

shall be clearly labelled in asuitable manner to indicate
the direction of tap changing.
t.
Transfer of source failure of one AC supply shall not

affect tap changing operation.
u.
One number each of Oil Surge Relay and Pressure Relief

Valve should be provided.
16.
Manual control
The cranking device for manual operation of the OLTC gear

shall be removable and shall besuitable for operation by a man
standing on ground level. The mechanism shall be complete
withthe following:
i.
Mechanical tap position indicator which shall be clearly

visible from near thetransformer.
ii.
A mechanical operation counter.
iii.
Mechanical stops to prevent over-cranking of the

mechanism beyond the extremetap positions.
1016 of 2461
PAGE 141 of 339
iv.
MMRDA
The manual control considered as back up to the motor

operated load tap changercontrol shall be interlocked with
the motor to block motor start-up during manualoperation.
The manual operating mechanism shall be labelled to
show the directionof operation for raising the secondary
voltage and vice-versa.
17.
Electric control
This includes the followings:
Local Electrical control
Electrical remote control from remote control panel.
The control circuits shall have the followings features:
i.
An interlock to cut off electrical control automatically upon

recourse being taken tothe manual control in emergency.
ii.
Reinforcement of the initiating impulse for a tap change,

ensuring a positivecompletion once initiated to the next
(higher or lower) tap.
iii.
Step-by-step operation ensuring only one tap change

from each tap changingimpulse and a lock-out of the
mechanism if the control switch (or push button)remains
in the "operate" position.
iv.
An interlock to cut-out electrical control when it tends to

operate the gear beyondeither of the extreme tap
positions.
v.
An electrical interlock to cut-off a counter impulse for
1017 of 2461
PAGE 142 of 339
MMRDA
reverse step change beinginitiated during a progressing

tap change and until the mechanism comes to restand
resets circuits for a fresh position.
vi.
Tap change in progress by means of an indicating lamp

at the Owner's control panel& necessary contacts for this
and for remote tap position indicator at Owners
controlpanel shall be provided by the Contractor.
vii.
Protection
apparatus,
considered
essential
by
the
Contractor according tospecialties.
18.
Remote Electrical group control
The OLTC control scheme offered shall have provision of

remote electrical group controlduring parallel operation of
transformers. This is in addition to independent control of OLTC.
i.
A four position selector switch having MASTER, Follower,

Independent andOFF position shall be provided in the
remote OLTC control panel for eachtransformer. This
shall be wired to enable operator to select operation of
OLTC inMaster, Follower or Independent mode.
ii.
Out of step relays with timer contacts shall also be

provided to give alarm andindication in case of tap
positions in all the transformers under group control
beingnot in same position.
iii.
MASTER Position
If the selector switch is in MASTER position, it shall be

possible to control the OLTCunits in the FOLLOWER
mode by operating the controls of the MASTER unit.
1018 of 2461
PAGE 143 of 339
MMRDA
Independent operation of the units under FOLLOWER

mode shall have to be prevented.
However, the units under independent mode will be

controlled independently.
iv.
FOLLOWER Position
If the selector switch is in FOLLOWER mode, control of

OLTC shall be possible onlyfrom MASTER panel.
v.
INDEPENDENT Position
In this position of selector switch, control of OLTC of

individual unit only shall bepossible.
19.
Type test
Following test reports, as per IEC 60214, should be submitted
for owners approval.
20.
i.
Short Circuit current test
ii.
Dielectric test
iii.
Temperature Rise test
iv.
Mechanical test
v.
Degree of Protection IP55 test on driving mechanism box.
Control cabinet
Local OLTC control cabinet, and remote OLTC panel.
1019 of 2461
PAGE 144 of 339
i.
MMRDA
Each three phase transformer unit shall be provided with

Local OLTC controlcabinet, and remote OLTC panel.
ii.
The cabinet and remote OLTC Panel shall be provided

with non-disconnecting stud type terminal blocks. Each of
the terminal blocks in the above panels should have20 %
spare terminals exclusively for Owner's use. Necessary
shorting of terminals shall be done at the local OLTC
cabinet and remote OLTC panel.
iii.
The Local OLTC control cabinet shall house all necessary

devices meant for OLTCcontrol and indication.
iv.
Following cabling are specifically excluded from the

scope of the Contractor.
However, interconnection drawings for the same are to be submitted by

theContractor.
Cabling between Remote OLTC panels to Local OLTC cabinet.
Cabling between Remote OLTC to Owners Panel.
Cabling between Local OLTC Cabinet to Owner's panel.
The sheet steel used shall be at least 2.6mm thick for indoor and 3mm
thick for outdoor use.
The degree of protection shall be IP 55 (FOR OLTC cabinet

&Marshalling Box) & IP 54(OLTC Remote control panel) in accordance
with IS 13947. All the separately mountedcabinets and panels shall be
free standing floor mounted type and have domed or sloping roof.
Test reports of degree of protection for the panels & MK Box shall be
submitted after award ofwork, in which the size and material of
1020 of 2461
PAGE 145 of 339
MMRDA
enclosures and gasket should be indicated.
The temperature indicators shall be so mounted that the dials are not
at height more than1600 mm from ground level. Glass door of suitable
size shall be provided for convenience ofreading.
A space heater and cubicle lighting with ON-OFF switch shall be

provided.
21.
Applicable standards
Control cabinet Applicable Standards
IS/IEC Standards
Particulars
IS-4237
Switchgear General Requirements
IS-4047, IEC-408
Air Break Switches
IS-2208, IEC-259-1
Fuses
IS-2959, IEC-158-1
Contactors
IS-1822, IEC-292
Starters
IS-1248, IEC-51
Indicating Instruments
IS-375
Panel Wiring
IS-13947
Degree of Protection
Terminal blocks:
i.
The terminal blocks to be provided shall be fully enclosed with

removable covers andmade of moulded, non-inflammable
plastic material with block and barriers mouldedintegrally. Such
block shall have washer and nut bolts for external circuit
wireconnections, a white marking strip for circuit identification
and moulded plastic cover.
ii.
All terminals shall be clearly marked with identification numbers

or letters to facilitateconnection to external wiring.
1021 of 2461
PAGE 146 of 339
iii.
MMRDA
All internal wiring to be connected to the external equipment

shall terminate on terminalblocks, preferably vertically mounted
on the side of each panel. The terminal blocks shallbe 1100 V
grade and have 10 amps continuous rating, moulded piece,
complete withinsulated barriers, non-disconnecting stud type
terminals, washers, nuts and lock nuts.
Terminal block design shall include a white fibre marking strip

with clear plastic, slip on /clip on terminal cover. Markings on the
terminal strips shall correspond to wire numberand terminal
numbers on the wiring diagrams.
iv.
At least 20% spare terminals shall be provided on each panel

and these spare terminalsshall be uniformly distributed on all
terminal blocks.
v.
Unless otherwise specified, terminal blocks shall be suitable for

connecting the minimumof one no. 2.5mm2 copper conductors
on each side.
vi.
There shall be a minimum edge to edge clearance of 250mm

between the first raw ofterminal blocks and the associated cable
gland plate. Also the clearance between tworows of terminal
blocks shall be a minimum of 150mm.
vii.
Arrangement of the terminal block assemblies and the wiring

channel within theenclosure shall be such that a row of terminal
blocks is run parallel and in closeproximity along each side of
the wiring duct to provide for convenient attachment ofinternal
panel wiring. The side of the terminal block opposite the wiring
duct shall bereserved for external cable connection. All adjacent
terminal blocks shall also share thisfield wiring corridor. A steel
strip shall be connected between adjacent terminal blockrows at
450mm intervals for support of incoming cables.
1022 of 2461
PAGE 147 of 339
viii.
MMRDA
The number and sizes of the multicore incoming cable will be

furnished by theContractor after award of contract.
The gaskets shall be of neoprene rubber.
Bolts & Nuts
All bolts and nuts exposed to weather shall be hot dip

galvanised / cadmium plated.
Wiring & cabling
a.
All external cabling will be carried out based on wiring diagram &
interconnection scheduleto be supplied by the contractor. Cable
box / sealing end shall be suitable for following
Types of Cables:-
i.
415 Volt power: 1100 Volt grade PVC insulated stranded

copper conductor cablewith Armour.
ii.
Control: 1100 Volt grade PVC insulated 7/0.737mm

stranded copper conductorcable with armour.
b.
Compression type cable connector shall be provided for

termination of power and controlcables.
c.
Not more than 2 wires shall be connected to one terminal. Each

terminal shall be suitablefor connecting two 7/0.737mm stranded
copper conductors from each side.
d.
All internal wiring shall be securely supported neatly arranged,

readily accessible andconnected to equipment terminals and
terminal blocks.
1023 of 2461
PAGE 148 of 339
e.
Engraved
code
MMRDA
identification
plastic
ferrules
marked
to
correspond with schematic diagramsshall be fitted at both ends

of wires. Ferrules shall fit tightly on wires and shall not fall
offwhen the wire is disconnected from terminal block.
Local OLTC Control Cabinet
The auxiliary devices for electrical control of the OLTC shall be housed
in a weather proofcabinet. It shall be complete with the following:
i.
A contractor with thermal overload devices for controlling the AC

auxiliary supply tothe OLTC motor.
ii.
Cubicle light with door switch.
iii.
Space heaters to prevent condensation of moisture.
iv.
Padlocking arrangement for hinged door of cabinet.
v.
Cable terminal glands for power and control cables to the OLTC
gear.
Remote OLTC Control Equipment
a.
Equipment to be mounted in RTCC: Control and signal devices

required to be mounted asfollow:
i.
Actuating switch for electrical raise / lower control
ii.
Remote tap position indicator.
iii.
Signal lamps for
Tap changer in progress
1024 of 2461
PAGE 149 of 339
iv.
MMRDA
Tap changer out of step
Tap changer motor trip
Tap changer Supply ON
Tap changer Supply OFF
Annunciator: A 6 window microprocessor based Annunciator

shall be provided forfollowing fascia:
b.
AC SUPPLY FAIL
OUT OF STEP RELAY OPERATED
TAP CHANGER MOTOR TRIP
TAP CHANGE INCOMPLETE
SPARE
Remote OLTC Control panel (to be supplied by the Contractor):

The auxiliary devices forremote electrical control of the OLTC
except those mentioned above shall be housed ina separate
panel to be placed in the control room. The size shall be 2312 x
600 x600mm and colour will be of shade 631 of IS: 5.
Data to be furnished by Contractor after award of work
i.
Bill of material for all the equipment
ii.
Control cabinet drawing showing outline dimensions, floor

openings, floor / wall /pedestal fixing arrangements,
weights,
and
Front
view,
inside
view
showing
themounting arrangement of various equipment.

1025 of 2461
PAGE 150 of 339
MMRDA
iii.
Schematic diagram of control cabinet.
iv.
Interconnecting drawing showing the external cable

connections to the controlcabinet.
v.
Manufacturer's
descriptive
literature
on
various
equipment mounted on controlcabinet.
vi.
Cabinet internal wiring diagram (This drawing shall be

submitted only forinformation and records and shall be
based
on
an
approved
schematic
drawing.
Thecorrectness of the drawing shall be the responsibility

of vendor
vii.
Test certificates for the control cabinet and the various

equipment mounted therein.
22.
Clamps & Connectors
Terminal connectors
a.
Bushing terminal shall be provided with bimetallic

terminal connectors for HV & LV, ofapproved type and
size, for connection of external parts. The terminal
connectorsoffered must have been type tested as per IS:
5561. HV terminal connector shall bebimetallic with STC
rating of 25 kA for 3 sec. Copper threaded Terminal
Connectorssuitable for connecting 2/3/4 nos. 6.6 kV
suitable XLPE cable and the rated current ofLV winding
terminal. Neutral bushing to earthing strip connection
shall be throughcopper flexible strip of size 50 x 10 mm.
1026 of 2461
PAGE 151 of 339
b.
MMRDA
All castings of the terminal connectors shall be free from

holes, surface blisters,cracks& cavities. All sharp edges
and corners shall conform to designation A6 to IS:617.
c.
No part of a clamp shall be with less than 10mm

thickness.
d.
All the bolts and nuts shall not be provided of size less
than 12 mm. Check nuts shallbe provided for all the bolts.
e.
All ferrous parts shall be hot dip galvanised, as per IS:

2633.
f.
For, bimetallic terminal connector, copper alloy liner of

minimum thickness of 2mm, shallbe cast integral with
aluminium body.
g.
All
current
carrying
parts
shall
be
designed
&
manufactured to have minimumresistance.
h.
The short time rating of terminal connectors shall be 25

kA for 3 sec.
i.
The type test report of accredited laboratory shall be

submitted.
Applicable standards:
Clamp & connectors
Standards
Codes
Descriptions
IS 2121
Fittings
for
Aluminium
BS3288
AluminiumConductors for Overhead Lines
IS 5561 BS159
Electric Power Connectors
1027 of 2461
and
Steel
Cored
PAGE 152 of 339
MMRDA
Codes
Descriptions
IS 2629 BS729
Hot Dip Galvanised Process
IS 398
ACSR Conductors
iii)
Drawings &Documentation
1.
Documentation
a.
The Contractor shall furnish the typical

dimensional drawings of transformer & all
otheraccessories after award of work.
b.
The drawings shall include the following

information
i.
Dimensions
ii.
Tolerances on dimensions
iii.
Material designation used for different

components with reference to standards.
iv.
Fabrication details, such as welds, finishes

and coatings.
v.
Catalogue
or
part
numbers
for
each
component & total assembly with bill

ofmaterials.
vi.
Identification marking
vii.
Weight of individual components and total

assembled weight.
viii.
All dimensions in drawings shall be in metric
1028 of 2461
PAGE 153 of 339
MMRDA
units unless, otherwise specified
c.
iv)
All drawings shall indicate the following:
Name of the Owner
Purchase order No / Contract No.
Title of the drawing
Date of drawing
Scale
Quality assurance plans
The contractor shall invariably furnish following

information's after award of work.
i.
QAP for incoming material, in process and final

checks and testing.
ii.
Statement giving list of important raw materials,

names of sub suppliers for theraw materials, list of
standard according to which the raw materials are
tested.
List of tests normally carried out on raw materials

in presence of contractor'srepresentatives, copies
of test certificates.
iii.
Information and copies of test certificates as in (i)

above in respect of bought outaccessories.
iv.
List of manufacturing facilities available.
1029 of 2461
PAGE 154 of 339
v.
MMRDA
Level of automation achieved and list of areas

where manual processing exists.
vi.
List of areas in manufacturing process, where

stage inspections are normally carriedout for
quality control and details of such tests and
inspections.
vii.
vii. Special features provided in the equipment to

make
it
maintenance
free
List
oftesting
equipments available with the supplier for final

testing of Field Quality Planshall be submitted.
Type test certificates of the raw material and
bought outaccessories.
viii.
The contractor shall present on demand the

routine test certificate of bought outaccessories
and central excise passes for raw material viz. Oil,
copper, aluminium,conductors, insulating material
& core material at the time of routine testing of
thefully assembled equipment.
ix.
The performance test should be carried out by the

manufacturer
on
all
theaccessories
(100%
inspection). This verification should be carried out

on receipt ofaccessories at store.
x.
The physical verification of bought out items viz.

CRGO sheet, press pan, tank, allbought out items,
windings, etc. should be carried out by the
manufacturer of thepower transformer and test
them either internally or at other laboratory to
correlatethe results with those of test certificate
received from the original manufactures. Thiswill
1030 of 2461
PAGE 155 of 339
MMRDA
be useful for design as well as analysis in the

event of the failure of transformer.
xi.
The contractor shall guarantee for the following:
Quality & strength of material to be used.
Satisfactory & trouble free operation of

transformer.
The contractor shall fill in the required

details against each parameter described
underGuaranteed Technical particulars.
v)
Tests & Inspection
1.
Type tests & special tests
a.
The equipment offered shall be fully

type tested and tested for special
tests as perrelevant standards. In
case the equipment of type and
design offered is similar to type
anddesign of higher rating / capacity
of same voltage class and same
voltage ratio as of thetransformer
offered, already type tested, the
contractor shall furnish the type test
reportsaccordingly.
Equipment
offered shall have all Type Test

Certificates from accreditedlaboratory
(accredited based on ISO/IEC Guide
25 / 17025 or EN 45001 by the
Nationalaccrediting
body
of
the
country where laboratory is located),

1031 of 2461
PAGE 156 of 339
MMRDA
as
per
IEC
IS
technicalspecification, The type test

reports shall not be older than FIVE
years.
b.
The above said test report submitted

for owners approval.
c.
No
load
losses
&
percentage
impedance of one of the transformers

of each rating shallbe measured by
Government approved laboratory, if
so
desired
by
atManufacturers
Owner,
works
in
the
presence of Owners representative.
2.
Acceptance & routing tests :
a.
All acceptance tests, as stipulated in the relevant

standards, shall be carried out by thesupplier in
the presence of Owners. All the routine /
acceptance
tests
shall
be
carriedout
on
transformer filled with oil to be supplied and fitted

with all accessories to besupplied with transformer.
3.
Additional tests:
a.
All required Additional tests shall be carried out in

the presence of Ownersrepresentative at no extra
cost to the Owner. Also HV bushings shall be
tested formeasurement of Tan Delta value and
capacitance
(both
C1
and
C2)
at
10
kV
andrecorded.
4.
The contractor shall submit the type test reports for the
1032 of 2461
PAGE 157 of 339
MMRDA
type tests carried out as per IS 5561(latest edition) on

terminal connectors of HV side and LV side.
5.
Tests for oil :
a.
Sample shall be taken from each lot of oil to be

used, in presence of Ownerrepresentative and
shall be tested from NABL accredited laboratory
for following tests:
b.
Specific Resistivity
Kinematic Viscosity
Total acidity
Tan delta
Water content in ppm.
Dissolved Gas Analysis
Before commissioning the transformer at site 2 Nos. joint

sample as per relevant IS maybe collected and sealed.
One sample will be sent for testing as per relevant IS
including gall above 6 tests at NABL accredited
laboratory to confirm the quality of transformer oiland
second sample will be preserved. In case of disputes
about results of first sample, 2ndsealed sample should be
got tested at any other approved test house by Owner
andresult shall be binding to vendor.
6.
Contractor shall have to offer transformer tank of each

rating of transformer for vacuum andPressure test as per
CBIP Manual (latest edition).
1033 of 2461
PAGE 158 of 339
7.
MMRDA
Test reports
a.
Four sets of certified type tests reports shall be

submitted for approval prior to dispatchof the
equipment. The equipment shall be dispatched
only when all the requiredacceptance & routine
tests have been carried out & the test reports have
beenapproved by the Owner.
b.
Four copies of the test reports for the tests carried

out on ancillary apparatus /shall be furnished to
the Owner for approval prior to dispatch.
8.
Inspection
a.
The Owner shall have access at all times to the

works and all other places ofmanufacturer / vendor
where the transformers are being manufactured
and
vendor
shallprovide
all
facilities
for
unrestricted inspection at his works, raw materials,

manufactureof all accessories and for conducting
necessary tests.
b.
The contractor shall intimate the Owner, In

advance, of the time of starting and progressof
manufacture of the equipment in its various
stages, so that arrangements can bemade for
inspection.
c.
The acceptance of any quantity of equipment shall

in no way relieve the vendor of hisresponsibility for
meeting all the requirements at this specification &
shall not preventsubsequent rejection, if such
equipments are later, found to be defective.
1034 of 2461
PAGE 159 of 339
d.
MMRDA
The contractor shall submit the following during

commencement period.
i.
Name of raw material as well as bought out

accessories and the names ofsub suppliers
selected from those furnished after award of
work.
ii.
Type test certificate of the raw material

bought out accessories.
iii.
Quality assurance plan with hold points for

Owner's inspection.
e.
The contractor shall submit the routine test

certificate of bought out items & rawmaterials at
the time of routine testing of the fully assembled
equipment.
f.
The contractor shall have to offer stage inspection,

during manufacturing process ofeach offered
power transformer. The proposed date of stage
inspection shall beinformed to Owner TEN days in
advance. Owner reserves the right to inspect at
anystage of manufacturing of offered transformer.
g.
The first stage inspection will be carried out by

Owner representative for offered lot ofCRGO
material (before slitting) and one sample will be
collected from the same. Alsoinspection will be
carried out when the core formation and all the
windings are ready forinsertion in core. At this time
contractor will have to demonstrate for guaranteed
corelosses. Owner will collect the sample from the
1035 of 2461
PAGE 160 of 339
MMRDA
built up core laminations of offeredtransformer and

will get it checked at any Government approved
laboratory if required atrisk and cost of the
Transformer manufacturer, for the particulars
guaranteed by thecontractor
h.
Similarly, the winding shall also be inspected for its

guaranteed particulars like crosssectional area,
material etc., and if required, the Owner will collect
the sample of paperand conductor used and get it
checked at any Government approved laboratory
ifrequired at risk and cost of the Transformer
manufacturer, for the particulars guaranteedby the
contractor.
Contractor
shall
make
necessary
provision during winding soas to take sample of

conductor of required length.
i.
During stage inspection the contractor shall have

to keep ready following documents andthe same
shall be verified by the inspector.
Following tests shall be carried out on selected sample of

CRGO and winding material.
i)
ii)
CRGO material:
Specific Core loss measurement
B-H curve
Lamination thickness
Winding Material
a.
Dimensions:
1036 of 2461
PAGE 161 of 339
b.
c.
9.
MMRDA
(i)
Size of bare and covered conductor
(ii)
Size of insulation on conductor
(iii)
Nos. of layers of insulating paper
(iv)
Overlap
(v)
Conductor finish
Mechanical Properties:
(i)
Corner radius
(ii)
Tensile strength
(iii)
Hardness
Electrical properties:
(i)
Conductivity
(ii)
Resistivity
Testing during manufacturing stage
a.
The manufacturer of the power transformer should keep

records of the tests carried outduring manufacturing
stage, in detail for the checks / test carried out during
assembling/ manufacturing of the transformers. The
manufacturer should keep the systematicrecord for
complete
drying
out
process,
covering
various
parameters for the powertransformer.
1037 of 2461
PAGE 162 of 339
b.
MMRDA
Instruments/Equipments
The manufacturer should keep the precise and accurate

measuring
instruments/equipments.
The
periodical
calibration should be carried out of all the instruments

/equipments used for the measurement during tests and
for assessing the various propertiesof the material and
accessories. The proper record of the same should be
maintainedduring manufacturing stage and shall be
shown to the inspecting officer on demand.
10.
Painting
a.
The transformer will be applied with one coat of epoxy

red oxide paint as per IS :104 andone each finishing
coats of epoxy & enamel paint conforming to shade 631
of IS 5, afterdue sand blasting treatment on tank. An
additional coat of synthetic paint will also, begiven to
minimize the chance of decomposition of epoxy in the
outside atmosphere. Theminimum total thickness of paint
shall not be less than 60 microns. The same paint
shallalso be applied to main equipment & accessories.
Transformer tank inner surface shallalso be painted with
one coat of epoxy red oxide paint as per IS: 104 and one
eachfinishing coats of oil resistive paint conforming to
glossy white shade of IS 5.
11.
Packing
a.
The equipment shall be packed in crates, suitable for

vertical / horizontal transportas the case may be, and
suitable
to
withstand
handing
during
transport
&
storageduring transit. The contractor shall be responsible

for any damage to the equipmentduring transit, due to
improper
and
inadequate
1038 of 2461
packing.
The
easily
PAGE 163 of 339
MMRDA
damageablematerial shall be carefully packed and

marked with the appropriate caution symbol.
Wherever necessary, proper arrangement for lifting, such

as lifting hooks etc shall beprovided. Any material / item
found short inside the packing cases shall be supplied
bythe contractor at his own cost.
b.
Each consignment shall be accompanied by a detailed

packing list, containing thefollowing information
(i)
Name of consignee.
(ii)
Details of consignment
(iii)
Destination
(iv)
Total weight of consignment
(v)
Sign showing upper / lower side of the crate
(vi)
Handing & unpacking Instruction
(vii)
Bill of material indicating Contents of each

package
4.3.8 Neutral Grounding Resistors
4.3.8.1
Scope
This
specification
covers
design,
supply,
testing,
commissioning of Neutral Grounding resistor.
Design Requirements
1039 of 2461
PAGE 164 of 339
MMRDA
Resistor elements
The resistors shall be non-inductive, stainless steel type.
The grids shall be securely supported at sufficient

number of points so that no damage is caused to the
grids due to vibrations and no mechanical stresses are
developed. The resistor elements shall be insulated from
supporting bars by mica tubes. The grid elements shall
be given a protective coat of a suitable heat resistant
paint.
The insulating material used in the construction shall be

heat resistant such as mica.
The temperature rise shall be 350 DEG.C.
All the resistor elements comprising one stack shall be

internally connected and end terminalsshall be brought
out of tank enclosure in the form of bushings. If resistor
taps are specified all taps shall also be brought out of the
tank enclosure in the form of bushings.
Enclosure
The grid resistor elements shall be enclosed in a tank

type enclosure. The enclosure shall be made of one
piece welded construction rigid frame fabricated from
steel angles. The frame shall be adequately protected
from antitrust and deterioration due to exposed conditions
by antitrust coating and a final aluminum paint. The frame
shall be fitted with removable louvered aluminum covers
on all sides, top and bottom. The enclosure shall be
completely weatherproof for outdoor operation. The
louvered openings shall be provided with fine galvanized
1040 of 2461
PAGE 165 of 339
MMRDA
wire mesh.
4.3.9 Outdoor substation structure
Technical
Specifications
for
Design,
Fabrication,
Galvanizing,
Fabricated Structure Materials,Bolts Nuts, Anchor bolts and

Accessories & Attachments.
4.3.9.1
Scope
The scope for supply work covered under this section

consists of:
i.
Preparation of fabrication sketches and get their

approvals for gantries and equipment support
structures
ii.
Procurement of raw-materials like steel, zinc, etc.

required for fabrication and galvanizing,
iii.
Procurement
of
bolts-nuts,
accessories
and
attachments for insulator string, earth wireclamp

etc., (for gantry structures)
iv.
Preparation of PROTO-MODEL assembly based

on its approved structural drawings, bills of
materials and fabrication sketches.
v.
Inspection of finished structure materials.
vi.
Inspection
of
bolts-nuts,
accessories
and
attachments at manufacturer's works.
vii.
Dispatch of all materials to destination, including

transit insurance.
1041 of 2461
PAGE 166 of 339
viii.
MMRDA
Guarantee of all above activities carried out from

(i) to (vii).
The steel shall confirm to IS 2062 grade-A.
All the work shall be carried out in accordance with the

revised and latest provisions under respective Indian
Standard.
The Contractor shall be fully responsible for supply of

complete structure inclusive of boltsnuts, accessories and
attachments for the final quantities ordered.
The contractor shall make his own arrangement for

procurement
of
required
Bolt-Nuts,accessories,
attachments like D shackles. U bolts, anchor bolts, step

bolts etc. well inadvance and supply as per scheduled
completion
period
along
with
the
inspection
at
subvenders premises.
4.3.9.2
Standards
The design, fabrication, galvanizing and testing of

material used for manufacture ofStructures shall conform
to the latest edition of the following standards (as
mentioned up to-Date) except where otherwise specified
in the Specification
Standards for substation structure

IS Codes
Description
IS: 209
Specification for zinc
IS: 800
Code of practice for use of structural steel in general

Building Construction
1042 of 2461
PAGE 167 of 339
IS Codes
IS: 802
MMRDA
Description
Code of practice for use of structural steel in overhead
Transmission line towers
IS: 1363
Hexagon head bolts, screws and nuts of product grade C
IS: 1367
Technical supply conditions for threaded fasteners (First

Revision)
IS: 2016
Specification of Plain washers
IS: 2062
Hot rolled low, medium and high tensile structures steel
IS: 2629
recommended practice for hot-dip galvanizing of iron and

steel
IS: 2633
Methods of testing weight thickness and uniformity of

coating of zinc coated articles
IS: 3063
Fasteners - Single Coil Rectangular Section spring lock

washers
IS: 4759
Specification for hot-dip zinc containing on structural steel

and otherAllied products
IS: 5358
Specification for hot-dip galvanized coating on fasteners
IS: 5613
Code of practice for design, installation and maintenance

of overhead power lines
IS: 6610
Specification of Heavy washers for steel structures
IS: 6639
Specification for Hexagonal bolts for steel structures
IS: 6745
Methods for determination of weight of zinc coating on zinc

coated iron and steel articles
IS: 12427
specification of Fasteners Threaded steel Fasteners

hexagon head TransmissionTower Bolts
4.3.9.3
Drawings and Bills of Materials
The contractor has to submit copies of drawings and documents

as
stated
for
Ownersapproval
before
commencing
the
production.
Proto-Model shall be prepared and got inspected for the

approval along with fabricationsketches, structural drawings and
bills of material.
1043 of 2461
PAGE 168 of 339
4.3.9.4
Design,
MMRDA
Fabrication,
Stamping
and
Galvanizing
of
Materials
Two sets of anchor bolt setting templates should be designed,

fabricated, and supplied foreach type of column and equipment
support structure.
Any extension or other type of structure, if required, to be

supplied by the contractor shalldesign and prepare Proto Model at no extra cost to the Owner.
All the activities like straightening, cutting, drilling punching,

bending, notching, stampingGalvanizing etc. Shall be carried out
according to technical part of this Specification.
4.3.9.5
Type of Structures
All the structures shall be fully galvanized using only structural

mild steel sections formembers. The use of high tensile steel is
not permitted. Hexagonal head bolts with nuts andspring
washers shall be used for connections.
The 132kV structures for gantries , equipment support etc. are

required for the switch yard of substation.
Weights:
The unit weights of each type of structure, including bolt-nuts,

accessories, attachments andanchor bolts shall be furnished
and / or to be approved by the Owner. The weight of
structureshall mean the weight calculated by using the black
sectional (i.e. ungalvanised) weights of asteel members of the
sizes indicated in the fabrication drawings and bills of materials
withouttaking into consideration the reduction in weight due to
1044 of 2461
PAGE 169 of 339
MMRDA
drilling of bolts, holes, skew cuts,chambering etc. or increase in

weight due to galvanizing, but taking into consideration
theWeight of the special fitting, bolts, nuts, washers and other
accessories.
4.3.9.6
Material
The steel required for fabrication of structure member shall

conform to IS: 2062 - Grade A.
The zinc required for galvanizing shall be of Zn-99.95% and

shall conform to IS: 209.
The bolts and nuts shall conform to IS: 6639 or IS: 12427. The
bolts and nuts shall be ofMinimum class 5.6.
The plain washers shall conform to IS: 2016. Heavy washers

shall conform to IS: 6610 springwashers for bolts and nuts shall
conform to IS: 3063.
All bolts and nuts shall have hexagonal heads. The heads, being
forged out of the solid, trulyconcentric and square with the
shanks, must be perfectly straight.
Fully threaded bolts shall not be used. The length of bolts shall
be such that the threadedportion will not extend into the place of
contact of the member.
All bolts shall be threaded as per IS: 1363 to take full depth of
the nut and be threaded enoughto permit firm gripping of the
member, but no further threaded portion of each bolt shall
projectthrough the nut at least 6mm. when fully tightened. All
nuts shall fit hand tight to the pointwhere the shank, of the bolt
connects to the head. Flat and tapered washers shall
beprovided wherever necessary.
1045 of 2461
PAGE 170 of 339
MMRDA
The diameter of bolts shall be 12 mm, 16mm and 20mm. The

thickness of spring washersshall be 2.5 mm, 3.5 mm and 4 mm
respectively. Spring washers shall be provided under allnuts.
These washers shall be positive lock type electro-galvanized.
Each structure shall be provided with step-bolt of not less than
16mm diameter. The step-bolt shall be fixed on one leg up to top
of structure as indicated in approved drawing. Each step-bolt
shall be provided with two nuts and one washer.
The attachments like U bolt, D shackle, strain plate etc. shall
be as per approved drawings.
4.3.9.7
Fabrication Workmanship
The details of fabrication shall conform to IS: 802.
All the structure members shall be accurately fabricated to bolt

together easily at site withoutany undue strain on the bolts.
The diameter of the bolt-hole shall be equal to the diameter of

bolt plus 1.5 mm.
All similar parts of structure shall be made strictly interchangeable.
All steel sections before any work is done on them, shall be

carefully, leveled, straightenedand made true to detailed
drawings by methods which will not injure the materials so
thatwhen assembled the adjacent matching surfaces are in
close contact throughout. No roughedges shall be permitted in
the entire structure.
4.3.9.8
Proto-Model Assemble
Before proceeding with mass fabrication the contractor shall

1046 of 2461
PAGE 171 of 339
MMRDA
fabricate one structure of each type (i.e. superstructure) for the

purpose of checking accuracy and workmanship. This structure
should be strictly according to the respective structural drawing
and bills of materialprovided and approved by the Owner. The
contractor shall be solely responsible forPreparation and
inspection of such PROTO-MODEL assembly.
4.3.9.9
Drilling and Punching
Holes for bolts shall be drilled or punched with a jig but drilled
holes shall be preferred. The following maximum tolerance of
accuracy of punched holes is permissible.
a.
Holes must be perfectly circular and no tolerance in this

respect is permissible
b.
The maximum allowable difference in diameter of the

holes on the two sides of plates orangle is 0.8 mm i.e. the
allowable taper in punched holes should not exceed
0.8mm of diameter.
c.
Holes must be square with the plates or angles and have

their walls parallel.
All burs left by drills or punch shall be removed completely.

When the structure members arein positions, the holes shall be
truly
opposite
to
each
other.
Drilling
or
ramming
to
enlargedefective holes shall not be permitted.
4.3.9.10
Erection Mark
Each individual structure member shall carry a code number

conforming to the componentnumber given to it in the bills of
material and fabrication drawing. This code number shall
bemarked with marking dies, having 16 mm size-letter before
1047 of 2461
PAGE 172 of 339
MMRDA
galvanizing and shall be legibleafter galvanizing. The letters

indicated for different types of structure shall be specified.
All mark shall be got approved from the OWNER.
Each structure member shall also be marked with indelible ink

through stencil of 16 mm sizealphabet /numerical.
4.3.9.11
Bending
Mild steel angle sections up to 75 x 75 mm (up to 6 mm thick)

shall be bent cold up to andincluding bend angle of 10 Deg.
angles above 75x75 mm (thickness up to 6 mm) and up toand
including 100 x 100 mm (thickness up to 8 mm) may also be
bent cold up to the bendangle of 5 Degree. All other angle
sections and bend angles not covered above shall be benthot.
All plates up to 12 mm thickness shall be bent cold up to a

maximum bend angle of 15Degree. Greater bends and other
thicknesses shall be bent hot.
All hot bent material shall be air cooled. The bends shall be of
even profile and free from anysurface damages.
4.3.9.12
Galvanising
The galvanising shall be done to all the structure members after

the fabrication work iscompleted. The nuts may be tapped or rerun after galvanising. Threads of bolts and nutsshall have neat
fit and can be turned with finger throughout the length of the
threads of boltsand they shall be capable of developing full
strength of bolts.
The zinc deposition should not be less than specified per

galvanised surface area of thefabricated structure member.
1048 of 2461
PAGE 173 of 339
MMRDA
The galvanizing of the structure members shall conform to IS:

2629 & IS: 4759 All galvanized Members shall withstand tests
as per IS: 2633. The weight of zinc coating shall be
determinedas per the method stipulated in IS: 2633. Spring
washers shall be electro galvanised as perIS: 1573
Unless otherwise specified the fabricated structures shall have a

minimum overall Zinccoating of 610 gm per sq. m of surface
except for plates & sections below 5mm which shallhave Zinc
coating of 460 gm per sq. m of surface. The average zinc
coating for all sections &plates 5mm & above shall be
maintained minimum 87 microns and that for sections
below5mm shall be maintained minimum 65 microns.
Under marine environment, the fabricated structures shall have

minimum overall Zinccoating of 900 gm/sq. m of surface are
except for plates and sections below 5 mm whichshall have a
minimum overall Zinc coating 610 gm/sq. m of surface area. The
average Zinccoating for all sections and plates 5 mm and above
shall be maintained minimum127 microns and that for plates
and sections below 5 mm shall be maintained minimum
87microns.
The foundation bolt shall be galvanized as per IS 1367(Part-XIII)

i.e. 375gms/sqMtr
(54Microns). The weight of zinc coating shall be determined as
per the method stipulated in IS:2633.
All the stubs, cleats and stub-setting templates shall be fully

galvanised.
4.3.9.13
General Guide-Line For Inspection
Fabricated Structure Members:

1049 of 2461
PAGE 174 of 339
MMRDA
i.
Visual examination and quantity verification of offered lot.
ii.
Sample selection from the offered lot at an appropriate

ratio of MT (or part thereof) 1no. For all tests.
iii.
Dimension, fabrication and trueness verification of

structure member from fabrication sketch.
iv.
Galvanizing test of each sample i.e. dip test, hammer test

and mass of zinc test.
v.
Random verification Zinc coating over galvanized surface

by Elcometer.
vi.
Tensile test and bend test of each sample.
vii.
Chemical composition test of at least one sample per lot

offered for inspection.
viii.
Verification of manufacturer's test certificate for mild steel

used in structure members.
Bolts-Nuts,
Washers,
Attachments
etc.:
(To
Accessories,
be
carried
and
out
at
manufacturesWorks.)
i.
Visual examination and quantity verification

of offered lot.
ii.
Sample selection from the offered lot as per

relevant IS for each item.
iii.
Dimension,
fabrication
and
trueness
verification from fabrication sketch.

1050 of 2461
PAGE 175 of 339
MMRDA
iv.
Galvanizing test of each sample.
v.
Other acceptance tests for respective item

as per relevant Indian Standard.
After award of work the contractor shall ensure

that the supply of equipment structure &base plan
shall got approved
4.3.10 Overhead conductor
Installation should be carried out as per relevant IS. While running out
conductors from drumscare should be taken that conductors should not
rub or touch against ground / any objects.
Conductors should be run out of drum from top in order to avoid

damage. Running blocks withpulleys should be provided wherever
required. Drums should be provided with suitablebreaking device to
avoid
loose
running out and prevent kinking of
conductors.
Conductorsshould continuously be observed for loose or broken

strands or any other damage. Propertensioning, sagging & clamping of
conductors should be carried out as per relevant ISspecification.
Conductor & Earth wire parameters:

S.No.
Description
Materials
Conductor
Earth wire
ACSR conductor
Galvanised
Panther/ Dog as
steel wire
required
2
Size & stranding
30/3.0-AL&7/3.0-ST
7/3.15
for Panther &

6 / 4.7 AL
7/ 1.6 ST for dog
1051 of 2461
PAGE 176 of 339
MMRDA
Ultimate Tensile
10400 Kgfor
strength
panther &
56.017 KN
3350 kg for dog

4
Weight
976 Kg. / Km for
434 Kg. / Km
panther
396 kg/km for dog
5
Overall diameter
21.00 mm for
9.45 mm
panther &
14.2 for Dog
6
Area of cross-section
261 mm2 for
54.57 mm2
Panther &
119 mm2 for dog
7
Modules of elasticity
8000 Kg / mm2
(Approx. for both)

Co-efficient of linear
8
1.933x106 Kg/
mm2
19.3x10-6/Deg.C.
Expansion.(Approx. for
11.5x106/Deg.C.
both)
Rest of condition such as wind pressure Max.Temperature, etc. shall

be as per site requirement
4.3.11 Protective Relays Demonstration
After award of work during technical scrutiny of the technical document

submitted by theContractor, Owner may ask to give demonstration of
the offered Protective Relays at Owners site. The contractor shall
demonstrate the Protective Relays within one week of intimation from
Owner.
1. DIRECTIONALO/C ANDE/FPROTECTIONRELAYS.
(A) Features:
a. Shall be Numerical type.

1052 of 2461
PAGE 177 of 339
MMRDA
b. Shall have 3 over current and 1 Earth Fault element.
c. TRUE RMS Measurement.
d. Have selectable and front panel programmable normal, inverse,

veryinverse, extremely inverse & long inverse IEC / ANSI
Characteristic.
e. Selectable CT Secondary. i.e. 1A & 5A
f. High set over current with selectable time delay.
g. High set Earth fault with selectable time delay
h. Have adjustable characteristic angle, lead/ lag, for Directional

overcurrent/ Earth Fault respectively.
i.
Shall decide directionality through zero sequence quantity, derived

internally.
j.
Shall have Breaker Failure Protection as in built feature.
k. Include hand reset Flag/LED indicators for phase identification for

all faults.
l.
Readable Human Machine Interface with LED/ LCD display.
m. Should be able to store at least last 3 events with fault data viz.
Fault current, Faulty Phase etc. with time stamp
n. Shall have in built Disturbance Recorder with total time minimum

3sec.
o. Shall have continuous self-hardware & software monitoring and

1053 of 2461
PAGE 178 of 339
MMRDA
diagnostic features
p. Relay offered shall be communicable type.
q. Relay shall have on line testing facility
(B) Technical Parameters:
1. Analogue input:
Rated Current: 1A & 5A (site selectable), 50 Hz 2.5 Hz
Rated Burden : <0.05VA/0.3 VA for 1/5 Amp
Over load capability: 4xIn continuous 100xIn 1 Sec.
25xIn 3 Sec.
250xIn Dynamic
Rated Voltage : 110/63.5V, 50 Hz 2.5 Hz Rated
Burden : <0.3 VA per phase
Over load Capability: 2XV continuous
2. Auxiliary Supply : 110/220 V DC 15 %
Power consumption : < 15W
Ripple (peak to peak) : < 12%

Item Specification
(C) Relay settings:
1. Over Current: 50% - 200% (In steps of 5%)

1054 of 2461
PAGE 179 of 339
MMRDA
2. Earth Fault: 5% - 80% (In steps of 5%)

3. High set O/C : 0.5 15 times In or more.
4. High set E/F: 0.5 12 times In or more.
5. Time multiplier for IDMT: 0.05 1.0 (In steps of 0.025)
(Independent forO/C & E/F)
6. Time delay for high set
Element: 0.02 to 2 sec (in steps of 0.01 sec)
7. Pick up : Within 1.1 times of set current value.
8. Reset current : 95% to 90% of pick-up current.
9. Operating Time : As per selectable characteristic. For Inst.

Element 50ms for 2xIn.
10. LBB feature :Current setting range 0.1 to 2 X In
11. Time delay - 0.1 to 2 sec (In steps of 0.010 Sec)
(D) Other Features:
1. Binary Inputs : Minimum 5 Nos.
2. Outputs :
Provide sufficient number of potential free contacts to cater the

needs of connection to alarm annunciation.
1055 of 2461
PAGE 180 of 339
MMRDA
Trip contacts : Minimum 2 N/O contacts with
Continuous carry 5 A
Make & Carry for 0.5 s 30 A
Signaling contact: Minimum 4 Nos. (Programmable at site)
3. Local PC Communication:
Ports - Front RS232 and Rear RS485
Protocol - IEC-60870-5-103
4. Housing
Flush Mounting
Screw Terminals (O Lug for CT Connection)
Degree of Protection IP51
5. Temperature and humidity
(a)
Ambient temp - 10 to 55 o C
(b)
Relative humidity 10% to 90% Non-Condensing
(c)
Operate range 0-95%
(d)
Storage temp. - 40 to 70 deg C
2. NONDIRECTIONALO/C AND E/FPROTECTIONRELAYS.

1056 of 2461
PAGE 181 of 339
MMRDA
(A) Features:
a. Shall be Numerical type.
b. Shall have 3 over current and 1 Earth Fault element.
c. TRUE RMS Measurement.
d. Have selectable and front panel programmable normal, inverse,

very inverse, extremely inverse & long inverse IEC / ANSI
Characteristic.
e. Selectable CT Secondary i.e. 1A & 5A
f. High set over current with selectable time delay.
g. High set Earth fault with selectable time delay
h. Shall have Breaker Failure Protection as in built feature.
i.
Include hand reset Flag/LED indicators for phase identification for

all faults.
j.
Readable Human Machine Interface with LED/LCD display.
k. Should be able to store at least last 3 events with fault data viz.
Fault current, Faulty Phase etc. with time stamp.
l.
Shall have Disturbance Recording facility with total time minimum

3sec.
m. Shall have continuous self-hardware & software monitoring and

diagnostic feature.
1057 of 2461
PAGE 182 of 339
MMRDA
n. Relay offered shall be communicable type.
o. Relay shall have on line testing facility
(B) Technical Parameters:
1. Analogue input:
Rated Current: 1A & 5A (site selectable), 50 Hz 2.5 Hz
Over load capability: 4xIn continuous
100xIn 1 Sec.
25xIn 3 Sec.
250xIn Dynamic
2. Auxiliary Supply : 110/220 V DC 15 % Power
Consumption: < 15W
(C) Relay settings:
1. Over Current : 50% - 200% (In steps of 5%)
2. Earth Fault : 5% - 80% (In steps of 5%)

3. High set O/C : 0.5 15 times In or more.
4. High set E/F : 0.5 12 times In or more.
1058 of 2461
PAGE 183 of 339
MMRDA
5. Time multiplier for : 0.05 1.0 (In steps of 0.025) (Independent for
O/C& E/F)
6. Time delay for high settlement : 0.02 to 2 sec (in steps of 0.01 sec)
7. Pick up : Within 1.1 times of set current value.
8. Reset current : 95% to 90% of pick-up current.
9. Operating Time : As per selectable characteristic.
For Inst. Element < 40 ms for 2xIn.

10. LBB feature : Current setting range 0.1 to 2 X In Time delay -0.1
to 2 sec(In steps of 0.010 Sec)
259/00/R0 11 July 2013
3. DIFFERENTIALRELAY WITHHIGHSET
(A) Other Features:
1. Binary inputs : Min 5 nos.
2. Outputs :
Signalingcontacts :Minimum 4 Nos. (Programmable at site)
1059 of 2461
PAGE 184 of 339
MMRDA
3. Communication:
Ports - Front RS232 and Rear RS485
Protocol - IEC-60870-5-103
4. Housing
Flush Mounting
a. Ambient temp -10 to 55 o C
b. Relative humidity 10% to 90% Non-Condensing
c. Operate range 0-95%
d. Storage temp. -40 to 70 o C
(B) Differential % BIASED protection
(i)
Be high speed with an operating time of less than 30 ms at 5

times the rated current.
(ii)
Shall have principle of biased differential type with highest

feature and adjustable slope characteristic.
(iii)
Shall be numerical type.
(iv)
Shall have true RMS measurement.
1060 of 2461
PAGE 185 of 339
MMRDA
(v)
Shall have ratio and phase angle matching through software.
(vi)
Shall have site selectable CT secondary 1& 5 A
(vii)
Be suitable for three phase two winding transformer.
(viii)
Be stable on heavy through faults.
(ix)
Be immune to magnetizing inrush current.
(x)
Have features to provide stability under over excited conditions

and have 2nd harmonic restraint features.
(xi)
Be triple pole type with faulty phase identification/ indication.
(xii)

needs of connection to alarm annunciation.
(xiii)
Shall have readable human machine interface with LED/LCD

display.
(xiv)
The relay shall have on line testing facility
Technical Parameters:
1. Analogue input:
Rated Current : 1A & 5A (site selectable), 50 Hz 2.5 Hz
Over load capability : 4xIn continuous100xIn 1 Sec25xIn 3

Sec.250xIn Dynamic
1061 of 2461
PAGE 186 of 339
MMRDA
2. Auxiliary Supply : 110/220 V DC 15 %
Power consumption : < 15W
Differential protection settings:
1. Diff. Current : 10% - 50% In
2. Bias Diff Current : 10% - 50% In
3. 2nd Harmonic Restraint ratio: 10 to 80%
4. Highest current : 400 to 2000% In
Other Features:
5. Output contacts

-
Signaling contacts : Minimum 3 Nos.

(Programmable at site)
6. Housing
Flush Mounting
1062 of 2461
PAGE 187 of 339
MMRDA
a. Ambient temp -10 to 55 o C
b. Relative humidity 10% to 90% Non-Condensing
c. Operate range 0-95%
d. Storage temp. -40 to 70 o C

2555/ENI/IWU/00/R0 11 Ju013
4. UNBALANCECURRENTRELAY
The relay shall be suitable for rated current of 1 amp & have
suitable D.C/D.Cconverter suitable for 110 / 220 V D.C. (Preferably
88V TO 300V D.C.). DCvoltage range of 15% to+ 25% harmonic
level is max, .2% at rated value. It shall
1. be Single pole OR two pole type (in case of controlling 2 Banks)
2. be of numerical type
3. be two Stage relay so that alarm & tripping can be set at

different values ofcurrent
4. Have current setting of 10- 50 % of rated current.
5. Have alarm and trip output contacts.
6. Have a local user interface (MMI) comprising of a 2-3 line

alphanumericLCD display and a soft touch key pad to access
the settings, events andrecords in the relay.
1063 of 2461
PAGE 188 of 339
MMRDA
7. Include hand reset flag/LED indicator.
8. be high speed with typical operating time of less than 25 ms.
9. Be provided with sufficient number of potential free contacts to

cater theneeds of connection to alarm annunciation.
10. Data acquisition and optional trip facility to be connected

wheneverneeded.
5. OVERVOLTAGERELAY
The relay shall
1. be electromagnetic/static type
2. monitor all three phases

3. Have adjustable voltage setting range of 100 150% of rated
voltage &adjustable time setting range of 0 to 10 seconds
continuously or in step of 1Sec.
4. Have independent alarm & trip out put contacts.
5. Have drop off to pick up ratio equal to or greater than 95%.
6. Be provided with Hand reset flag/LED type operation indicator.
6. UNDERVOLTAGERELAY
The Relay shall
1. be electromagnetic/static type
1064 of 2461
PAGE 189 of 339
MMRDA
2. Be triple pole type.

3. Have adjustable voltage setting range of 40 90% of rated
voltage &adjustable time setting range of 0 to 10 seconds
continuously or in step of1 Sec.
7. AUXILIARYRELAYS FORTRANSFORMERTROUBLES
Buchholz trip.
1 No.
Buchholz alarm
1 No.
OLTC Buchholz trip
Oil temperature trip
1 No.
Oil temperature alarm
1 No.
1 No.
Winding temperature trip
1 No.
Winding temperature alarm
1 No
P.R.V. trip
2 Nos.
Low oil level alarm
1 No.

needs ofconnection to alarm annunciation, Data acquisition and
optional trip facility
8. HIGH SPEEDTRIP RELAY
As per the system design sufficient relays having potential free

contacts for trip circuit 1 & 2 of main / coupler breaker shall be
provided. The relay shall
1065 of 2461
PAGE 190 of 339
MMRDA
1. Have Heavy Duty Contacts for trip circuit.
2. Provide sufficient number of potential free contacts to cater the

needs of connection to alarm annunciation, Optional trip facility
to be connected where needed.
3. It shall be instantaneous with inherent operating time less
4. Than 10 ms.It shall have 8 NO & 2NC hand resetting type

contacts. It shall be 220/110V DC operating and preferably
provided with single coil.
5. Be provided with operation indicators.
9. TRIP CIRCUITSUPERVISIONRELAY
Trip circuit supervision relay shall be provided for each trip coil of
the breaker.
The relay shall
a. Monitor the complete trip circuit with circuit breaker in pre- close
&post-close condition.
b. Monitor loss of battery supply. c) Have a delay on drop off
c. Provide alarm output.
d. Include hand reset flag indicator.
e. Provide sufficient number of potential free contacts to meet the

scheme& future requirement.
10. PT SELECTIONRELAY
1066 of 2461
PAGE 191 of 339
MMRDA
The necessary PT selection relay shall be provided for bus Voltage

selection.
It shall be provided with sufficient contacts for selected P.T. to

protection and metering circuits and D.C permissive to protection.
The relay should be latched type with operating and resetting coils.
The relay shall have clear Visible indication flag/LED.
4.3.12 Battery, Battery charger and DCDB
This specification covers the requirements of stationary lead-acid

storage battery and suitable battery charger required for the operation
and control of circuit breakers/emergency lighting system.
The design, manufacture and performance of the equipment shall

conform to the following Standards
Codes
Description
DIN 40736 Lead Acid Batteries-Part-I Stationary vented cells with

plastic tubular plates inplastic containers
IS : 8320
General requirements and methods of tests for lead-acid

storage batteries
IS : 1146
Rubber and plastic containers for lead-acid storage

batteries
IS : 6619
Safety code for semiconductor rectifier equipment
IS : 6071
Synthetic separators for lead acid batteries
IS : 2147
Degrees of protection provided by enclosures for low

voltage switchgear andcontrol gear
IS : 4237
General requirements for switchgear for voltages not

exceeding 1000 V AC
IS : 8623
Specification for factory built assemblies of switchgear

and control gear (up to51000 volts)
IS :
Fuses with breaking capacity for industrial application
1067 of 2461
PAGE 192 of 339
MMRDA
9224(II)
IS : 4064
Specification for air break switches, disconnector and

fuse combination units
IS : 266
Battery Grade Sulphuric Acid
IS : 1069
Quality tolerance for Water for Storage Batteries

specification
4.3.12.1
Battery
Capacity - The ampere-hour capacity at ten-hour rate of

discharge shall be based on the requirements of loads. It
may be assumed that the battery is fully charged to 2.15
volts at the start of the cycle and is discharged to a
voltage of 1.85V/cell at the end of the cycle.
The battery offered shall preferably by lead-acid (tubular)

in transparent SAN container type.
The batteries shall be suitable for indoor installation.
The cell containers shall be of hard rubber / glass or

plastic. Suitable acid level indicators shall be provided.
The cells shall be sealed and filter vent plugs shall be

provided to avoid spillage, spray and emission of acid
vapors.
Inter-cell and inter-tier connectors shall be of lead or leadplated copper depending on the discharge rate to which
the battery will be subjected.
Terminal posts shall be designed to accommodate

external bolted connection. Each terminal post shall have
two bolt-holes of the same diameter, preferably at right
angle to each other. All metal parts of the terminals shall
1068 of 2461
PAGE 193 of 339
MMRDA
be of lead or lead-coated type. The junction between

terminal posts and cover and between cover and
container shall be so sealed as to prevent any seepage of
the electrolyte.
The electrolyte shall be battery grade sulphuric acid

conforming to relevant standards.
Required quantity of electrolyte for first filling with 10%

extra shall be supplied in nonreturnable containers.
Battery shall be complete with battery racks preferably in

single tier arrangement. For smaller units, utilizing
sealed-in type of batteries, mounting of the battery in
sheet metal cubicle will be acceptable.
Battery racks shall be constructed from good quality teak

wood and painted with two coats of approved acidresisting paint. The construction of the racks, unless
otherwise specified in the data sheet, shall be suitable for
fixing on a flat concrete floor. The racks shall be rigid,
freestanding type and free from warps and twists. The
complete rack shall be suitable for being bolted end to
end to form a continuous row.
The battery shall be complete with accessories and

devices including the following:
Battery racks
Porcelain insulators, rubber pads, etc.
Set of intercell and interior connectors as required for

the complete installation
1069 of 2461
PAGE 194 of 339
MMRDA
Accessories for testing and maintenance:
One - -3 to +3 volts DC voltmeter with suitable leads

for measuring cell voltage
One - Hydrometer for measuring specific gravity of

electrolyte in steps of 0.005
One - Filler hole thermometer fitted with plug and cap

and having specific gravity
correction scale
One - Pocket thermometer
One - Acid-resisting funnel
Two - Rubber aprons
Four - Rubber gloves
Two - Cell lifting straps
One set - Terminals and cable boxes with glands for

connecting cables as required
Spare Connectors
Spare vent plugs
Spare nuts and bolts
Suitable set of spanner
1070 of 2461
PAGE 195 of 339
MMRDA
PVC spill trays under the battery cells
Each cell shall be marked in a permanent manner to

indicate the following information:
Cell number
Type of positive plate
Ampere-hour capacity at 10 hour rate
Type of container
Manufacturers name
Month and year of manufacture.
The battery shall be transported in dry and uncharged

condition. The acid shall be supplied separately in nonreturnable sealed containers. Adequate quantity of
distilled water shall also be supplied in a sealed
container.
4.3.12.2
Battery charger and DCDB
The battery charger shall be indoor, cubicle type floor/wall

mounted, dust and vermin proof and front attended.
The control panels shall comprise rigid structural frame

enclosed by 2 mm thick cold rolled (CRCA) sheet steel.
Doors and covers shall be from 1.6 mm thick CRCA sheet
steel.
Structural frame-work with foundation bolts/fixing bolts,

etc. at the bottom / back side shall be provided to mount
1071 of 2461
PAGE 196 of 339
MMRDA
the battery charger panels directly on concrete floor/steel

channel base or directly on wall as required.
The charger and control equipment shall be arranged in

the panels such that the components related to boostcharging, float-changing, common equipment and D.C.
distribution are physically segregated in order to avoid
haphazard placement and mix-up of the components.
Location of the various equipment and components in the

panels shall be as per proper logic and sequence.
All doors and removable covers shall be gasketed all

around preferably with neoprene gaskets.
The battery charger and control panels shall be complete

with the following:
Removable cable gland plate, brass cable glands and

as specified in datasheet
650 V grade terminal blocks. 10% additional terminal

blocks shall also be provided as spare
Earth bus bar of size and material as specified in data

sheet.
The battery charger shall be static type with silicon

controlled rectifiers (SCRs) connected in three phase full
wave bridge circuit or single phase circuit with ripple
filtering device.
The rectifier transformer shall be indoor dry type, double

wound, with adequate number of primary/secondary taps.
1072 of 2461
PAGE 197 of 339
MMRDA
The composite (float/boost) charger, or separate float and

boost chargers, shall be designed for supplying the DC
loads as specified in the data sheet in addition to float
charging /boost charging the battery.
The battery charger shall consist of:
a.
One (1) - TPN/DP incoming switch on a.c. side of

the charger along with HRC fuses as required
depending on three/single phase supply (one for
boost charger and one for float charger) along with
two nos. voltmeters with selector switches.
b.
Three (3)/one (1) - Multiple LED type potential

indicating lamp(s) on a.c. supply side depending
on three/single phase supply.
c.
One (1) set - Automatic voltage regulator unit (for

float charger) with auto/manual selectorswitch and
Constant current controller for boost charger with
auto/manual selector switch.
d.
One (1) set - Coarse and fine control knobs for

manual control.
e.
One (1) - Selector switch for mode for charging i.e.

floats charging/boost charging.
f.
One (1) set - Double wound dry type main

transformer of suitable rating with adequate
primary and secondary windings.
g.
One (1) set - Taps for the charger output voltage

control with off load tap changing switch for
changing the taps on the transformer.
1073 of 2461
PAGE 198 of 339
MMRDA
h.
One (1) set - Booster transformer, as required.
i.
One (1) set - Silicon rectifiers connected in three

phase full wave bridge circuit/single phase circuit,
as per requirement indicated in data sheet, with
ripple filtering device
j.
Two (2) - D.C. Volt-meter
k.
Two (2) - D.C. Ammeter with Shunts
l.
One (1) - Switch fuse unit in D.C. output side of

each charger, with HRC fuses.
m.
Two (2) - Silicon diodes in series in the boost

charger circuit.
n.
Two (2) - A.C. contactors (or auxiliary relays)

connected across the incoming supply to give
alarm on Annunciator.
o.
One (1) - Cubicle space heater suitable for 240V

A.C., 50 Hz single phase supply with switch.
p.
One (1) - 240V A.C. Lamp for cubicle internal

lighting with switch.
a)
Performance
The automatic constant voltage regulator

shall regulate the DC voltage within +1% of
the set value from no load to full load under
fluctuations in supply voltage and frequency
by + 10%and +5% respectively of their
1074 of 2461
PAGE 199 of 339
MMRDA
normal values.
The float charger shall have built-in current

limiting feature to drop the output voltage for
currents more than 110% of the rated
current.
Suitable ripple filtering circuits shall be

provided to give a smooth D.C. output. The
ripple content shall be limited to less than
+5% on resistive load.
4.3.12.3
Tests
Routine
tests
(acceptance
tests)
such
as
visual
inspection, dimensional check, etc. shall be conducted as

per relevant I.S.
259055/ENI/IWU/00/R0 11 July 2013
Type test certificates for retention of charge, etc. shall be
submitted. Type tests shall be carried out if specified in
Data Sheet.
Seven copies of the routine and type test certificates shall

be submitted for the Owners approval before dispatch of
the equipment.
4.3.12.4
Technical data
1.
Battery:
Ambient temperature : 500 C max. :
Humidity : 95% Max.
Battery capacity : lead-acid (tubular) in

1075 of 2461
PAGE 200 of 339
MMRDA
transparentSAN container type, High discharge

performance
Total effective voltage required : 110V D.C.
Voltage per cell : 2.2V
Total nos. of cells : 55 Nos.
Voltage per cell at the end of discharge : 1.85V
No. of identical batteries required : 2X100% One

set of 55 Cells 110V DC
Proposed application : Alarm, Closing and tripping

ckts. of Breakers, Indicating lamps, Tripping of
Protective Relays, Annunciators, Hooters
Accessories and spares : As required
Approved makes : As per Approved vendor list
2.
Battery charger and DCDB
Rating : As required
Input voltage : 415V, + 10%, 3Phase, 50Hz, + 3%

A.C.
Output voltage : 110V D.C.
TYPE : Float cum boost with trickle Charging

Facility and automatic battery over drain
protection.
1076 of 2461
PAGE 201 of 339
MMRDA
4.3.13 Metal Enclosed HV Switchgear Panel
4.3.13.1
Scope
This specification covers the design, manufacture, testing

& supply of 6.6 kV indoor switchboards to operate 6.6kV
3 phase Induction motors at pumping station.
For indicative power distribution scheme Electrical single

diagram shall be referred. All therating shown in the
referred drawing represents the minimum requirement
only; exact rating, number and type of feeder etc. shall be
decided by the contractor.
4.3.13.2
Codes and standards
The equipment shall comply with all currently applicable

electricity rules, approval of fire insurance, association,
statutory regulations and safety codes in the locality
where the equipment will be installed.
Unless otherwise specified equipment shall conform to

the following latest applicable ISStandards. Equivalent
IEC standards shall be used as applicable.
IS Codes
Description
IS: 5
Columns for ready mixed paints and enamels
IS: 1248
Direct acting indicating analogue electrical measuring
(Part-1)
instruments and theiraccessories: General requirements.
IS:1777
Specification for industrial luminaries with metal reflector
IS: 2099
Bushings for alternating Voltages above 1000 Volts
IS: 2147
Degrees of protection provided by enclosures for low

voltage switchgears &control gear
IS: 2705
Current transformers: General requirements
1077 of 2461
PAGE 202 of 339
MMRDA
IS Codes
Description
(Part-1)
IS:2834,
Specification for Shunt capacitors for power system
13925
IS:3043
IS: 3156
Voltage transformers: General requirements
(Part-1)
IS: 3231
Specification for electrical relays for power system

protection
IS: 3427
A.C. Metal enclosed switchgear and control gear for

rated voltages above 1 KV &up to & including 52 KV
IS:9385
High voltage fuses
IS: 12729
General requirements for switchgear & control gear for

voltages exceeding 1000V.
IS: 13118
Specification for High Voltage A.C. Circuit breaker
IS:13703
Specification for low voltage fuses for voltages not

exceeding 1000V
IS:13947
Specification for low voltage switchgear and control gear

assemblies
CODES DESCRIPTIO
4.3.13.3
Design criterion
The switchgear shall be used to supply power to HV

motors, transformers and other loads ofpumping station.
Duty involves starting of large induction motors through

6.6 kV soft starters. The motor startingcurrent varies from
2.5 to 3 times the full load current.
For
continuous
operation
at
specified
ratings,
temperature of the various switchgear

Components shall be limited to the permissible values
stipulated in the relevant IS/IECstandards.
The switchgear and components thereof shall be capable

1078 of 2461
PAGE 203 of 339
of
MMRDA
withstanding
the
mechanicalforces
and
thermal
stresses of short circuit listed in the data sheet and SLD

without anydamage or deterioration of material.
Circuit breaker shall not produce any harmful over

voltage during switching off inductionmotors, unloaded
lines and unloaded transformers. If required surge
protective devices shallbe provided in the scope of supply
to limit over-voltage.
4.3.13.4
Constructional features
The Switchboards shall be indoor type and shall conform

to latest version of IEC: 62271-200,IAC-AFLR-25 kA for 3
second, PM, LSB for use on 6.6kV systems. It shall be
Internal Arc typetested for 25 kA for 1 second for four
sides; shall have metal partitions and shall conform toloss
of service continuity. It shall have porcelain clad, gang
operated, triple pole vacuumcircuit breakers/SF6 circuit
breaker. Adequate phase clearance and height shall be
providedto meet standard and safety requirements. The
circuit breakers shall be fully draw out typewith distinct
service test and Isolated positions.
Switchboards shall be dust, moisture and vermin proof.

The degree of protection of enclosureshall be IP 4x.
Switchboards shall be suitable for 3 phases, earthed A.C

system. Supply voltage, ratedcurrent and system fault
level shall be as per enclosed data sheets and single line
diagrams.
The switchgear assembly shall comprise a continuous,

dead front, line-up of free standing,vertical cubicles. Metal
enclosed unit shall comprise rigid welded structural frame
1079 of 2461
PAGE 204 of 339
MMRDA
enclosed by2.5 mm thick cold rolled metal sheets.

Structural framework with foundation/fixing holes etc.shall
be provided at the bottom to mount switchboard directly
on concrete/ steel channel base.
Separate labels shall be provided for switchgear,

cubicles, relays, instrument, switch etc.
Danger boards shall also be provided. All component

mounted
inside
the
panel
shall
beprovided
with
identification nameplate. Nameplates shall be of anodized

aluminium orapproved design. Letters shall be in white
colour, rear engraved on black background.
The inspection window provided on the VCB door shall

be made of thick toughened glass toensure the capability
to withstand an internal arc in CB compartment. Use of
acrylic or ordinarythin fibre glass shall be prohibited. Each
cubicle shall have front hinged door with latches anda
removable back cover. All covers and doors shall be
provided with neoprene gaskets. Theoperating height of
any switch, push button etc shall not exceed 1.8 metres.
Painting shall include emulsion cleaning, pickling with

dilute acid, washing and rinsing bywater, phosphatizing
and oven drying. One (1) coat of stoving type zinc
chromate primer andtwo (2) coats of synthetic enamel
paint or paint as specified in data sheet shall be applied.
The main busbars shall run horizontally at top. These

shall be made from electrolytic gradealuminium. The
continuous and short time current withstand capacity
shall be as per datasheets. The busbars shall be
supported on non-hygroscopic insulators. The spacing
betweenphase busbars and insulator supports shall be
1080 of 2461
PAGE 205 of 339
MMRDA
such as to withstand forces arising out ofspecified short

time current without distortion.
Circuit breakers, instrument transformers, bus bars, cable

compartment
etc.
shall
be
housed
inseparate
compartment within the cubicle. The design shall be such

that the failure of oneequipment shall not affect the
adjacent units.
The LV compartment shall be located above the circuit

breaker
cubicle
and
it
shall
be
easy
toaccess
relays/metres when standing on the switchgear room

floor. All relays, meters, breakercontrol switches, selector
switches and indicating lamps shall be flush mounted on
therespective cubicle door or on the control cabinet built
on the front of the switchboard.
Mechanically operated shutters shall be provided so that

busbar sprouts are covered bybarriers when the circuit
breakers are drawn out.
Dummy panel shall be provided in the switchgear line up,

if required, for easy terminationaccess of power and
control cables. Dummy panel/bus trunking panel shall be
of full cubiclewith closed roof and rear cover similar to
enclosures for active cubicles.
The circuit breaker shall be fully withdrawable type. The

circuit breaker shall be operated by acommon shaft.
Operation counter shall be provided.
Vacuum Circuit Breaker (VCB) shall have enclosure

containing fixed, moving & arcing contact,individual for
each phase, suitable arrangement shall be provided to
check the contacts wear& tear, vacuum bottle consisting
1081 of 2461
PAGE 206 of 339
MMRDA
of highly evacuated casing with ceramic cylinder. The

vacuumbottle shall be completely encapsulated in epoxy
housing with three independent poles foreach phase. The
open pole construction is not acceptable.
Sulphur hexafluoride (SF6) circuit breaker shall have

each pole consisting of insulatingenclosure of synthetic
resin
containing
fixed,
moving
&
arcing
contacts
connected withoperating mechanism by insulated tie rod.

SF6
gas
shall
be
filled
up
with
non-return
valve,interrupting contacts with special alloy capable of

withstanding
arc
temperature
and
reducechopping
current, pole chamber shall be filled with sulphur

hexafluoride gas at desiredpressure. SF6 gas pressure
switch with contact should be provided to lockout closing
ortripping of the circuit breaker and give alarm in event of
the pressure falling below desiredvalue.
Operating mechanism shall be non pumping electrically

and mechanically. When the circuitbreaker is already
closed, failure of any auxiliary spring shall not prevent
tripping and shall notcause damage to the breaker or
endanger the operator. A mechanical OPEN/CLOSE
positionindicator visible with closed door shall be
provided. Mechanical trip and close devices shall
beprovided.
Circuit breaker shall be provided with motor wound spring

charging
mechanism,
complete
withmotor.
Spring
charging motor shall preferably be a universal motor.

Motor shall be usedsolely for storing energy in the spring
- and not for direct closing of the circuit breaker.
Limitswitch shall be provided to cut-off the motor power,
when the spring is charged fully, with acontact for spring
charged indication lamp on the panel. Also mechanical
1082 of 2461
PAGE 207 of 339
MMRDA
indication for springcharged/discharged shall be provided.
The circuit breakers shall have facility to charge the

spring by the manual charging handle. Itshall be ensured
that whilst manual spring charging is in operation,
Electrical power to thespring charging motor should be
cut off automatically.
The circuit breaker incoming and outgoing terminals shall

be suitable for cables as shown inthe single line diagram
drawings.
Each outgoing feeder in 6.6 kV switchboards for Motor

shall comprise vacuum circuit breakerfor switching 450
kW & 600kW (indicative) rated Induction motors that
drives the vertical turbinepumps. Contractor shall include
surge arrester, if required, for the motor feeders.
Forprotection a comprehensive, solid state, numerical,
communicating type Motor protection.
Relay shall be provided on each outgoing motor feeder.

The
protection
features
shall
includeminimum
the
following:
a.
Over current
b.
Earth Fault
c.
Negative phase sequence
d.
Single phasing
e.
Stalled rotor
f.
No. of starts per hour
1083 of 2461
PAGE 208 of 339
MMRDA
g.
Stator thermal withstand
h.
Starting current Vs time
i.
Stator differential protection
25055/ENI/IWU/00/0 11 July 2013_thout logo.doc

4.3.13.5
Power factor correction
The reactive power compensation requirement for 6

numbers 450 & 600 kW HV Induction motors at RWPH
and CWPH is mentioned in the SLD.
The HV capacitors connected on 6.6 kV bus shall

discharge through directly connecteddischarge device
from the residual voltage value to 50 volts or less within 5
minutes after thecapacitor is disconnected from the
source of supply.
The contractor shall provide timer for capacitor feeder so

that the circuit breaker does notreclose prior to 5 minutes
after it is switched off.
Fix capacitor for power factor improvement of Motor from

0.78
to
0.96
and
in
APFC
panel
power
factor
improvement from 0.96 to 0.99.
The HV capacitor shall be suitable for voltage factor of

1.3 (multiple of rated voltage) formaximum duration of 1
minute. The HV capacitor units shall be suitable for
continuousoperation at a current (rms value) of 1.3 times
the current that occurs at rated sinusoidal voltage and
rated power frequency excluding transients.
The circuit breaker for capacitor feeder shall be restrike

1084 of 2461
PAGE 209 of 339
MMRDA
free.
4.3.13.6
Interlocks
The main 6.6kV Switchboard has 2 incoming feeders

from main transformer, andone bus section circuit
breakers. These Incomer circuit breakers shall be
properly interlocked.
The circuit breakers shall be fully draw-out type and it

shall not be possible to insert inservice position. It shall
not be possible to withdraw the circuit breaker unless it is
openedfirst. In test position it shall be possible to close
and open the circuit breaker with all powerconnections
remaining isolated.
Switchgear cubicle shall be so sized as to permit opening

of the front access door only whenthe breaker is pulled
out to the TEST position. The movement of the circuit
breaker from TESTto SERVICE position should be
possible only with the breaker door closed.
Each circuit breaker shall be equipped with cable side

earthing switch mechanically
Interlocked with the circuit breaker main contacts.
4.3.13.7
Protection, Metering & Indication
The offered feeder protection relay should be completely

numerical
with
protective
elementshaving
software
algorithm based on sampling of energized currents,

analog to digitalconversion and numerical handling.
Relays shall be suitable for flush mounting type and

consisting of multifunctional draw out typemodules. The
1085 of 2461
PAGE 210 of 339
MMRDA
flush mounted relays shall have to design where the

display can be kept at anincline from the horizontal to
ease the observation of the viewer
The relay shall have minimum 4 CT inputs, which can be

used as 3 Nos. over current and 1Earth fault. The relay
shall be suitable for both 2 CT and 3 CT connections.
It shall be possible to energize the relay from either AC or

DC auxiliary supply. The relay shallbe suitable for both
110VDC (20%) and 220 VDC (20%).
Relay shall have configurable binary input, which can be

used to develop blocking basedscheme and 5 freely
configurable output contacts. The Input shall have
galvanic isolation. Thetrip out put contact should be
capable of controlling the circuit breaker and shall
beprogrammable for either hand reset or self-reset. One
relay should be permanently assignedfor self-supervision
system.
The relay enclosure shall be dust tight having degree of

protection minimum as IP5X.WU
/00/R0 11 July 2013
The relay must have facility for local settings through front
keypad from relay itself. Relayshould have facility of
online relay setting i.e. it should be possible to alter
setting withoutswitching off breaker or contactor.
The offered relay shall have LED / LCD display for

settings, status, measurement and faultdata & indication.
It shall have Fixed function LEDs (for fault trip, relay
healthy, control supplyON & Relay out of service).
Relay shall have comprehensive self-diagnostic feature

1086 of 2461
PAGE 211 of 339
MMRDA
with indication of relay failure on relayfront and alarm

should
be
generated
without
tripping
the
feeder.
However, while diagnosticcircuit runs, it must not interfere

in the main protective relay circuit and allow working of
mainprotective circuit continuously.
Minimum 5 Nos. of latest fault trip records should be

recorded in relay for post fault analysisenabling clear the
fault faster and reduce downtime.
No separate earth bus shall be required for the relays. It

shall be possible to connect the relayearth to the common
earth bus in the substation.
The offered relay must be immune to any kind of

electromagnetic interference. Vendor tosubmit all related
type test reports for the offered model after award of work
for ownersapproval.
The relay should conform to the requirements of IS: 3231

/
IEC60255
standards
with
respect
tofeatures/
construction/design etc.
1 Set of software should be supplied along with relays for

viewing and downloading
Measurement, fault records and to carry out easy settings
of relays locally.
All the operational data should be stored in the relays on

a non-volatile memory so that dataretains even in case of
loss of power.
The relays should have functions to monitor circuit

breaker condition and give comprehensivemeasurement
1087 of 2461
PAGE 212 of 339
MMRDA
The relays should have access control keys up to 3 level

of individual access
Viewer/operator,Owner,Administrator. This shall prevent
unauthorized access.
The relay shall be suitable for providing the following

protections:
1. Three
phase
over
current
and
earth
fault
protection
The relay shall have 2 independent stages for both

over current and earth fault.
First stage can be selected as definite time or inverse

time
over
current
characteristic.
Theinverse
characteristics shall as per IEC which should include

normal inverse, very inverse,extremely inverse, long
inverse curves and shall be software selectable at
site.
The
second
stage of
protection
can be
with
instantaneous or definite time operation thereshould

be possibility to disable the unit in case of contactor
controlled feeders.
Relay shall be suitable for both residually connected

CT input as well as CBCT input.
This protection should have automatic doubling

function when the protected object isconnected to
network i.e. at starting, allowing the set value being
lower than the connectioninrush current.
Relay should have minimum2 nos. independent

1088 of 2461
PAGE 213 of 339
MMRDA
selectable setting groups.
2. Circuit Breaker failure protection
The relay should have a feature of circuit breaker

failure protection, which generatesanother trip signal if
the breaker fails to trip on fault, which can be wired to
upstreambreaker trip coil.
The earth bus bar shall be of sufficient cross section

to carry safely momentary short circuitcurrent for 1
sec. or as specified in data sheet. It shall extend for
the full length of theswitchboard. All non-current
carrying metal parts shall be effectively bonded to the
earth bus.
The earth bus shall be provided with two-bolt drilling

with G.I. bolts and nuts at each end toreceive. CT and
VT secondary neutrals shall be earthed through
removable links so that earthof one circuit may be
removed without disturbing other.
The contractor shall include one earthing truck for

earthing of the bus bar section when itsincoming and
bus section circuit breakers are open. The trucks shall
have a voltagetransformer and an interlock to prevent
earthing of any live connection. The trucks shall
haveaudio-visual annunciation to warn the operator
against earthing of live connections. It shall notbe
possible to use bus-earthing truck for cable earthing&
vice versa. Earthing truck shall benon- fault making
type.
4.3.13.8
Cubicle accessories and wiring for mechanism box
1089 of 2461
PAGE 214 of 339
MMRDA
Cubicle internal wiring and inter panel wiring shall be

carried out with 2.5mm2 flexible PVCinsulated stranded
copper conductor for control circuits, 1.5mm2 flexible
PVC insulatedstranded copper conductor for voltage
circuits and with 4mm2 copper conductor wires for
CTcircuits. Wiring of AC and DC circuits shall be colour
coded. AC / DC wiring shall haveseparate color-coding.
Wire termination shall be made with crimping type

connectors with insulating sleeves. Wiresshall not be
spliced between terminals.
All spare contacts of relays, timers, auxiliary switches

shall be wired up to the terminal block.The following shall
be provided:-
a.
4 Pole MCB for 110 V AC control supply from

VTs and 2-Pole MCB for 110V DC and240 V, 1
Phase AC control supply. MCB shall be trip free
with manual close/openmechanism. Automatic
tripping provision for over load and short circuit
shall be provided.MCBs shall be rated for full fault
level of the system.MCB shall be provided with
requirednumber of auxiliary contacts as per circuit
requirement.
b.
650 V grade terminal blocks of polycarbonate type

including 20% spare terminals orminimum 4 Nos.
whichever is higher, shall be provided. Terminals
shall be stud type,suitable for terminating 2 nos.
2.5 mm2 stranded copper conductor and provided
withacrylic insulating cover.
c.
Cubicle space heater along with MCB /switch fuse

and thermostat control. Motor feedercubicle shall
1090 of 2461
PAGE 215 of 339
MMRDA
be wired-up for feeding the motor space heater

through
suitable
ratedindependent
breaker
auxiliary NC contact and/or contactor.
d.
Plug point with switch.
e.
Cubicle illuminating lamp CFL/FL with control

switch and door limit switch in theinstrument
chamber.
f.
All
spare
contacts
of
Relays/Breaker
Aux.
Contacts/Contactors etc. shall be wired up tothe

terminal block, such that same can be used as and
when required.
g.
Trip-Neutral-close controls switch for the circuit

breakers. Breaker control switch shall bemulti
stage, spring return to normal with lost motion
device and pistol grip handle.
h.
Start/Stop push buttons for motor feeders with kV

switchboards- Push button shall beheavy duty,
shrouded, push to actuate type with colored button
and inscription plate.
Each push button shall have 2 NO + 2 NC contacts, rated

10A and 0.5A at theirrespective AC and DC
operating voltage.
i.
Local / Remote Selector Switch. Lockable stay put

type remote selector switch shall beprovided as
per requirement and mounted on switchgear
cubicle.
j.
Meter selector switches shall be maintained
1091 of 2461
PAGE 216 of 339
MMRDA
contact, stay put type with knob handle.
Ammeter and voltmeter selector switches shall be of four

position type. Ammeterselector switches shall
have make before break feature to prevent the
open circuiting ofCT secondary.
k.
Test terminal blocks
l.
Fuses shall be HRC, link type with minimum

interrupting capacity equal to the listedshort circuit
current. Fuses shall be furnished with fuse bases
and fittings.
m.
One set of tools, required for operation &

maintenance
shall
be
supplied
for
eachswitchboard.
Entries of all power and control cables shall be from the

bottom. Sufficient space shall beprovided for ease of
termination and connection. The Contractor shall provide
undrilled cablegland plates for both power and control
cables. These of
gland
plates shall be
secured
againstgaskets. Gland plates shall be minimum 3mm

thick. The gland plate and supportingarrangement for 1 C
power cable shall be of aluminum. Sufficient space shall
be providedbetween power cable termination and gland
plate. Core balance CT wherever specified, shallbe
accommodated within this space inside the cubicle.
Bus bars and feeder/ jumper connection shall be

insulated with heat shrinkable sleeve forrated voltage with
adequate phase/ground clearances. Insulating sleeves
for bus bars andcast-resin shrouds for joints shall be
provided, suitable for maximum temperature rise of
1092 of 2461
PAGE 217 of 339
MMRDA
busbars.
Capacitance type voltage indicator shall be provided for

each cable. This shall indicatepresence of voltage at
cable terminations
4.3.13.9
Instrument transformers
Current Transformer (CT) and Voltage Transformer (VT)

shall conform to the requirements ofIS: 2705 and IS:
3156 respectively. CT/VT shall be separately mounted in
the cubicle. Theratings specified are indicative only and it
shall be Contractors responsibility to ensure that
theratings are adequate for relays/meters application
considering load resistance etc.
CT shall be cast resign type. All secondary connections

shall be brought out to terminal blockswhere wye or delta
connection shall be made. CT terminals of shorting links
type shall beprovided at terminal blocks.
Accuracy class of CT shall be:
a.
Class PS for differential relaying (or as required

depending on the type of relay selected)
b.
Class 5P20 (or 5P10, if specified in the drawing)

for other relaying.
c.
Class 0.5 and ISF<=5 for metering
d.
Class 0.5 or better and ISF <=2 for performance or

precision metering on motor feeders)
CT secondary shall be 1 A or 5 A, depending on the

1093 of 2461
PAGE 218 of 339
MMRDA
requirement.
Motor feeder requires remote metering and shall be

provided with current transducers withCalibration for full
scale reading.
VT shall be cast resin, 3- phase; star/star/star connected,

draw out type and shall have anaccuracy class of 0.5.
VT shall be accessible from front side of the panel without

affecting the position or operation ofthe breaker.
High voltage winding of VT shall be provided with

adequately rated encapsulated currentlimiting fuses on
primary side. The VT and fuses shall be completely
disconnected.
Low voltage winding of VT shall have MCB, installed in all

under grounded secondary leads.
MCBs shall be suitably collated to permit easy
replacement while the switchgear is energised.
4.3.13.10
Tests
The Contractor shall test each cubicle as per relevant

standards with all componentsassembled and fully wired.
Routine tests shall be carried out on all components as

per relevant standards.
Owner reserves the right to witness the following routine

tests on switchboards andcomponents mounted in
switchboards. The tests shall include but not necessarily
limited to thefollowing:
1094 of 2461
PAGE 219 of 339
i)
MMRDA
Operational Test (Electrical & Mechanical) of

Circuit Breakers.
ii)
Primary/Secondary current injection test to check

the operation of meters andrelays.
iii)
Simulating actual operational conditions to check

the operation of circuit breakers,indicating lamps,
interlocks etc.
iv)
Pick-up & Drop-off voltage test for shunt trip and

closing coil.
v)
Current Transformers Polarity Test.
vi)
Voltage Ratio Test for Voltage Transformers.
vii)
Insulation Resistance Test of Power and Control

Circuits, before and after HighVoltage Test.
viii)
High Voltage Test on Power and Control Circuits.
ix)
Earth continuity Test, with low voltage tester.
x)
Physical dimensional check as per the approved

drawing and visual inspection ofthe switchboards.
xi)
Circuit Breakers contact opening and closing time

at rated voltage, at 70 to 110% ofrated voltage and
also synchronous operation test.
xii)
Millivolt drop test of circuit breakers.
Type test reports for following minimum tests shall be

1095 of 2461
PAGE 220 of 339
MMRDA
submitted that are performed on atypical section of the

bus assembly, otherwise the equipment shall have to be
type tested, freeof charge, to prove the design :
i)
Impulse Test& PF withstand test
ii)
Temperature rise Test
iii)
Short circuit Test
iv)
Internal Arc Test for 25 kA 1 sec
v)
Short circuit test duties
vi)
Mechanical Endurance test
Four (4) copies of test certificate shall be submitted for

Owners
approval
before
dispatch
ofswitchboards.
Contractor shall also submit 4 sets of Test certificates of

all bought out itemssupplied along with the switchboards
such as Relay, CT, VT, metres, etc.
Owner or his authorised representatives will carry out

inspection including witnessing tests.
Contractor
shall
notify
Owner
or
his
authorised
representatives in writing at least fifteen (15) days prior to

scheduled date of inspection.
All apparatus, instruments etc. required for tests shall be

provided by the Contractor and shall have been checked
and tested for accuracy during the twelve month, prior to
the test, bearing tag No. of competent authority.
4.3.14 Electrical Motors

1096 of 2461
PAGE 221 of 339
MMRDA
General Specifications
4.3.14.1
Type
Motors shall be of the ac cage rotor induction type as

specified. Energy-efficient type motors shall be provided
IS 12615. They shall have minimum efficiencies at rated
output, and maximum ranges of efficiency between half
and
full
rated
output,
which
meet
the
following
requirements:
1.
Motor rated output (kW)
2.
Guaranteed minimum efficiency at rated output
(%)
3.
Guaranteed Maximum efficiency range half to full-
rated output (%)
4.3.14.2
Rating and Duty
Motors shall comply with the general requirements for

rating, Testing and performance as stipulated in IEC
60034-1:2004 except where amended below. Unless
otherwise
specified,
motors
shall
be
suitable
for
continuous operation(S1) at rated output at (a)any

voltage between 94% and 106% and (b) any frequency
between 97% and 103% of rated values or any
combination of (a) and (b).
4.3.14.3
Operating Condition
Criteria for selection of voltage levels for motors & Power

devices:
1097 of 2461
PAGE 222 of 339
MMRDA
AC squirrel cage induction motors of ratings up to 7.5 kW

shall be fed at LT, 415V, 3 phase, 4 wire, 50 Hz with
DOL.
AC motors of ratings from 7.5kW up to 18.5kW shall be

fed at LT, 415V, 3 phase, 4 wire, 50 Hz with Star Delta
Starter
AC squirrel cage induction motors of ratings from 18.5kW

to 225 kW may be fed at LT, 415V, 3 phase 4 wire 50 Hz,
with Soft starters where full torque load starting and
speed variation is not required. A.C. motors shall be
capable of operation for up to fifteen seconds under
running conditions at rated load and frequency with a
minimum of 70% of rated voltage at the motor terminals.
Refer Soft Starter specifications.
AC squirrel cage induction motors of ratings above

250kW may be fed at HT, 6.6kV, 3 phase 50 Hz, with Soft
starters where full torque load starting and speed
variation is not required.Refer Soft Starter specifications.
If Transformer rating is 8.5MVA/10MVA no soft starters

are required motors shall be operated on DOL.
Motor starting current shall be 600% of full load current.
Unless otherwise required by the driven equipment, two

consecutive starts from motor Hot condition and three
consecutive starts from motor cold condition, both with
subsequent steady continuous operation for 20 minutes,
shall be guaranteed without exceeding the specified
temperature rise limit.
1098 of 2461
PAGE 223 of 339
MMRDA
A.C. motors shall be capable of withstanding, without

damage, unsynchronized automatic transfer of power
supply with motor residual voltage of 100% and of 180
degree phase difference from the source voltage. Motors
shall not suffer any damage when subjected to 120%
nominal speed for 2 minutes. Motors will be subjected to
significant frequency rises following generator load
rejection. Motors shall be protected from damage in this
event. Protection which trips the motor on over speed
and restores it to service when the speed falls will be
accepted.
4.3.14.4
Windings and Insulation
Winding insulation shall be Class F or better to IS 325

and the maximum temperature shall not exceed that
permitted for Class B.
Windings shall be supported, braced, wedged and

blocked to provide adequate rigidity under all conditions
of service. Special attention shall be given to the windings
of direct-on-line started motors and the support of
windings of vertical motors to prevent any permanent
displacement during the service life. The coil overhang of
rotor windings shall be tension banded. Cage-type rotors
shall be designed to provide an adequate factor of safety
against mechanical failure due to fatigue during the
service life of the motor. Special attention shall be given
to the design of cage rotors fitted to motors which are
subject to operation at speeds in excess of rated speed,
and where flywheels or large inertia loads are involved.
Electrical joints and connections shall withstand the
mechanical and thermal stresses under normal and
abnormal operating conditions. Stator end windings shall
be blocked and braced to provide high rigidity.
1099 of 2461
PAGE 224 of 339
MMRDA
Completed windings, including connections, shall be

subjected to a minimum of two cycles of vacuum
impregnation with solvent-free resin varnish followed by
curing, so as to fill effectively the gaps between individual
conductors, to enhance mechanical strength and to
provide a high resistance to moisture, oil and chemical
contamination.
The insulation of flexible cables connecting stator

windings
to
terminal
chlorosulphonated
boxes
polyethylene
shall
be
of
the
(CPS)
or
ethylene
propylene rubber (EPR). Natural rubber insulated cables

shall not be used. Cables shall be securely fixed to the
stator frame. The winding insulation materials and cable
insulation shall be resistant to flame propagation.
4.3.14.5
Degree of Protection for Motor Enclosures
The degree of protection for motor enclosures shall be in

accordance with IEC 60034-5:2000. Unless otherwise
specified, the following minimum degrees of protection
shall apply:
Motors located Indoor IP55 as per IS 4691
Fans and blades external to the enclosure shall be

protected against contact by means of guards. The
degree of protection offered by guards shall comply with
IEC 60034-5:2000.Totally-enclosed motors shall be
provided with suitable means for breathing and for
drainage to prevent the accumulation of water.
4.3.14.6
Cooling
1100 of 2461
PAGE 225 of 339
MMRDA
Cooling arrangements shall be in accordance with IEC

60034-6:1991. Unless otherwise specified, the cooling
classifications shall be as follows:
Motor cooling shall be totally enclosed fan cooled. Other

forms of ventilation may be used with the approval of the
Engineer.
Motors located Indoor: IC41.
4.3.14.7
Dimensions
Motor dimensions of three phase foot mounted A.C

Induction motors shall be in accordance with IS 1231.
4.3.14.8
General Constructional Features
Motor frames shall be cast iron, fabricated from steel

plate
or
aluminum
as
appropriate.
Frames
shall
incorporate substantial internal ribbing to provide high

structural strength. End covers, end shields, external fan
cools and other external components shall be of
adequate
strength
and
robustness,
and
shall
be
constructed of metal unless otherwise approved by the

Engineer. Plastic components shall be designed to take
into account the environmental conditions and the longterm effects of operating temperature, ageing, and
thermal stability of the material. Where used for external
components, the material shall be resistant to flame
propagation. Where plastic covers enclose live parts, the
design shall eliminate the risk of electrical shock to
personnel during operation of the motor. IP protection of
motor for hazardous zone shall be explosive proof class
(explosive ex class).
1101 of 2461
PAGE 226 of 339
MMRDA
Motors shall be designed for normal sound power as

defined by IS 325 or BS 4999.
4.3.14.9
Bearings
General Bearings shall be capable of accepting: the

mechanical and electrical forces imposed on them by the
rotor; the forces imposed by the motor altitude; external
forces due to the drive method.
Bearings shall be of the rolling or plain type as

determined by consideration of motor rating and speed,
shaft system, duty, method of drive and the type of
bearing of the driven equipment. Unless otherwise
specified or approved by the Engineer, motors rated up to
and including 375kW at above 1500rpm shall be fitted
with rolling-type bearings.
Where bearings are insulated from the main frame to

suppress shaft circulating currents, they shall be
connected to earth at one point via a link. The link shall
be removable to permit testing of the bearing insulation.
Oil and water pipes, direct driven oil pumps and any other
ancillary equipment shall be insulated as necessary to
maintain the integrity of the bearing insulation. The
insulation shall not be short circuited by the application of
electrically-conducting paint.
a.
Bearings - Rolling-Type Bearings
Rolling bearings shall comply with the relevant

International Standards and the assembly shall be
designed to exclude the ingress of dirt and water.
The bearings shall be grease-lubricated or oillubricated where the shaft speed is in excess of
1102 of 2461
PAGE 227 of 339
that
MMRDA
permitted
by
the
former.
The
bearing
assembly shall be sealed to prevent leakage of the

lubricant along the shaft and shall be designed to
permit the easy removal of bearings. Oil-lubricated
bearings shall be fitted with a breather.
Rolling-type bearings shall be selected to meet the

following requirements:
1.
minimum life of 40 000 hours when the

forces on the bearing are from the motor
only and
32 000 hours when the forces
include those from the motor and the driven

unit;
2.
Re-lubrication intervals preferably of 8000

hours but not less than 4000 hours;
3.
maximum outer-race temperature of 80C.

Rolling bearings of the sealed-for-life type
shall operate for a minimum of 18 000
running hours, or for a period of 5 years if
the latter occurs sooner.
Grease-lubricated bearings shall be packed

with lithium-based grease at the time of
assembly. A separate grease nipple shall
be provided for each lubricating point.
Grease nipples shall be manufactured from

steel and shall comply with IS4009-3 (1995)
Bearings shall be provided with facilities to
eject surplus grease. Oil-lubricated bearings
shall be provided with an oil reservoir,
1103 of 2461
PAGE 228 of 339
MMRDA
breather and, if appropriate, an external

make-up reservoir. The reservoir shall have
a filler plug and an oil-level indicator. Where
there is a danger of vibration from other
plant being transmitted to a stationary
motor, provision shall be made to prevent
fretting damage to the bearings.
It shall be possible for lubrication to be

carried out with the motor stationary or
running and without the need to remove
guards.
b.
Bearings - Plain Bearings
Plain bearings shall be self-lubricated by oil rings

or discs, or alternatively, shall be forced-lubricated.
The bearings shall be designed to exclude the
ingress of dust and water, shall have provision for
breathing and shall be sealed to prevent leakage
of oil.
Bearings shall be fitted with an accessible drain

plug, provision to permit the cleaning of the oil
sump,
and
transparent
window
or
other
approved facility for observing the oil feed.
The two bearing-shell parts shall have white-metal

linings and shall be self-aligning. The two bearing
shells shall be located to each other by dowels.
The temperature of the oil leaving the bearing shall
not exceed 70C. Bearings shall incorporate
thermometer pockets or shall be fitted with a dialtype
thermometer
thermometers
shall
1104 of 2461
as
specified.
incorporate
Dial-type
two
sets
of
PAGE 229 of 339
MMRDA
adjustable contacts for alarm and motor-trip

initiation. The contacts shall be wired to a terminal
box. The oil rings or discs of self-lubricating
bearings shall run in an oil-bath. Bearings shall
have provision for filling and a clearly-visible oillevel indicator.
The oil-level indicator may be fitted externally to

the bearing. Forced-lubricated bearings shall be
supplied from a self-priming oil pump driven from
the main shaft system or from a separate pump.
An oil-flow indicator shall be provided for each
bearing together with oil cooler, oil tank filter
valves and all interconnecting pipework. Unless
otherwise specified, the oil-feed system shall be
fitted with a pressure gauge and flow switch. The
pressure gauge shall incorporate two sets of
adjustable contacts for alarm and motor-trip
initiation. The contacts shall be wired to a terminal
box.
4.3.14.10
Balancing
Rotors shall be dynamically balanced with full key. The

rotors of motors fitted with an external fan shall be initially
balanced without the fan and then with the previously
statically-balanced fan fitted. Any additional weights shall
be fitted to the fan balance rings.
4.3.14.11
Noise Levels
Unless otherwise specified, the mean sound power level

as per IS 12065/IEC 60034 to work safely without fatigue,
for eight hours a day and without causing health hazard
on a continuous basis.
1105 of 2461
PAGE 230 of 339
4.3.14.12
MMRDA
Vibration Levels
Unless otherwise specified, the maximum limits of

vibration severity for horizontally mounted motors shall be
quality grade N (normal) as given in IS 12075. For
vertical motors, the same limits shall apply to the lower
bearings and 1.5 times these limits for top bearings
unless otherwise agreed with the Engineer. Maximum
r.m.s value of vibration velocity shall not exceed 2.8
mm/s.
4.3.14.13
Lifting Facilities
All heavy parts of motors shall be provided with facilities

for lifting.
4.3.14.14
Temperature-Monitoring Devices
Monitoring
devices
for
motor-winding
temperature
indication and thermal protection shall be of the

resistance or thermocouple type as specified. For thermal
protection
application
only,
positive
temperature
coefficient (PTC) type thermistors shall be used unless

otherwise
specified.
Resistance
and
thermocouple
monitoring devices shall be distributed evenly around the

stator periphery and installed at the hottest points. The
devices shall not be directly exposed to the cooling air.
Thermistors shall be installed in the stator end winding
and shall be distributed evenly over the winding
periphery. The thermistor reference temperatures for
alarm and tripping shall be in accordance with IS
325.Monitoring devices shall be wired to an insulated
terminal strip within a dedicated terminal box fitted with
an identification label. Devices for bearing and cooling air
1106 of 2461
PAGE 231 of 339
MMRDA
temperature monitoring shall be of the thermocouple

type.
The
requirements
for
temperature-monitoring
devices shall be as specified.
4.3.14.15
Anti-Condensation Heaters
Anti-condensation heaters shall be fitted to all low-voltage

motors located outdoors and all high-voltage motors. The
requirement for anti-condensation heaters for low voltage
motors located in other areas shall be specified. The
rating per unit length of the heaters shall be such that the
surface temperature of the heater does not exceed 200C
in an ambient temperature of 40C. The heater voltage
shall be 240V unless otherwise specified. Heaters shall
be connected to an insulated terminal strip within a
dedicated terminal box by means of flexible butyl rubber
insulated leads. The terminal box cover shall be fitted
with a warning label advising the need to isolate the
supply before removing.
4.3.14.16
Terminal Boxes
Terminal boxes shall be cast iron or fabricated from sheet

steel as appropriate to the motor frame construction and
shall have a matching cover. A neoprene-bonded gasket
shall be fitted between the box and motor frame and
between the box and cover. Care should be taken for
explosive hazardous area where motors are installed in
plant termination shall be explosive proof.
Terminal boxes shall be dimensioned to permit external

cables to be satisfactorily connected. The cable box
design shall take in to account the need to connect
oversized cables required for volt-drop or short-circuit
considerations. Terminal boxes shall be provided with a
1107 of 2461
PAGE 232 of 339
MMRDA
removable cable gland plate and shall be capable of

being turned through 360 in steps of 90. Unless
otherwise specified, gland plates fitted to motors for use
with variable-frequency converter-type speed controllers
shall be insulated from the cable box with facilities for
shorting out. The termination arrangement for low-voltage
motors shall be of the air-insulated stud type. The
termination arrangement for high-voltage motors shall be
of the phase-insulated, phase-separated or phasesegregated
stud
type
as
specified.
Terminations,
associated leads and terminal boxes shall withstand the

effects of a short circuit at the motor terminals without
damage. For low-voltage motors, unless otherwise
specified, it may be assumed that the supply protective
device will be of the current-limiting type. For high-voltage
motors, the short-circuit withstand requirements shall be
as specified. Winding terminations and terminal markings
shall comply with BS 4999-145:1987 and BS EN 600348:2007 respectively. The terminal boxes shall have a
degree of protection of at least IP 55 for Indoor
application.
4.3.15 Distribution Transformer
Distribution transformers shall comply with IS 2026 and as per IEC

60076.
The kVA and current ratings of every transformer shall be sufficient to

enable it to continuously feed the maximum electrical load which shall
be connected to it. For this purpose, it shall be assumed that all duty
drives are running and all lighting loads etc. are in operation. Where
two identical transformers are used in parallel, it shall possible to
continue operation of total plant with one transformer out of service.
The calculation shall be carried out for the system with one such
transformer out of service. i.e. No. of operating transformer shall be
1108 of 2461
PAGE 233 of 339
MMRDA
equal to no. of standby transformer.
When the kVA maximum demand from the transformer has been
established, it shall be used to establish the maximum current which is
to be drawn from the transformer secondary. For this calculation the
nominal system voltage shall be used.
The following factors shall also be taken into account when selecting
the kVA rating of atransformer:
i)
Any need to derate the nominal kVA rating to allow for arduous
operating conditionssuch as a high level of harmonic current
ii)
The need to avoid excessive voltage regulation, due to high

starting current, at the timeof starting the drive which is fed from
the transformer
iii)
The need to limit the prospective fault level for the system fed by
the transformer
Every distribution transformer shall be of the oil-filled type.
The following fittings shall be provided:
(i)
lifting lugs
(ii)
earthing terminal
(iii)
Jacking or Lifting lugs
(iv)
skid mounted
(v)
winding temperature high thermostat,
(vi)
winding temperature high-high thermostat,
1109 of 2461
PAGE 234 of 339
(vii)
MMRDA
Thermostat to start and stop the possible future cooling fan,
HV cable terminations shall be fully-insulated.
LV cable terminations or bus duct shall be fully insulated and when the
transformer is de-energised, it shall be possible to easily disconnect
and reconnect the LV cables or bus duct without damaging any
insulation or shrouding.
Each oil filled transformer shall comply with IS 2026 and cooled by
means of natural circulation of air and windings shall be cooled with
help of oil within the transformer (ONAN).
The vector group of each transformer shall be Dyn11 unless otherwise

specified.
The primary winding of each transformer shall be provided with an offCircuit tap-changer with tappings of5% in addition to the nominal
tapping. Facilities shall be provided for padlocking the tap-changer in
each position.
The impedance of the transformer shall be as per Indian standard
Unless otherwise specified, the transformer shall be of the conservator

type with a silica gel breather.
Every transformer shall be either skid mounted or provided with

wheels. It shall be provided with lifting lugs or jacking points as per
rating of the transformer.
Every transformer shall be provided with a liquid temperature gauge.

This gauge shall beprovided with two volt-free changeover contacts,
the first of which is to generate a Liquidtemperature high signal and
the other to generate a Liquid temperature high-high signal.
1110 of 2461
PAGE 235 of 339
4.4
MMRDA
415V SWITCHGEAR
4.4.1 General Specification of Low Voltage Switchgear
The feeder list indicated in the SLD is only tentative. The Contractor
has to design thefeeder configuration on the basis of attached SLD,
equipment / load locations marked in theplan layout, load list & 10%
spare capacity for future addition. These schematics shall besubmitted
to Clients, along with the bids. Since designing is Contractors scope,
lump sum prices quoted by the Contractor in the price schedule shallbe
binding.
4.4.2 Panel Construction Details
a)
The Panels/ DBs shall be floor mounted, free standing type.
b)
All switchgear shall be easily extendible on either side. The

Contractor shall supply switchgear in various shipping sections
comprising incomer, ties etc. Maximum single shipment section
shall not be more than 2300 mm in length.
c)
All mounting accessories like base channels, cross angles if

required, nuts, bolts etc. shall be supplied by the Contractor/
Contractor under the scope of this contract.
d)
All the indoor switchgear panels shall be suitable for IP-52

degree of ingress protection for the enclosure. Outdoor panels
shall be with minimum IP-55, degree of protection. Explosion
proof for hazardous zone.
e)
All doors & cover shall be fabricated with 14/16 SWG (2.0 / 1.6
mm) CRCA sheets and all loading members and main sections
of panel as well as ACBs shall be fabricated with 12/14 SWG
(2.6 / 2.0 mm) CRCA sheets. Doors & covers more than 650 mm
1111 of 2461
PAGE 236 of 339
MMRDA
shall be fabricated with 14 SWG CRCA sheet. All panels shall

be compartmentalized in construction & shall easily expandable
from both end.
f)
Gland plate thickness shall be 10SWG (3.15mm).
g)
Each door & cover shall have adequate reinforcement of

suitable ribs & stiffeners inside door.
h)
All panels shall conform to FORM 4 as per IS 8623: 1993, Part I.
i)
All doors shall be with concealed type hinges and captive

screws. Rear doors of panels requiring rear access shall be
provided with removable hinged doors. Side covers of panels
shall be with removable panels.
j)
Feeder shall have hinged open able (more than 90) type door
with panel locks. All bus-barcovers and other panel covers shall
have screw fixed. Cable alley shall have minimum width of
300mm.
k)
Switch board shall be complete with all fabrication work like

drilling, punching, shearing & welding etc. before proceeding to
7 tank processes. All interiors and exteriors of switchgear/
enclosure etc. shall be finished and painted to produce a neat,
fire resistant and durable surface which would prevent rusting
and corrosion.
l)
Any post painting fabrication activity like drilling, cutting,

welding may liable for rejection of complete panel.
m)
Sheet
the
n)
metal
seven
components
tank
shall
phosphating
be
pre-treated
using
process
Consisting of de-greasing, acid pickling, de-rusting, phosphating
1112 of 2461
PAGE 237 of 339
MMRDA
and passivation including repeated rinsing in between each

process. On completion of passivation of the components they
shall be preheated and then epoxy powder coated with Siemens
grey RAL 7032 shade. Thickness of all painting shall be
minimum 80 microns DFT suitable for corrosive environment.
o)
Length of PCC/MAIN LT PANEL shall not exceed 8M.
p)
Suitable
barriers
terminals
connected
q)
shall
to
be
provided
different
between
two
voltage supplies.
Hinged doors shall be earthed through flexible earthing braid of

adequate cross section.
r)
All door locks shall be provided with special keys to

ensure opening by authorized personal only.
s)
Earth bus-bar shall be extended outside the switchboard at both
the ends.
t)
Panel
height
shall
not
be
more
than
2300
mm
(Including 100mm base ISMC). The depth of panel shall

not exceed 1350mm & any operating handle of switchgear shall
not be more than 1800 mm and not lower than 300 mm from
base of the panel.
u)
Caution board written

Hindi
&Marathi)
in
shall
three
be
languages
riveted
(English,
at appropriate
locations on front and rear door.

v)
Breaker up to 1000 A shall be installed in two tiers and

above 1000A; it shall be mounted in single tier.
w)
Inside components shall be provided with self-adhesive type

paper labels with lettering marked by permanent marker.
1113 of 2461
PAGE 238 of 339
x)
MMRDA
Each compartment & component shall be provided with

Aluminium anodized name plates (with white letters on Black
back ground) at front inside & rear side.
y)
Equipment nameplates shall be fixed by screws/rivets and shall

not be pasted.
z)
Drawing pocket shall be provided on the inside of incomer
feeder door.
aa)
Provision for Top / Bottom cable entry shall be made to suite the
site condition.
bb)
All
hardware
fasteners
e.g.
etc,
Nuts,
bolts
&
gasket,
anchor
are included in the Contractor's scope. No
separate claim shall be entertained, in this respect. Atleast 10%

extra hardware shall be considered for any installation/fixing
work. This is to ensure ready availability of hardware in case of
loss of some hardware during installation.
cc)
All PVC/engineering plastic based items (including but not

limited to conduits, casing-capping, trough, trunking, enclosures,
doors, covers, plugs, etc) shall be with FR properties.
dd)
Lifting
hooks/eyes
shall
be
provided
in
each
shipping
section of the equipment and shall be removable type.
4.4.3 Equipment Requirement
a)
All
ACBs
shall
be
rated
for
be
in
415V,
50
draw out
Hz,
50
modules.
kA
ACBs
shall
service breaking
capacity (Ics=Icu=Icw= 100%) with 6 NO and 6 NC auxiliary

contacts (spare available for Clients use) rated 10A at 230V for
spring charging motor, door I/L, emergency P.B., safety shutters
1114 of 2461
PAGE 239 of 339
MMRDA
etc.
b)
The incomer ACBs & MCCBs shall be suitable for remote

closing and tripping.
c)
Transformer incomer &buscoupler breaker (1250A) shall be 4

pole electrically operated draw-out type (EDO). All remaining
ACBs shall be 3 pole with isolable neutral link (TPN) Electrically
operated draw-out type (EDO).
d)
Transformer incomer breakers on PCC/MAIN LT PANEL shall

be provided with 2 nos. No Volt relays (between R-Y and Y-B
phases).
e)
All incomer ACBs shall be provided with microprocessor based

direct acting, continuous adjustable overload, short circuit, earth
fault and under/no voltage releases.
f)
Gas Generated &DG Incomer and Bus coupler Breaker as

required.
g)
For Incomer of all the panels & outgoing of PCC/MAIN LT

PANEL, ACB / MCCB feeders shall be provided with
microprocessor based direct acting, continuous adjustable
overload, short circuit, earth fault (inbuilt in breaker) releases &
for all other DB & panel outgoing feeders shall be provided with
thermal magnetic release O/L, S/C & E/F ( with CBCT) release.
h)
All the incomers/ feeders having rating 800A &above shall be

draw out type ACBs.
i)
All incomer & Outgoing ACBs of PCC/MAIN LT PANELs shall be

EDO.
j)
All ACBs shall be of approved make as mentioned in list of
1115 of 2461
PAGE 240 of 339
MMRDA
Approved Makes.
k)
Contractor shall clearly indicate the features and model/type

being considered for ACBs and MCCBs. No downward
dilution/variation of any kind shall be allowed at a later stage
based on any justifications for offering a lower rated or different
item.
l)
For multiple interlocking arrangements PLC and hard wire with

AUTO/MANUAL and PLC OFF conditions required.
m)
Power supply for PLC shall be supplied from UPS.
n)
PLC I/O Interlocking cable color code shall be different.
o)
Separate Terminal block shall be provided for PLC I/O with

glass fuse wherever applicable.
p)
All protective components esp. ACBs and MCCBs installed in

PCC/MAIN LT PANEL and at Incomer of downstream Panels
shall be with Utilization Category "B" (i.e. offering time
discrimination with downstream devices).
q)
All overload releases (overload protection in bimetal/ electronic/

static/ microprocessor form) shall have thermal memory feature.
r)
Protective releases shall be EMC compliant. The release shall

be protected against non-linear loads and shall not cause
nuisance tripping due to harmonics.
s)
For circuit breakers, potential free contacts for CLIENTSs use

in addition to those required for control and indication shall be
provided, as per the various module drawings. If any contact
multiplication is done, it should be done by an auxiliary relay and
not by contactor.
1116 of 2461
PAGE 241 of 339
t)
MMRDA
The make, rating and type of the circuit breakers with derated
currents, with supporting documents shall be furnished in the
offer. Type test reports shall be furnished for CLIENTSs
approval. If the breakers offered are not acceptable, breaker
acceptable to Clients shall be offered. A copy of the catalogue of
the breaker included in the offer shall be enclosed with the bid.
u)
All MCCBs shall be Four pole (FP) for PCC/MAIN LT PANEL

outgoing and MLDB incomer. All outgoing feeders of MLDB shall
be FP MCCB. All MCCBs shall be rated for 415V, 50 Hz, &
service breaking capacity as per SLD (Ics = Icu = 100% rating).
All MCCBs shall be in fixed module.
v)
All the MCCBs shall be of current limiting type and shall provide
a cut off in 4-8 ms for prospective currents during faults. MCCBs
shall have ON, OFF & TRIP indication lamps. Necessary
auxiliary contact block is included in scope. The Contractor shall
ensure coordination between upstream & downstream MCCBs.
w)
All outgoing MCCB feeders on PCC/MAIN LT PANEL, MLDB

and Incomer of Shop Distribution board / Panels shall be
provided with microprocessor based O/C, S/C & E/F releases
and all outgoing feeders of MLDB shall be thermal magnetic
O/C, S/C and earth fault releases.
x)
All MCCBs shall be provided with rotary handle with door

interlock feature.
y)
All MCCBs shall be among one of approved make as

mentioned in list of approved make.
z)
MCCB terminals shall be shrouded type & shall be designed to

receive cable lugs for relevant cable sizes.
1117 of 2461
PAGE 242 of 339
aa)
MMRDA
All current transformers shall have 5A secondary and all meters

shall be suitable for 5A operation. All instrument transformers
shall be cast resin type and shall have insulation of class B or
better. All CTs shall be provided with temporary shorting links.
bb)
All instruments (including meters, analysers, and recorders)

shall be true RMS type; class of accuracy shall be 1.0 or better.
cc)
Load Manager/ Multi-Function Meter shall display all electrical

parameters like (but not limited to) current, voltage, kW, kVA,
KVAr, kWH, PF, F etc. and shall have provision for RS 485 port
for remote communication in future. Load manager shall be of
approved make equivalent to EM6400 with class 0.5 accuracy or
better.
dd)
Provision for adjusting the Maximum demand shall be available

in the Load managers in order to control the load by Alarm and
trip command through potential free contacts. 4NO + 4 NC
Potential free contacts linked with MD limit shall be provided on
the Load Manager for CLIENTSs use (Breaker trip/ ATS
operation etc.). If required contacts shall be multiplied as
specified above.
ee)
Load Managers shall be provided for feeders with 250A and

above rating feeders.
ff)
All MCCB feeders with 125A shall be provided with kWH meters.
gg)
All the outgoing feeders including & above 125A shall be

provided with 72mm x72 mm size analogue ammeter.
hh)
For all incoming feeders analogue type 96mm x 96mm ammeter

& voltmeter (taut band) with selector switches in addition to load
manager shall also be provided.
1118 of 2461
PAGE 243 of 339
ii)
MMRDA
Separate metering compartment shall be provided for all

analogue / digital meters like load manager, voltmeter, ammeter,
indication lamp etc. All wiring & MCB / fuses shall be mounted in
metering
compartment
such
that
meter
maintenance
is
independent of the power compartments
jj)
VA burdens of the CT / PTs shall be decided by Contractor/

Contractor,
however,
minimum
10VA
burden
shall
be
considered.
kk)
Contractor / Contractor has to ensure Type - 2 Co-ordination for

all motor feeders.
ll)
Indication lamps Red/ Green/ Amber/ White/ Blue colored for

ON/OFF, AUTO TRIP, Test and Service position indications, trip
circuit healthy and spring charged indication on all ACB feeders
shall be provided.
mm) All the MCCB feeders shall be provided with ON/OFF, TRIP
Indications using Red / Green & Amber colored lamp
respectively.
nn)
Provision for interlocking with HV side breaker shall be provided

such that if the HV breaker trips then the 415V breaker will trip
and it shall not be possible to close the 415V breaker unless the
HV side breaker is closed.
oo)
Selector/control switches shall have an 'Off position. The 'off

position shall not be wired in any circuit and shall be utilized to
disconnect (or bypass) power supply to control circuit for any
maintenance work.
pp)
Start push button shall be recess type, spring return. Stop push
button shall be stay-put lockable type. The pushbuttons shall be
dust and vermin tight.
1119 of 2461
PAGE 244 of 339
MMRDA
qq)
All indicating lamps shall be of multichip LED type.
rr)
20% spare terminals to be provided for each terminal strip for

each panel.
ss)
Additional red colored ferrule to be provided for all panels.
tt)
Panel
wiring
ferruled.
&
Ferrules
cabling shall be with straight + crossshall
be
etched
&painted type.
('Printed' ferrules are not acceptable).
uu)
Padlocking facilities shall be provided for locking the shutters

positively in closed position in all the panels.
vv)
Caution name plate, Caution Live Terminal shall be

provided at all the points where the terminalsare likely toremain
live and isolation is possible only at remote end i.e. Incomer to
the switchboard.
ww)
All unused contacts of the circuit breaker, protection, auxiliary,

control relays shall be wired up to the terminal block.
xx)
Protective covers of transparent plastic for placing over live

parts of the terminal block shall be provided.
yy)
Suitable barriers shall be provided between two terminals

connected to
zz)
different voltage supplies.
Earth bus-bar shall be extended outside the switchboard at the

ends.
aaa) Panel illumination lamp shall be 9 /11 W CFL with fixture & door
limit switch.
1120 of 2461
PAGE 245 of 339
MMRDA
bbb) Panel shall be provided with thermostat (range 25 to 90 degree

centigrade) & space heater in each cable alley.
ccc)
5/15A, 5 pin socket with switch & plug shall be provided in each
panel.
ddd) Each control wire shall be with identification ferrule of

Terminal
No.,
component
design nationand cross ferruling
on both sides.
eee) Insulated sleeves shall be provided for control wires.
fff)
Feeder and board name plates to be provided at front and rear

of switchboard.
ggg)
All terminals of different control voltages shall be separate from

each other.
hhh) Stud type terminals and ring type lugs shall be used for control
cables.
iii)
Looping of all RS485 ports shall be done using 3 core twisted &
shielded 1.5 sq.mm Cu cable& shall be terminated at one
incomer
jjj)
All lamp test facility shall be provided for all ACBs
4.4.4 Control Circuit
a)
Following control voltages shall be used in PCC/MAIN LT
PANEL
All ACBs tripping - PCC/MAIN LT PANEL - Direct acting
releases
1121 of 2461
PAGE 246 of 339
b)
MMRDA
All ACBs tripping - Other DBs- Direct acting releases
All ACBs closing- PCC/MAIN LT PANEL- 230V AC
All ACBs closing- Other DBs - 230V AC
All ACBs closing motor - 230V AC
Indications for PCC/MAIN LT PANEL ACBs- 230V AC
Indications for Other DBs ACBs- 230V AC
Space heater etc. - 230V AC derived from AC bus.
The trip coil and closing coils of ACBs (230 V AC) shall operate
satisfactorily under thefollowing conditions of supply voltage.
Closing coils 85 % to 230 % of rated voltage
Trip coils- 70 % to 230 % of rated

voltage
PLC interlocking logic with software & Hardwire logic both are
required
c)
All auxiliary relays/protection relays on PCC/MAIN LT PANELs

shall be suitable for 230V AC auxiliary supply.
d)
415V AC, 230V AC and other voltages shall be segregated to

avoid mix up of voltages.
e)
Control transformers suitably rated of voltage ratio 415/230 V, on

the Bus shall be provided. 230 V AC control supply inside the
panel will be obtained from 415V/230V control transformer in
PCC/MAIN LT PANEL for bus section refer standard scheme
1122 of 2461
PAGE 247 of 339
MMRDA
enclosed. For these control transformers, fuses shall be provided

on the 415V side and MCBs on the 230V side. The control
transformer shall be cast resin type only. Rating of the control
transformer shall be decided by the Contractor depending on
the system requirements
f)
Control wiring shall be done by 660 volts grade PVC FRLS

insulated multi-stranded copper wire. CT circuit wiring shall be
done with 2.5 Sq.mm size wire. Control and Potential circuits
shall be wired with minimum 1.5 sq. mm size wires. Wires shall
be gray colored with suitable crimp able copper lugs. CTs & PTs
wiring shall be color coded for multi-phase identifications (R-Y-BN).
g)
The trip coil and closing coils of ACBs (For PCC/MAIN LT

PANELs & other panels/DBs - 230V AC and other panels/DBs
shall operate satisfactorily under the following conditions of
supply voltage.
Closing coils 85 % to 230 % of rated voltage.
Trip coils- 70 % to 230 % of rated voltage.
4.4.5 Busbars / Cable Entry
a)
Busbar rating of all panels shall be designed for Continuous

current at site conditions.
b)
All Busbars shall be of electrolytic grade aluminum. Busbars for

PCC/MAIN LT PANELs shall be of 36kA (min), 1sec short circuit
rating and for other panels/DBs it shall be as per 415V SLD for 1
sec short circuit rating.
c)
Main Horizontal bus-bars of PCC/MAIN LT PANEL shall be

interleaved type. Vertical bus-bars shall have S.C. rating same
1123 of 2461
PAGE 248 of 339
MMRDA
as main bus bar and shall be suitable for all connected load of
vertical section.
d)
Bus-bars of PCC/MAIN LT PANEL, MLDB incomer/outgoings,

Battery charging feeders and feeders below 63A shall be 4 pole
(neutral bus bar size shall have same rating as that of phase)
and bus-bars of all other PDBs / Panels shall be TPN. All busbars shall be covered with heat shrinkable black PVC sleeves.
Coloured polyester tapes for phase identification shall be
provided at suitable locations.
e)
Termination on bus bars at ACB, MCCBs shall be as per

IS13947 part 2 for aluminum bus bars and IEC60947-2 for
copper bus bars. For terminations on MCCBs, where phasephase and phase to earth clearance are not possible, copper
bus bars shall be used.
f)
The exposed bus live parts in the cable alley shall be totally
covered against accidental contact by a shroud (Not by sleeve)
to protect the workmen working on the switchgear.
g)
The Contractor shall furnish calculations along with the bid

establishing the adequacy of the bus bar sizes to meet the
continuous and short time current ratings specified.
h)
For the PCC/MAIN LT PANEL, Contractor shall ensure that

incoming feeders from transformer and DG Switchgear shall be
suitably designed for terminating cables
i)
A suitable gland plate shall be supplied for termination of power,

control and instrumentation cables.
j)
The bus-bars shall be designed considering the following criteria:
k)
Sleeving made of insulating material on all bus bars.
1124 of 2461
PAGE 249 of 339
l)
MMRDA
Site ambient and final temperature of the bus-bars as

required.
m)
Bus bars being inside the panel
n)
Bus bars carrying rated current continuously
o)
Bus bar supports shall only be SMC irrespective of bus bar

size.
p)
All applicable derating factors shall be considered for sizing the

bus bar.
q)
All bus-bar shall be treated with anti-oxide paste wherever bimetallic contact is required.
4.4.6 Earthing:
a)
Earthing bus-bar shall be terminated at both ends of the

switchgear to suit the connections to Clientsearthing conductor.
b)
All components inside the module are required to be earthed

individually with green wire of size 4 sq.mm stranded copper
conductor and are to be looped & connected to horizontal earth
bus.
c)
Earth bus bars of GI material shall be properly supported to

withstand stresses induced by the momentary short circuit
current of value equal to the momentary short circuit rating of the
associated switchboard/ panel.
d)
FRLS PVC Insulated cable/wire for earthing shall be of green

colour (with yellow band). Black cable/wire shall not be
acceptable.
1125 of 2461
PAGE 250 of 339
MMRDA
4.4.7 Terminals
i) CT circuit-
ii) PT circuit-
Isolating link type terminals with shorting facility
Clip on type terminals
Spare contacts shall be wired upto terminal block. 20% spare terminals
shall be provided for each module.
All panels shall have Terminal block suitable for connecting min
6sq.mm. conductor unless otherwise stated.
4.4.8 General
a)
It is the CONTRACTORs responsibility to offer the panels as per

the feeder list with the correct module type as indicated in the
specification. Also the bill of material in each module shall be as
per specification requirement. Specific confirmation with regard to
this clause shall be furnished in the bid as the details furnished by
the CONTRACTORs cannot be verified at this stage to specifically
confirm that all equipment shown on the control wiring diagram for
each module are provided.
b)
Contractor shall furnish separate single line diagram for each

panel indicating equipment details, rating etc.
c)
The exposed bus live parts in the cable alley shall be totally
covered against accidental contact by a shroud (and not by
sleeve) to protect the workmen working on the switchgear.
d)
The equipment shall be given tropical and fungicidal treatment.

As stated in Section-B, thedesign ambient temperature of air
outside the switchgear enclosure shall be considered as 45
deg. Cent. for the design of all equipment supplied against this
1126 of 2461
PAGE 251 of 339
MMRDA
specification.
e)
Space heater indicated in the breaker modules represents the

space heater for each vertical section of the switchboard. Where
breakers are mounted in two-tier formation, then only one space
heater with associated MCB and thermostat is adequate for the
vertical section.
f)
Door padlocking arrangement shall be provided for all modules.
g)
Panel illumination (CFL/FTL) with 1 no. socket shall be provided

for each vertical section.
h)
All the metering & protection equipments shall be communicable

on IEC 61850 protocol &shall be able to integrate with SCADA
system.
i)
All final approved scheme drawings and single line diagrams shall
be submitted in ACAD 2004 hard copies.
4.4.8.1
Layout Requirement
a)
The incomer to the PCC/MAIN LT PANEL shall be

a Cable entry from top/Bottom as required. All
outgoing cables shall be from the top / bottom.
b)
All panels / power DBs located in Main Shop area /

Office shall be suitable for top cable entry & exit
whereas MLDB, ACDB located in Electrical room
shall be suitable for bottom cable entry and exit.
c)
Blank covers approx. 1M for 3 sides of panels shall

be provided for all top entry cables so that cable
termination can be done.
1127 of 2461
PAGE 252 of 339
4.4.8.2
MMRDA
Maintenance Requirements
a)
Easy access shall be provided for all components

in the switchgear for maintenance.
b)
The
Contractor
shall
furnish
operating
and
maintenance instructions manual to enable the

Clients to carry out maintenance of the equipment
effectively and safely.
c)
As far as possible the switchgear shall be so

designed that no special tools are necessary for
installation and maintenance. However, if special
tools are required, the Contractor shall include
price of one complete set in his bid.
d)
The Contractor shall include supply of Essential

spares specified in Data sheet-A1 and also
Recommended Spares for five (5) years trouble
free operation, in Section-F.
e)
Contractor shall furnish detailed inter panel wiring

diagrams,
internal
wiring
diagrams,
detailed
component layout drawings to enable the Clients

to carry out maintenance work.
f)
CONTRACTOR
shall
also
quote
unit price
for a trolley for easy handling of circuit breakers if

any, mounted on top tier
4.4.8.3
Performance Tests
a)
Contractor shall carry out all routine tests as

specified in relevant IS/IEC standards on all major
components and furnish copies of test reports for
1128 of 2461
PAGE 253 of 339
MMRDA
CLIENTSs
approval.
Wherever
required,
Contractor shall conduct the necessary type tests

in the presence of CLIENTSs representative
based on the unit prices available in the bid.
b)
Contractor shall also carry out all routine and

functional tests as specified in the relevant IS on
the assembled switchgear panels in the presence
of the CLIENTSs representative at works before
dispatch and furnish copies of test reports for
approval. If required stage inspection will be carried
out by the Clients.
c)
CONTRACTOR shall furnish copies of routine test

report for all bought out items for CLIENTSs
approval.
d)
The Contractor shall submit type test certificates

along with the bid for PCC/MAIN LT PANEL for the
following.
a) S.C. withstand capacity for 1 sec
b) Degree of protection
c) Temperature rise
4.4.8.4
Schedule of Submission of Contractor Drawings
a)
Following time schedule for submission of various

Contractor drawings shall be strictly adhered to by
the Contractor. The time period indicated below
shall be considered from the date of letter of intent
(LOI).
1129 of 2461
PAGE 254 of 339
i)
MMRDA
Single
line
diagrams
control
schematics
ii)
Bill of materials for each PCC/MAIN LT

PANEL, PDB & MLDB -
iii)
General
arrangement
drawings
of
PCC/MAIN LT PANEL, PDB & MLDB -
iv)
Foundation drawings
v)
Internal wiring diagram -
vi)
Terminal
block
diagram
with
terminal
numbers
vii)
All necessary calculations for cable sizing,

Bus bar design/size, etc.
b)
The Contractor
shall
depute
competent
engineers for discussions on outstanding issues

when called upon by MMRDA / CONSULTANT.
4.4.9 Circuit Breakers
4.4.9.1
Miniature Circuit Breakers
Miniature circuit-breakers shall comply with IEC 608982:2006. Miniature circuit-breakers shall directly indicate
the true position of the contacts and shall comply with
local electrical regulations. Operating mechanisms shall
be mechanically trip-free from the operating handle to
prevent the contacts being held closed under overload or
short-circuit conditions. The operating handle shall be of
the toggle type and shall have an integral facility for
1130 of 2461
PAGE 255 of 339
MMRDA
padlocking in the off position.
Each pole shall be fitted with a bi-metallic element for

overload protection and a magnetic element for shortcircuit protection. Multiple-pole circuit-breakers shall be
mechanically linked such that tripping of one pole
simultaneously trips all the other poles. The magnetic
element tripping current classification shall, unless
otherwise specified, be Type C. Miniature circuit-breakers
shall be capable of accepting a full range of accessories
such as auxiliary switches, terminal shrouds and interphase barriers. Miniature circuit-breakers shall have a
rated current and category of duty as specified. The latter
shall, unless otherwise specified, be not be less than M9.
The short-circuit rating shall be not less than that of the

system to which they are connected. Where this cannot
be attained, a back-up fuse link or links shall be fitted.
4.4.9.2
Residual Current-Operated Circuit Breakers
Residual current-operated circuit breakers shall comply

with
IEC
61008-1:2004
and61008-2:1995.Residual
current-operated circuit breakers shall be double-pole for

single-phase and four-pole for three-phase and neutral
circuits. The rated current shall be as specified.
Unless otherwise specified, the trip settings shall be as

follows:
(a)
rated current up to and including 40A: 30mA;
(b)
rated current above 40A and up to 100A: 100mA;
(c)
rated current above 100A: 300mA.
1131 of 2461
PAGE 256 of 339
MMRDA
No intentional time-delay shall be fitted unless specified.
4.4.10 Motor Starter
4.4.10.1
Soft Starter (L.T) Specification
The Soft starter shall be designed for Supply Voltage

Variation of 10% & Frequency variation 5 %.The LT
Soft Starter shall be rated corresponding to the Motor
Power & shall be capable of Operating satisfactorily with
the Motor under the various loading & starting condition
of the Motor over the entire Operating Range. The Soft
Starter rating offered shall not be less than the rated KW
of the Motor. The Soft Starter shall be so rated as to allow
at least three starts equally spaced per hour or one hot
start.
Soft Starter must be able to limit the starting inrush

current up to 3 times of Motor Full load Current with
connected on line side.
LT soft starter must have following protection:
Interlock failure
Single phasing/phase Sequence
Over current protection
Control voltage failure
Total number of starts
Over temperature fault
1132 of 2461
PAGE 257 of 339
MMRDA
CTMR must have a proper visual annunciation for the

faults.
The LT Soft Starter shall have suitable hour meter and

operation counter for counting motor running hours &
counting no. of startstop operations of the motor. The LT
Soft Starter shall have Anti Condensation Heater with
switch & Thermostat. The Heater shall have interlocking
in such a way that it is switched OFF when Motor is in run
mode. The LT Soft Starter shall have suitable rated
control switchgear like Contactors, Timers, Push Buttons
& Indication Lamps. The LT Soft Starter shall be indoor,
metal clad with separate metal enclosed compartments
for
I.
Control, Metering & Push Buttons with indicating
Lamps
II.
Power Switchgear
III.
Power Cable Terminations
Each cubicle of LT Soft Starter shall be fitted with a label

in the front & rear of the cubicle, indicating the panel
designation, rating & duty. Each relay, instrument, switch,
fuse & other devices should be provided with separate
labels.
The Soft Starter shall be housed in a CRCA sheet

enclosure of thickness not less than2 mm & internal
frame 3 mm. The enclosure shall be painted with powder
coating corrosion resistive paint as per IS-5. The degree
of Protection shall be IP 51. The enclosure should be only
CNC fabricated.
1133 of 2461
PAGE 258 of 339
MMRDA
The LT Soft Starter should be suitable for up to 50 degree

Ambient Temperature and Altitude up to 1000 m.
Protection Functions
The Amp control MPA motor Protection Relay provides

protection functions for:
i.
Overload
ii.
Short Circuit
iii.
Earth Leakage
iv.
Motor Contactor Fail
v.
Phase Current Unbalance
vi.
Undercurrent/Over-current Alarms
vii.
Over Temperature - PTC Thermistor
viii.
Under-voltage
ix.
Insulation Test
x.
PT-100 RTD Temperature Protection
Rating Plate:
Each Reactor shall be provided with weatherproof rating

plates fitted in visible position showing in all cases the
appropriate items indicating below:
1134 of 2461
PAGE 259 of 339
MMRDA
1. Type of reactor
2. Indoor application
3. Number of this part of IEC 60076

4. Manufacturers Name
5. Manufacturers serial number
6. Year of Manufacture
7. Insulation level
8. Number of phases.
9. Rated Power
10. Rated Frequency
11. Rated Voltage
12. Rated Current
13. Max. Operating Voltage
14. Reactance at rated voltage or inductance at rated

voltage.
15. Thermal class of insulation
16. Transportation Mass/Total Mass, etc.
4.4.10.2
Test
1135 of 2461
PAGE 260 of 339
MMRDA
The general requirements for routine test, type test and

special test are prescribed in IEC 60076-1
4.4.10.3
Routine Tests
The following routine test shall be performed:
Measurement of Winding resistance (IEC 60076-1);
Measurement of Reactance;
Measurement of Loss at ambient Temperature
Measurement of Insulation resistance and/or capacitance

resistance and dissipation factor Tan Delta of Winding
insulation.
4.4.10.4
Type Test
Temperature Rise test
Measurement of acoustic sound level
Dielectric test
4.4.10.5
Special Test
Measurement of Zero sequence reactance on three

phase reactor
4.4.10.6
Schedule of Submission of Contractor Drawings
a) Following
submission
of
various
Contractor
drawings shall be strictly adhered to by the

Contractor. The time period indicated below shall
1136 of 2461
PAGE 261 of 339
MMRDA
be considered from the date of letter of intent

(LOI).
1) Bill of materials for each Soft starter
2) General arrangement drawings of Soft starter
3) Foundation drawings
4) Internal wiring diagram
5) Terminal block diagram with terminal numbers
Variable Frequency Drives (VFD) for WTP motors
General
AC induction motor in Water Treatment Plant wherever

applicable for variable speed purpose shall be coupled
with a Frequency drive of rating commensurate with the
rated motor. The Frequency drives shall be of Current
Source Inverter Pulse Width Modulated (CSIPWM) with
GTO/ IGBT/ IGCT/ SGCT/ DTC technologies or later
version, which performs precise speed and torque control
of standard squirrel cage motors with optimum efficiency.
Each drive must have a soft starting feature and a bypass
arrangement for DOL starting of motors. All frequency
dives shall be suitable for data connectivity with PLC/
SCADA system and shall have suitable communication
port
and
protocol.
The
drives
must
be
easily
programmable. The drives shall be provided with surge

protection, programmable lockable code. The Frequency
drive shall have following characteristics:
Accurate open loop torque control

1137 of 2461
PAGE 262 of 339
MMRDA
Torque step rise time typically less than 5 ms
Speed control inaccuracy typically 0.1% to 0.5% of

nominal speed
150% overload capacity for 60 second
Total Harmonic distortion shall comply with the provisions

of
IEEE
519.
Necessary
metering,
self-diagnostic
arrangement (including display and alarm facilities) shall

be provided for local/ remote monitoring.
Technical parameters
Main connection
Voltage
3 phase, 415 +/ - 10 % permitted tolerance
Frequency
45 to 65 Hz, maximum rate of change 17%/

s
Imbalance
Max. +/ - 3% of nominal phase to phase

input voltage
Fundamental
Power :
0.97 (at nominal load)
factor
Motor connection
Voltage
3 phase, from 0 to applied incoming supply

voltage, 3-phase symmetrical
Output Frequency
0 to 250 Hz
Frequency Resolution
0.01 Hz
Continuous Current
1.0 * I2N(normal use)
Short
Term
Overload :
I2max = 1.1 * I2N
Capacity (1min./ 10min)

Field Weakening point
8 to 300 Hz
Acceleration Time
0 to 1800 sec
Deceleration Time
0 to 1800 sec
Efficiency
Min. 97% at nominal power level
1138 of 2461
PAGE 263 of 339
MMRDA
Environment limits
Ambient temperature
0 to 45 deg. Cent.
Standard control connections

3 programmable differential analogue inputs (1 voltage signal, 2 current
signals)
7 programmable digital inputs
2 programmables analogues outputs (current signal)
3 programmable digital outputs ( from C relays)
Optional analogue and digital extension modules can be added as well as
a wide range of field bus adapters.
Protection
Over current
Short circuit at start-up
Input phase loss
Output phase loss
Motor overload
Earth fault
Overvoltage
Undervoltage
Over temperature
Motor stall
Application macros
The features a selection of built-in, pre-programmed application macros for
configuration of inputs, outputs, signal processing and other parameters. It
shall have interfacing facilities to communicate data to SCADA system.
These include:
FACTORY SETTING for basic industrial applications
HAND/ AUTO CONTROL for local and remote operation
PID CONTROL for closed loop processes
TORQUE CONTROL for process where torque control is required.
SEQUENTIAL CONTROL for processes where torque control is required.
USER MACRO 1 and 2 for users own parameter setting
Comprehensive testing and diagnostic function
1139 of 2461
PAGE 264 of 339
MMRDA
Tests
Each unit of Variable frequency drive shall be tested at

the manufacturers work. Test result must satisfy the
efficiencies on various loads and at different frequency
levels against their quoted values during bidding.
4.4.11 Automatic Power Factor Control
4.4.11.1
415V Capacitor Control Panel
Power Factor Correction at 415V:
For sizing of APFC Panel located at Electrical room to

improve power factor from 0.8 to Unity, following points
shall be considered.
a) Contactor Controlled 5.67/7% detuned APFC

Panel as required for loads (without welding
process) shall be provided to improve load power
factor of 0.8 to Unity.
b) Fixed type capacitor banks connected at the 415V bus

will be provided and will be automatically controlled
through APFC relay of 8-14 stage microprocessor
based.
c) MCCB of suitable rating for the required kVAR

capacitor banks respectively without releases shall be
provided for incomer to APFC panel.
4.4.11.2
Capacitor Banks
a) Capacitors shall be APP type having following

specifications:
1140 of 2461
PAGE 265 of 339
MMRDA
b) Supply: 3 phase and 3 wire
c) Rated voltage: 415V
d) Rated frequency: 50HZ
e) Permissible overvoltage: 1.1Vn
f)
Permissible over current: 1.5In
g) Temperature category: 50 deg C
h)
The capacitors shall have Low Dielectric Loss of
<0.5 W/ kVAR
i)
Bushing should have high mechanical strength &

method of fixing should be proper so that no leakage
occurs.
j)
Minimum current rating under site conditions, of circuit

breakers, contactor, fuses and cables shall be at least
150% of rated capacitor current, to take care of
harmonics.
k) Power contactor for switching of capacitor banks.
l)
One contact of power factor correction relay shall be

provided for annunciation POWER FACTOR LOW.
The relay shall switch-on / off capacitor banks for loads
from 10% to 100%. The annunciation window shall be
with test, accept and reset push button & hooter.
m) Capacitor switching and automatic power factor

correction panel shall be designed in such a way that
1141 of 2461
PAGE 266 of 339
MMRDA
power factor of Unity shall always be maintained.

Timings to cut in capacitors shall be provided in such a
manner to facilitate capacitor discharging before next
switching and shall also avoid hunting due to
temporary fluctuations of load. The timer shall be
provided in both auto and manual mode.
n) The Automatic power factor correction panel and

capacitor panel are integral type, prewired including
power connections. Due consideration shall be given
for adding/removal of capacitor or other components
and maintenance considerations.
Contractor shall
submit GA drawings of capacitor and capacitor

control panel, with description of power factor control
panel with its components, along with the Bid.
o)
APFCpanel sizing shall be suitable for full loadingof

transformer to which
the APFC is connected.
415 V APFC PANEL- TECHNICAL DETAILS

S.
Description
Unit
Technical Particulars
No.
1
General
(a)
Quantity
Nos.
(*)
(b)
Rated Capacity
KVAR
As per the Requirements
(c)
Rated voltage
433
(d)
Rated frequency and phases
(e)
Ambient temperature
(f)
Cable gland required
Yes
(g)
Size of cable
1.1
(h)
Cable entry
(*)
Top/Bottom
Constructional Requirement
50 Hz, 3 Phase
o
1142 of 2461
50
kV, XLPE, Al. Conductor
PAGE 267 of 339
S.
MMRDA
Description
Unit
No.
(a)
Thickness of sheet steel
i)
Frame,
mm
Technical Particulars
Cold rolled 2.0
Frame
(b)
enclosures, doors covers and

Degree
partitionof protection
IP 54
(c)
Colour finish shade
Interior : Glossy white

Exterior : Light Grey Semi
Glossy Shade 631 of IS
General
(d)
Earthing bus Material
(e)
Earthing
Aluminum
Size
mm
x (*)
Material
mm
GI
conducto
Size
r
mm
Design Requirements
mm
(a)
Insulation level
kV (rms) 2.5
(b)
Capacitor bank connection
(c)
Short circuit withstand for

busbarsi)
(d)
x mm (*)
Delta
kA (rms) 36(*)
Short time (1
ii)
sec)Dynamic
kA
65(*)
Type of switching
(peak)
Automatic
responsive
switching
to power
factor
(e)
Switching steps
(f)
Rating of contactor
through power factor sensing

Minimum 8 steps
relay
To suit KVAR unit
(g)
Incomer switch current rating
To
(h)
Bus bars
KVAR
Aluminum
(*) The numbers and ratings
suit
rated
capacity of
have to be worked out by the
Contractor during execution and will be approved by Engineer
4.4.12 Other Requirements
4.4.12.1
Earthing
1143 of 2461
PAGE 268 of 339
MMRDA
Single enclosures shall be provided with an earth stud or

earth bus bar. Multi-cubicle type enclosures shall be
provided with a continuous earth bus bar which shall
extend over the full length. Each cubicle shall be bonded
to the earth bus bar. The earth bus bar shall be externally
mounted or in an alternative position giving unrestricted
access. The earth bus bar shall be provided with two
terminal assemblies for connection to the electrical
system main earth terminal. All steelwork parts shall be
equi-potentially bonded. A positive earth connection shall
be provided to all enclosure doors on which electrical
components are fitted. Earthing via the door hinge will not
be accepted. The short-time current rating of the earth
bus bar and connections shall be not less than the fault
rating of the switchgear. The temperature rise of the bus
bar and connections under fault conditions shall not
cause damage to the connections of any equipment to
which they may be connected. Earth terminal bolts or
studs shall be brass and shall not be less than 10mm
diameter.
4.4.12.2
Cable boxes, gland plates and terminations
Cable boxes, gland plates and terminations shall be

arranged to facilitate easy access for installation and
connection of cables and cable circuit testing. Cable
gland plates shall be manufactured from sheet steel for
multi-core cables and non-ferrous metal for single-core
cables. Gland plates shall be mounted not less than
300mm above the base of the enclosure. Space for
cabling within terminal enclosures on switchgear for
operation up to 3300 volts shall be in accordance with BS
5372:1997. Adequate space shall be provided for the
termination
of
over-size
cable
conductors.
Unless
otherwise specified, high-voltage switchgear shall be

1144 of 2461
PAGE 269 of 339
MMRDA
provided with enclosed metal clad cable boxes with drytype
encapsulated
terminations.
Auxiliary
cable
terminations on high voltage switchgear shall comprise

segregated enclosed cable boxes externally on the
switchgear enclosures providing unrestricted safe access.
On
low-voltage
switchgear
and
control
gear,
full
separation shall be provided between power cable

terminations.
Power-cable
glanding
and
cable-core
termination on incoming feeder panels and on unit

panel/cubicle main distribution feeders shall be contained
within each respective circuit panel and fully separated by
metallic or non-metallic rigid barriers. On multiplecompartmented outgoing feeder and motor control circuit
panels, power cable termination segregation shall be
achieved by one of the following:
(i)
cable-core termination within the respective circuit

unit compartment but with glanding elsewhere;
(ii)
core termination and glanding within a common

cabling compartment but with each circuit terminal
assembly separated by approved insulating covers;
(iii)
Each functional circuit unit having its own separate

and enclosed cable termination and glanding
facility. Where cable glands are remote from the
cable
terminals,
purpose-made
cable-tray
or
trunking shall be provided within the enclosure for

securing or accommodating the cable cores.
Terminal assemblies shall be provided for all
incoming and outgoing cable conductors, and
where applicable, core screen drain wires. The
direct connection of external cable conductors onto
switchgear
and
control
gear
onto
active
components will not be accepted. Terminals for

1145 of 2461
PAGE 270 of 339
MMRDA
low-voltage application shall comply with IEC

60947-7-1:2002 and shall be of the lug or pillar
type unless otherwise approved by the Engineer.
Pillar terminals shall be of the indirect pressure
type.
Screw less-type terminals will not be accepted.

High-voltage switchgear cable-core terminations
shall be of the lug type. Auxiliary cable and wiring
terminal assemblies in a common compartment
associated with different voltages or circuit type
shall be segregated into clearly labelled groups.
Barriers shall be provided between each terminal
group. Not more than one cable core or internal
wiring core shall be connected to a single terminal.
Where duplication of terminal connections is
necessary, multiple terminals shall be provided
with purpose made solid bridging links. Terminals
which remain energised when the main equipment
is isolated shall be shrouded and fitted with a
warning label.
4.4.12.3
Paint Finish
Enclosures shall be subjected to a comprehensive

system of preparation, protective coating and stoved
finish painting. The finish coat of paint shall be applied by
the electrostatic process. The finish colour shall be as
specified
or
as
approved
by
the
Engineer.
The
preparation and painting system shall be suitable for the

environment in which the enclosures will be installed.
4.4.12.4
Local control panels
Local control panels shall be of heavy-duty construction

1146 of 2461
PAGE 271 of 339
MMRDA
having external fixing brackets and unless otherwise

specified shall have a minimum enclosure protection
classification IP54.Small control stations housing up to
three control components shall be of moulded polyester
or die-cast Aluminum construction complete with screwfixed or bolt-fixed front covers. Larger stations shall be of
fabricated sheet steel construction complete with hinged
front access doors. All mounted control equipment and
internal components shall comply with that specified for
switchgear and control boards. Control stations shall be
provided with bottom-entry cable termination facilities with
adequate glanding space provided for the required
number of cables including clearance for the use of
spanners. Cable-core terminal assemblies shall be
provided for all cable cores which shall be identified
according to the corresponding wiring diagrams. An
earthing terminal shall be provided. Pendant type local
control stations for cranes, hoists and the like shall be of
moulded neoprene or equivalent heavy, flexible, high
impact strength materials. The station shall be connected
by a long moulded-in cable-strengthening sleeve, to
minimise the possibility of cable fracture at the bending
point. The enclosure shall be self-coloured in safety
yellow. Large floor-mounting local control panels wider
than 900mm shall have:
4.4.12.5
(a)
Anti-condensation heater with fuse;
(b)
Pad locking facility, padlock and two keys;
(c)
earthing bar with terminal holes;
(d)
door-controlled internal light with fuse.
Marshalling panels and boxes
1147 of 2461
PAGE 272 of 339
MMRDA
The cable-marshalling units shall comprise wall-mounting

boxes or floor-mounting panels according to size and
function.
Marshalling
boxes
and
panels
shall
be
constructed of sheet steel with ample space for routing

and
terminating
cables
and
cores.
Wall-mounting
marshalling boxes shall have front bolt or screw fixed

cover plates. Floor-mounting marshalling panels shall
have lockable front access doors. Construction standards
shall be in accordance with the general standards
specified for switchgear and control gear.
Enclosure classification shall be:
outdoor mounting: IP65
indoor mounting: IP54
All marshalling boxes and panels shall be arranged for

bottom cable entry and termination unless otherwise
specified.
Undrilled
cable-glanding
plates
shall
be
provided. Gland plates on floor-mounting marshalling

panels shall be located not less than 300mm above floor
level, shall permit cable glanding and termination from the
panel front and shall provide an effective vermin seal to
the panel base. Cable-core termination assemblies shall
be provided for all cable cores including earthing cores
and screens, and shall be arranged and grouped
according to able and circuit functions. At least 20%
spare terminals shall be provided overall and to each
terminal group. Terminal assemblies shall be generously
spaced to permit ease of cable termination, the routing of
cable cores from the cable-gland plates, the fitting of
core-identification ferrules and their subsequent reading,
together with general direct access for inspection and
1148 of 2461
PAGE 273 of 339
MMRDA
circuit-test purposes. Terminal assemblies shall be

located not less than 150mm from cable-gland plates,
panel sides and cover plates. Cable cores shall be
installed between gland plates and terminations in wiring
trunking providing a cable to free-space factor not
exceeding 50%.All marshalling panels and boxes shall be
provided with an earthing termination, together with front
identification labels and internal labelling for the terminal
assemblies and allauxiliary equipment. Large floormounting marshalling panels wider than 900mm shall
have:
(a)
anti-condensation heater with fuse;
(b)
padlocking facility, padlock and two keys;
(c)
earthing bar with terminal holes;
(d)
Door-controlled internal light with fuse.
Switchboard,
control-board
bus-bars
and
bus
bar
connections Bus bars and bus bar connections shall be of

hard-drawn high-conductivity aluminum and shall be
suitable for the specified rated voltage, rated and shorttime current, and frequency and insulation level. Lowvoltage switchgear and control-board bus bars and bus
bar connections shall comply with the performance
criteria given in IEC 60439 part1:1999.
Low-voltage switchgear bus bars and primary conductors

shall be:
(a) Bare Aluminum for waterworks or similar areas with

non-aggressive
atmospheric
environmental
conditions;
1149 of 2461
PAGE 274 of 339
MMRDA
(b) Tinned copper and/or PVC insulated for wastewater

works or similar areas with potentially-aggressive
atmospheric environmental conditions.
In all switchgear, bus bars and primary conductors shall

be contained in segregated compartments accessed only
by
bolted
removable
cover
plates.
High-voltage
switchgear bus bars and bus bar connections shall

comply with IS 375 Bus bars shall be of the nonsegregated phase metal-enclosed and air-insulated type.
Bus bars and bus bar connections shall be insulated with
shrunk-on plastic sleeving or epoxy resin. Joints shall be
shrouded by PVC or resin mouldings. Bus bars shall be
colour coded at each switchboard section access point.
Bus bar supports shall be resin mono block mouldings.
Bus bars and bus bar connection arrangements shall
have been type tested by an independent testing
authority to verify thermal, dielectric and short-circuit
withstand performance. Copies of type-test certificates
shall be provided by the Contractor at the time of
tendering. In special circumstances and subject to the
agreement of the Engineer, the performance of bus bar
and bus bar connections may be substantiated by test
data
and
experience
in
service
on
comparable
arrangements. Bus bar and bus bar connection systems

whose performance cannot be verified will not be
accepted.
4.4.12.6
Switchboard and control board wiring
Wiring other than interconnections between electronic

equipment shall be carried out using 1.1kV grade PVCinsulated cable complying with type of IS 7098 Part
2:1985 7098 With the exception of current transformer
1150 of 2461
PAGE 275 of 339
MMRDA
circuits, the cable conductor size shall be not less than

1.0mm. For current transformer circuits, the cable
conductor size shall be not less than 2.5mm subject to
the knee point voltage. For interconnections between
electronic equipment, the appropriate cable shall be
used. Wiring shall be installed in a neat and systematic
manner and shall be securely fixed. Wiring shall be
arranged so that access to any equipment or connection
point is not impeded. Wiring installed in trunking shall
have a cable to free-space factor not exceeding
50%.Each cable shall be fitted with a full ring interlocking
type identification ferrule at each end. The numbering
shall read from the terminal outwards. The wiring
identification shall correspond with the wiring diagram.
Unless otherwise indicated or approved, wiring shall be
coloured as follows:
Phases: red, yellow or blue
Neutral: black
Control (ac): black
Earth: green and yellow
Where wiring passes through metalwork the access hole

shall be fitted with a suitable grommet. At enclosure
break points, interposing terminal blocks shall be
provided each side of the break. Wiring on to hinged
doors or plates which are subject to movement shall be
run in helical binding and shall be supported securely at
both ends of the moving section. Wiring associated with
instrumentation and electronic equipment which could be
affected by power frequency interference shall be
screened and/or physically segregated. Crimped-on type
1151 of 2461
PAGE 276 of 339
MMRDA
terminal connectors shall be fitted to all cable ends. Cable

trunking, tray and other supports for accommodating and
supporting switchboard and control board wiring, shall be
fixed by means of screw fasteners to the board structure;
fixing by adhesive will not be permitted.
4.5
General Specification of Earthing and Lightning Protection
4.5.1 Earthing
1)
Design
The earthing system shall be designed and installed in

accordance with IS 3043:1987 and Indian Electricity Act 1956.
The materials used and the method of installation shall be such
as to ensure effective and reliable operation over a prolonged
period under the conditions appertaining to the Site. The
earthing installation shall consist of equipotential bonding
conductors capable of carrying the prospective earth fault
current and a group of pipe/rod/plate electrodes for dissipating
the current to the general mass of earth without exceeding the
allowable temperature limits as per relevant Indian Standards in
order to maintain all non-current carrying metal works
reasonably at earth potential and to avoid dangerous contact
potentials being developed on such metal works;
The metalwork of all items of electrical plant, electrical system

neutral points, power and auxiliary cable armouring and screens
and extraneous metalwork including structural steelwork,
pipework, fences and gates, shall unless otherwise specified, be
connected to the earthing installation.
4.5.2 Earth electrodes
The earth electrode installation shall be provided to suit the site ground
1152 of 2461
PAGE 277 of 339
MMRDA
conditions, which shall be as detailed elsewhere, or which shall be

determined by site survey, as specified.
The earth electrode installation shall be subject to the approval of the

Engineer and shall comprise one of the following:
(a)
A system of interconnected driven rods;
(b)
A grid configuration of horizontal buried bare copper/MS/GS

tapes or stranded cable;
(c)
A single or system of interconnected buried copper/MS plates;
(d)
Other approved system to suit extreme ground conditions.
The earth electrode system shall be installed at least 1 metre below

ground water level with full allowance made for seasonal variation in
water level. The electrode system shall, where possible, comprise the
rod type incorporating copper/GS or copper-clad high-tensile lowcarbon steel cored rods. Copper-clad type rods shall have a minimum
copper thickness of 0.25mm which shall be molecularly bonded to the
steel core. Rods shall have hardened tips and driving caps to prevent
damage during installation. Couplings shall be manufactured from
Aluminum bronze and shall have completely enclosed threads to
prevent damage and corrosion. Where soil conditions are very
aggressive, solid copper earth rods shall be used. Where multiple rods
are installed, they should be separated by a distance of not less than
their driven length. Bare copper/MS/GS tape or multi-stranded cable,
buried at a minimum depth of 400mm, shall be used for the
interconnection of rods. Each rod shall be provided with a non-ferrous
clamp for the connection of the earthing conductor. The connections to
rod or alterative design electrodes shall be made in concrete or other
approved material inspection chambers set flush with the finished
ground level. The inspection chambers shall be permanently marked
electrical earth. The resistance to earth of the earth electrode system
1153 of 2461
PAGE 278 of 339
MMRDA
shall be as specified.
4.5.3 Conductors
Earthing, circuit protective and equipotential bonding conductors shall

be high conductivity Copper or aluminum tape/MS/GS tape or 1.1kVgrade PVC-insulated multi-stranded cable. The conductors shall be
sized in accordance with the Reference Standard. PVC cable insulation
shall be green and yellow. Cable lengths shall be continuous. Where
aggressive atmosphere may be present, the copper tape shall be
tinned or PVC-covered. Cable armouring and screens shall be bonded
to earth at both ends unless otherwise specified. Earthing of
instrumentation cable screens shall be as specified elsewhere. Cable
armouring shall not be used as the only earth protective conductor.
The earthing conductor interconnecting the main earthing terminal and

electrode shall be PVC-insulated copper/GS tape or multi-stranded
cable. Conductor size for connections to various equipment shall be as
per the table as follows:
Equipment Conductor Size
Motors
Up to 11 kW
- 8 SWG GI wire
11 kW up to 22 kW
- 4 SWG GI wire
22 kW up to 37.5 kW
- 25 x 3 mm GI flat
37.5 kW to 90 kW
- 25 x 6 mm GI flat
90 kW to 200 kW
- 40 x 6 mm GI flat
Above 200 kW
- 50 x 10 mm GI flat
PCC
- 50 x 6 mm GI flat
PDB
- 50 x 6 mm GI flat
DG & other panel
- 50 x 6 mm GI flat
Local control station, streetlight pole - 8 SWG GI wire

& its junction box
All switchyard equipment
- 50 x 6 mm GI flat
1154 of 2461
PAGE 279 of 339
MMRDA
Main earth grid
- 50x6
mm
specified
GI flat/or as
in
earthing
drawing
Lighting Panel
- 25 x 3 mm GI flat
Indoor fixtures
- 14 SWG GI wire
All paint, scale etc. shall be removed before earthing connections are
made. Anchor bolts or fixing bolts shall not be used for earthing
connections.
4.5.4 Earthing terminal
The main earthing terminal shall be mounted in an accessible location

and shall provide facilities for connecting:
(i)
Theearthing conductor(s) between the earthing terminal and

electrode(s) or electricity supply company earth terminal;
(ii)
circuit-protective conductors between the earthing terminal and

exposed conductive parts;
(iii)
The main equipotential bonding conductors between the earthing

terminal and extraneous conductive parts; and (iv) the system
neutral earthing conductor (where specified).
Facilities (i) and (ii) shall be removable with a tool to permit

measurement and testing. The earthing terminal shall comprise a
terminal block or bus bar on an insulated frame as appropriate. A label
shall be provided inscribed main earth terminal.
4.5.5 Installation
The earthing installation shall be of robust construction and protected

from mechanical damage and corrosion. The circuit-protective
conductors and equipotential bonding conductors shall be of the radial,
1155 of 2461
PAGE 280 of 339
MMRDA
grid or ring form as dictated by the plant layout. Joints in tape

conductors shall be tinned rivetted and soldered, brazed, or
exothermically welded. Non-corrosive flux shall be used for soldered
joints. Compression-type lugs shall be provided for the termination of
earthing cables. The conductors shall be secured to building structures,
cable racks and trays using proprietary fixings. Protective, earthing or
bonding conductors extending between buildings or to external plant
shall comprise PVC-insulated cable direct buried or installed in buried
ducts. The interconnection of conductors below ground to or forming
part of the electrode system shall be by means of exothermic welding
or brazing.
4.5.6 Earthing of extraneous metalwork
(a)
Fences: Metallic fences, including plastic-covered chain-link

fencing, associated metallic support posts, stays, gates and anticlimbing fittings, shall be earthed.
Metallic fences separated from the electrical earthing system

and exposed and extraneous conductive parts connected to the
electrical earthing system, by a distance of not less than 2m,
shall be independently earthed. Metallic fences which are
situated within the area of the electrical earthing system or
cannot be separated from it by a minimum distance of 2m, shall
be bonded to the electrical earthing system.
Additionally, a bare conductor shall be installed around the fence

perimeter. The conductor shall be buried 0.5m deep and 1m
outside the fence, and shall be bonded to the fence at intervals
not
greater
than
50m.The
earthing
requirements
for
independently-earthed fences and for fences bonded to the

electrical earthing system shall comply with BS 7430:1998.
(b)
Structural steelwork:
1156 of 2461
PAGE 281 of 339
MMRDA
All structural steelwork within the Site, including handrailing,

ladders, walkways and the like, shall be bonded to the electrical
earthing system.
(c)
Pipework:
An equipotential bond shall be provided to all metal pipework at

the point of entry into a building or chamber where electrical
apparatus is installed. Electrical continuity across all pipe joints
within the structure shall be ensured. Where pipework
incorporates a compression coupling (such as a Viking-Johnson
coupling), a bond shall be provided to any isolated section.
4.5.7 Instrumentation earthing system
An instrumentation earthing system shall be provided throughout in

accordance with the requirements of IS 3043. The instrument earthing
system shall be isolated from the main electrical earthing system
except at their point of connection which shall be at the main earth
terminal in the relevant process area. Instrumentation earth cables
shall be segregated from other power and earth system cables in order
to reduce electrical interference on the instrumentearthing system. The
instrument earthing system shall be used for the connection of any
signal
system
zero-volt
point
and
all
communications
and
instrumentation cable screens. Cable screens shall be earthed at one

end only. Instrument cable armours shall not be used as protective
screens. Instrument cable armours shall be earthed to the electrical
earth system at one end only. Avoidance of earth loops shall be
paramount in the design of the instrument earthing system.
Each instrumentation, control, communications and telemetry panel

shall be provided with an:
Electrical system earth bar bonded to the metalwork of the panel and
providing earth connections for all cable armours and power circuit
1157 of 2461
PAGE 282 of 339
MMRDA
protective conductors;
Instrumentation earth bar insulated from the panel metalwork for

connection of signal system zero-volt connections and connection of all
signal cable screens.
The design of the instrument earthing system shall be incorporated as

part of design of the overall earthing system for the works.
Contractor has to submit Earthing Calculations along with plan layout

as per IS 3043 for the approval.
4.6
Lightning Protection
4.6.1 Design
The lightning protection installation shall be designed and installed in

accordance with IS 2309:1989.
4.6.2 Materials
Materials used for the manufacture of the component parts of lightning

protection installations shall comply with BS 6651:1999 and IS
2309:1989.Conductor material shall be bare or PVC-covered copper or
Aluminum tape or solid circular conductor or GS/MS tapes as specified.
The colour of PVC-covered conductors shall be agreed with the
Engineer. Careful attention shall be given to the selection of materials
to minimise the risk of corrosion, including galvanic corrosion.
4.6.3 Dimensions of component parts
The dimensions of component parts shall be not less than those

specified in IS 2309:1989.
4.6.4 Fittings
1158 of 2461
PAGE 283 of 339
MMRDA
Fittings shall be mechanically robust and shall have a high degree of

resistance to corrosion and erosion by the environment in which they
are installed.
4.6.5 Metallic building fabric
Metallic building fabric used for air terminations shall be electrically

continuous. Comprehensive details of the methods to be used for
ensuring electrical continuity and making connections to structural
steelwork and down conductors shall be submitted for the approval of
the Engineer.
4.6.6 Bonds and clamps
Bonds shall be mechanically and electrically effective and shall be

protected from corrosion. Bonds to structural steelwork, reinforcing
bars and pipes shall be made using proprietary clamps. The drilling of
metallic building fabric to secure bonds shall not be carried out without
the approval of the Engineer. When the reinforcement in concrete
structures is used for down conductors, the metal bars shall be
interconnected, either by welding or by metal binding wire, to provide
definite electrical continuity. The interconnection shall be provided for
both vertical to vertical and horizontal to vertical bars. The external
conductor shall be connected to the reinforcing bars via a proprietary
non-ferrous built-in type bonding point.
The bonding points to be cast into the structure shall be provided by

the Contractor together with a drawing showing the required location.
4.6.7 Conductor fixings
Conductors shall be fixed to the building structure using proprietary

clips and holdfasts. The Fixings shall be purpose-made for the
conductor type used and shall allow for expansion. Non-metallic clips
1159 of 2461
PAGE 284 of 339
MMRDA
shall be manufactured from high-grade polypropylene. The material

shall be stabilized against degradation by sunlight and shall not
become brittle at the minimum temperature at the location where
installed.
No welding or drilling of structural steelwork or drilling or cutting of the

outside building fabric for the attachment of fixings shall be carried out
without the approval of the Engineer. Fixings shall be securely attached
to the building structure; mortar joints shall not be used.
4.6.8 Joints
Joints in conductors shall be kept to a minimum and shall be

mechanically and electrically effective. Joints shall be clamped, riveted,
bolted or welded. The overlap of conductors shall not be less than
50mm.Contact surfaces shall be thoroughly cleaned and coated with a
suitable anti-corrosive compound to inhibit oxidation. For bi-metallic
joints, a separate abrasive shall be used to clean each metal. Bimetallic connectors shall be used for joints between two dissimilar
metals. Bi-metallic joints shall not be made at test joints or in the
conductor between the test joint and the earth electrode.
4.6.9 Test joints
A test joint shall be provided in each down conductor in a convenient

position. The connection between the test joint and earth electrode
shall be PVC-insulated copper/GS tape.
4.6.10 Earth electrodes
Earth electrodes shall normally comprise copper or copper-clad hightensile low carbon steel cored rods. Copper-clad type rods shall have a
minimum copper thickness of 0.25mm which shall be molecularly
bonded to the steel core. Rods shall have hardened tips and driving
caps to prevent damage during installation. Couplings shall be
1160 of 2461
PAGE 285 of 339
MMRDA
manufactured from Aluminum bronze and shall have completely

enclosed threads to prevent damage and corrosion. Where soil
conditions are very aggressive, solid copper earth rods shall be used.
Earth rods shall penetrate aminimum of one meter below ground water
level. Due attention shall be given to seasonal variation in ground water
level. Where multiple rods are installed, they should be separated by a
distance of not less than their driven length. Bare copper/MS/GS tape
or multi-stranded cable, buried at a minimum depth of 400mm, shall be
used for the interconnection of rods. Each rod shall be provided with a
nonferrous clamp for the connection of the earthing conductor. The
connection shall be made in a concrete or other approved material
inspection chamber set flush with the finished ground level. The
inspection chamber shall be permanently marked lightning protection
earth. Where soil conditions make the use of rod type electrodes
impractical or uneconomical, a grid configuration shall be used. The
grid shall comprise horizontally buried bare copper/MS/GS tape or
multi-stranded cable. The resistance to earth of the earth electrode
system shall be as stated in IS 2309:1989. Bonding to other services
unless otherwise specified, the lightning protection and electricity
supply earth electrode systems shall be interconnected.
4.7
General Specification of Cabling Installations

4.7.1 Cabling General Requirements
Cables shall be supplied from an approved manufacturer and, where

possible, the same manufacturer shall be used for all cables and wires.
Each drum or coil of cable shall be accompanied by a certificate stating
the manufacturers name, rating of cable, result and date of tests. All
cables shall be delivered with cable ends effectively sealed. When a
cable is cut from a drum, both ends shall be immediately sealed to
prevent ingress of moisture. Cables shall be adequately rated for
current-carrying capacity under normal and short-time fault conditions
at the specified voltage.
1161 of 2461
PAGE 286 of 339
MMRDA
Assessing the rating and cross section of any cable shall be in

accordance with IEC 60287-1-1:2006 and shall take into account the
following factors:
(a)
Maximum voltage drop permissible;
(b)
Type and magnitude of load;
(c)
Fault level and duration related to circuit protection;
(d)
Over-current setting of relays;
(e)
Method of laying;
(f)
Route length and disposition of cables;
(g)
Ambient temperature, including ground thermal resistivity for

buried cables.
Unless otherwise specified, cable sizing with respect to power system

voltage depression shall be based on the following parameters. Cable
sizes in conjunction with electrical-plant operating characteristics shall
ensure the maximum circuit volt drops are not greater than:
main feeder cables to and between system switchboards at rated

circuit current: 1%;
feeder circuits from control switchgear and panels to terminal

equipment at rated load current: 2%;
the transient voltage depression at the started motor terminals is

not greater than 15%;
the Steady state voltage depression at the motor terminals during

running shall not be greater than 10%;
1162 of 2461
PAGE 287 of 339
MMRDA
the transient voltage depression at the bus bars of any power

system switchboard does not exceed 5%.
Transient voltage drops for motor starting conditions shall include the
dynamic loading of all running plant. Cable schedules shall be
submitted for approval detailing ratings, sizes, lengths, method of
installation and function of all individual cables.
4.7.2 Cables
1)
Cable Conductors
Cable conductors shall be plain annealed copper complying with

IS 8130-1984.Unless otherwise specified, low-voltage threephase and neutral power cables shall not incorporate a reduced
neutral conductor.
4.7.3 Power cables
Unless otherwise specified or approved, all power, control and

instrumentation cables shall be galvanised steel wire or tape armoured
with PVC overall sheath. Single-core power cables shall have nonmagnetic armour of hard-drawn Aluminum. Cross-linked polyethylene
(XLPE) insulated cables for rated voltages 600/1000V and 1900/3300V
shall comply with IS:1554 - I & 2. XLPE-insulated cables for rated
voltages 6600V shall comply with IS:7098 (Part-I & II).PVC-insulated
power cables for rated voltages of 600/1000V and 1900/3300V shall
comply with IS:1554 (Part-I & II).Low smoke and fume (LSF) cables for
rated voltages up to 1900/3300V shall comply with IEC 60332-1.Low
smoke and fume cables for rated voltages of 3800/6600V and
6350/11000V shall comply with IEC 60332-2 but shall have bedding
and over sheath material complying with the LSF requirements of IEC
60332-3.
1163 of 2461
PAGE 288 of 339
MMRDA
4.7.4 Control cables
Multi-core cables shall be of the PVC-insulated or LSF-type having a

rated voltage 600/1000V. PVC-type cables shall comply with IS: 1554
(Part-I & II). LSF cables shall comply with IEC 60332-3. Cables for
conduit and trunking wiring systems Cables shall be single-core PVCinsulated non-sheathed type complying with IS:1554 - I & 2 or LSF-type
complying with IEC 60332-3 as specified. The minimum conductor size
shall be 1.5mm for lighting circuits and 2.5mm for socket outlet and
heater circuits.
4.7.5 Mineral insulated cables
Mineral insulated copper sheathed cables shall comply with BS 62073:2001. Unless otherwise specified, mineral insulated cables shall be
provided with a standard PVC covering, coloured orange. Voltagesurge suppressors shall be fitted to all cables associated with inductive
loads.
4.7.6 Use of proprietary cable types
Where a proprietary cable type is required for a particular item of

equipment, the Contractor shall submit a detailed specification and
application of the cable type to the Engineer for consent. Where the
cable is to be installed in outdoors, in plant areas, in ducts or clipped
direct or on cable tray, the cable shall be armored and provided with an
overall PVC sheath.
4.7.7 Cable glands, terminations and joints
1)
Cable glands
Cable glands shall comply with IS 12943:1990 and unless

otherwise specified, shall be manufactured from brass. Glands
for use with aluminum armoured cables shall have zinc or nickel
1164 of 2461
PAGE 289 of 339
MMRDA
plated armoure clamp and spigot. Glands for single-core

armoured cables and armoured instrumentation cables shall be
earthed at the source end only and insulated from earthed
metalwork with facilities for shorting at the other end. Glands for
armoured cables shall be fitted with earth tags. Cable glands for
use outdoors shall have cable inner and outer sheath seals.
Glands for indoor use shall have a cable outer sheath seal.
Mineral insulated cables shall be terminated using proprietary
termination kits comprising moisture seal, insulating sleeving
and gland. The type of seal shall be compatible with the
continuous operating temperature of the cable. The termination
kit and cable shall be of the same manufacture. Exposed cable
glands, that is those not contained within an enclosure, shall be
fitted with PVC shrouds.
4.7.8 Cable termination, joints, sleeves and tape - general
The Contractor shall employ personnel who are fully-qualified and

competent for the types of joints and terminations to be made. Proof of
competence for all personnel shall be submitted to the Engineer before
any jointing or termination work commences.
The Contractor shall provide evidence to the Engineer that the

materials or kits to be used for jointing and termination are suitable for
the type of cable to be jointed or terminated. Full details of jointing and
terminating arrangements supported by manufacturers literature shall
be submitted by the Contractor to the Engineer prior to commencement
of cable installation. Cables shall not be cut or uncapped until the
jointing or termination is ready to start. Cable ends shall be free from
moisture. Jointing and termination shall, wherever practical, be
completed without interruption. During the work all reasonable
precautions shall be taken to prevent damage and ingress of moisture
and impurities. Where circumstances prevent the completion of jointing
and termination work, the cable end or ends shall be sealed. Where
cores need to be crossed to preserve phasing, a cross core joint of
1165 of 2461
PAGE 290 of 339
MMRDA
adequate dimensions to incorporate the cores, shall be used. Where

numbered cores are jointed to coloured cores, the system adopted
shall be consistent throughout all cable runs and, on sites with existing
installations, consistent with the system already in use. For joints in
armoured cables, a bonding conductor of sufficient size to withstand
the system earth fault current shall be connected across the armouring.
A split ferrule shall be placed under the armouring to prevent
deformation of the cable by the clamp.
4.7.9 Terminations
Cables shall be terminated in an unfilled type cable box or air insulated

enclosure using a mechanical type gland. A proprietary heat-shrink
type termination kit shall be used for terminating high-voltage cables.
Conductor terminations shall be by means of compression fittings or
mechanical clamps. Aluminum conductors shall not be clamped in
pinch-screw type tunnel terminals unless the terminal is certified for
such use. Cable sockets shall be of the correct size for the conductor.
Oversize sockets will not be accepted. Compression connectors and
associated dies for the compression tool shall be the correct type and
size. The tool shall be so designed that the correct compression force
must be applied before it can be released.
4.7.10 Joints
Unless otherwise specified, joints for direct burial in the ground shall be
of the cast resin type and those located in chambers or indoor areas
shall be of the proprietary heat-shrink type. Joints for 1.1kV grade
cables shall comply with BS 6910-1:1988.
Resin-based compounds shall, as far as is reasonably practicable, be

safe and without risk to health. Each pack shall include warnings as to
any hazards in use, such as dermatitis or toxic properties, with details
of the precautions which the user must take and package disposal
instructions.
1166 of 2461
PAGE 291 of 339
MMRDA
4.7.11 Sleeves
Sleeves shall be of the shrink type. They shall provide sufficient

thickness of insulation to suit the particular application.
4.7.12 Tape
Insulating tape used in joints and terminations shall be compatible with,

and have a temperature rating and insulating property not less than,
the cable insulation, and shall comply with approved standards.
Pressure-sensitive adhesive tapes shall comply with IS 3687 (1987).
All tapes shall be stored in sealed containers until required.
4.7.13 Cable installation
1)
Cable installation - general
To avoid the risk of damage, cables having PVC insulation

and/or sheathing shall not be handled or installed if both they
and the ambient temperature isbelow 0C.For LSF cables, the
temperature may be
10C. Cables shall have been kept at or
above the stated minimum temperature for at least 24 hours

immediately prior to installation; any special measures to
achieve this shall be approved by the Engineer. Care shall be
taken to prevent damage to the cable over sheath during
installation. At the discretion of the Engineer, minor damage
may be repaired. Full details of the repair procedure shall be
provided for approval. In the case of major over sheath damage,
the Engineer reserves the right to have the whole section of the
cable replaced at no cost to the Employers. Cables shall not be
bent during installation to a radius less than that recommended
by the cable manufacturer. Where practical, larger radii shall be
used.
1167 of 2461
PAGE 292 of 339
MMRDA
Cable drums shall be unloaded carefully by means of either a

crane or ramp. Cable drums shall not be dropped onto the
ground. Cable drums unloaded using ramps shall be guided by
holding ropes with the aid of winches or block and tackle. Cable
drums shall be supported on axles and axle stands during the
unwinding operation. Under no circumstances shall cables be
unwound from a drum-laying flat. Drums shall be turned during
unwinding to prevent the cable being subjected to damaging
tensile stresses. Cables shall be pulled using a pulling eye or
stocking.
Where cables are supported on rollers, they shall be spaced to

prevent the cable being dragged over the ground or other
surfaces which could cause damage to the over sheath or other
corrosion protection.
Where cables are pulled by a winch, the following measures

shall be taken:
(a)
a continuous check shall be carried to ensure the tensile stress

on the cable does not exceed the permissible value;
(b)
a shearing pin or other rupturing device to interrupt the pulling if

the maximum permissible tensile stress is exceeded shall be
provided at the winch.
4.7.14 Arrangement of single-core cables in three-phase systems
Three-phase cable systems comprising two or more single-core cables

per phase shall be arranged in three-phase, that is red, yellow and
blue, groups. This is to equalize, as far as practicable, mutual
inductance. The three-phase groups may be in trefoil or flat formation
as dictated by the cable system design. Cables shall not be arranged in
groups comprising the same phase.
1168 of 2461
PAGE 293 of 339
MMRDA
4.7.15 Cable spacing
Unless otherwise specified, the minimum space between cables shall

be as follows:
High-voltage: 50mm;
Low-voltage: Touching unless current rating considerations dictate

otherwise;
High and low-voltage: 300mm;
High-voltage and control: 300mm;
Low-voltage and control: 150mm;
High-voltage and instrumentation telephone: 300mm;
Low-voltage and instrumentation telephone: 150mm;
Control: Nil.
Where cables are installed in close proximity to or cross those of

authorities such as telecommunication, electricity supply and railway,
spacing shall comply with the regulations of those authorities.
4.7.16 Cable and core identification
All cables shall be permanently identified at each end and at entry and
exit points of ducts. Identification shall be by means of approved cable
markers with semi-rigid black PVC carrier strip which shall be fixed
axially by means of two PVC straps or other marker type approved by
the Engineer. On rotating plant and transformers where, to achieve the
required direction of rotation or phasing, it is not possible to connect
the phase cores to the appropriate terminals, additional core ferrules
1169 of 2461
PAGE 294 of 339
MMRDA
shall be fitted to identify each core with the terminal to which it is

connected. Control cables shall have individual cores identified by
means of suitable permanent ferrules bearing the same number at both
ends. Core identification shall occur at every point of termination using
an approved system of ferrule markers. The size of the ferrule markers
shall be such as to match the overall diameter of conductor plus
insulation. Numbering shall read away from the termination on all
cores.
4.7.17 Installation in buildings
Surface-run cables shall be secured by cleats, installed on trays or

ladders, or installed in conduit or trunking. Surface-run cables, trays,
ladders, conduits and trunking shall be neatly installed vertical,
horizontal and parallel to walls, beams or other structural members.
Conduit systems concealed by wall finishes shall be installed vertical
and horizontal. Cables in structural trenches shall be secured to the
trench side by cleats or installed on trays as applicable. Cables shall be
installed in accordance with the recommendation of the cable
manufacturer. Cables on tray and ladder systems shall be installed to
minimize crossovers. The spacing of fixings shall be in accordance with
IS 3961(Part-1)-1967. The method of securing fixings shall be by
means of non-corrodible screws. Plastic self-locking cable ties shall be
as the Insulok range manufactured by HellermannInsuloid or similar.
Plastic cable ties for outdoor use shall be resistant to ultra-violet
degradation. Cable ties for use with LSF cables shall be manufactured
from flame-retardant material. Plastic ties for use with cable tray shall
be of the two-part type having lugs for retention behind the tray slot.
Plastic cable ties shall not be used for fixing groups of single-core
cables forming a three phase circuit. Proprietary cable cleats shall be
used for this purpose. All cables installed on ladder systems shall be
fixed by means of proprietary cleats. Cable cleats shall be
manufactured from materials which shall have no deleterious effect on
cable sheaths. Cleats for single-core cables carrying alternating current
shall be manufactured from non-magnetic material. Trefoil, three-way
1170 of 2461
PAGE 295 of 339
MMRDA
flat, two-way or single-way cleats shall be used as required by the

cabling system design. Cleating arrangements for single-core cables
shall be of sufficient strength to withstand short circuit forces. Unless
otherwise specified or approved, where several cables are terminated
in an enclosure, they shall approach the enclosure from a common
direction and shall be terminated in a neat and systematic manner.
Cables shall be installed not less than 150mm from water service
pipework and below heating and hot water pipework. Cables and
chemical pipework shall not be installed in the same trench or service
duct unless approved by the Engineer. Cable installations crossing
structural expansion and settlement joints shall have provision for
movement. Conduits shall have a flexible section. Trunking shall be
fitted with purpose-made expansion couplings.
4.7.18 Cable systems
1)
Conduit
Conduit systems shall be of the steel or plastic type as specified.

Steel conduit and fittings shall comply with IS 2667 and IEC
50086-1:1994, shall be screwed and hot-dip zinc coated inside
and outside. The nominal size of conduit shall be not less than
20mm.The ends of conduits which are liable to be left open for
any length of time during building work shall be plugged to
prevent the ingress of dirt and covers shall be fitted on all boxes.
No holes shall be drilled through any structure without prior
approval.
Damaged
galvanising
shall
be
cleaned
and
immediately painted with two coats of an approved zinc-based

paint. This treatment shall be carried out as the work proceeds.
Non-metallic conduit and fittings shall be of the rigid PVC heavy
duty
type
complying
with
IEC
50086-2-1:1996
and
IS
2667.Joints into couplers, slip type bends and spouted fittings

shall be made using silicone grease or a permanent solvent.
Silicone grease shall be used for expansion couplings.
Expansion couplings shall be fitted in surface installations at
1171 of 2461
PAGE 296 of 339
MMRDA
intervals as recommended by the manufacturer. PVC conduit

shall not be installed in areas that receive direct sunlight. The
installation of metallic and non-metallic conduit systems shall be
carried out in accordance with IS 6946.
2)
Trunking
Trunking shall be manufactured from hot-dip zinc-coated steel or

heavy-duty plastic. When fitted, partitions shall be of the same
material as the trunking. The gap between the partitions and the
trunking cover shall be a minimum to ensure the segregation of
circuits is maintained. Trunking shall be installed using factorymade accessories. Site-fabricated fittings will not be accepted.
Blind ends of trunking runs for future extensions shall be fitted
with removable covers. Trunking with covers on the side or
bottom shall be fitted with removable cable-retaining straps at
intervals not exceeding 1000mm. Where trunking runs vertically,
cables shall be supported at intervals not exceeding 5m. The
method of support shall allow for future easy removal or addition
of cables and shall be subject to approval. Bonding links shall be
provided at each joint of steel trunking which shall be secured by
screws, shake proof washers and nuts. The bonding link shall
make contact with the metal of the trunking or fitting, and
continuity shall not depend on contact through screws or on the
removal of a paint finish. Factory-made connectors shall be
used at joints. Nonflammable fire barriers shall be inserted
where the trunking passes through walls or floors. Conduit
connections to trunking shall be made by flanged couplings and
male bushes. Trunking shall be supported at intervals not
greater than 2m horizontally or 2.5m vertically. All cut or drilled
edges in steel trunking shall be treated with an approved zincbased paint.
3)
Tray
1172 of 2461
PAGE 297 of 339
MMRDA
Cable tray shall be heavy-duty hot-dip galvanised steel,

stainless steel or glass reinforced plastic as specified. Plastic
tray shall be heavy duty with return flanges. Wherever possible,
galvanised steel cable trays shall be installed in full lengths
without cutting. Cut edges shall be treated with an approved
zinc-based paint. Cable trays shall be installed using proprietary
accessories and support systems. Plastic tray and accessories
shall be approved by the Engineer. All cables shall be firmly
secured to the tray using approved purpose-made fixings. Cable
tray shall be mounted not less than 25mm from the face of the
structure.
4)
Ladder
Cable ladders shall be heavy-duty hot-dip galvanised steel,

stainless steel or glass reinforced plastic as specified. Wherever
possible, galvanised steel cable ladders shall be installed in full
lengths without cutting. Cut edges of steel ladders shall be
treated with an approved zinc-based paint. Cable ladders shall
be installed using proprietary accessories and support systems.
All cables shall be firmly secured to ladders using approved
purpose-made fixings.
5)
Installation directly in the ground
Unless otherwise specified, the minimum cover for cables shall

be as follows:
Low-voltage: 500mm;
Control and instrumentation: 500mm;
High-voltage: 800mm.
Cables shall be laid on a minimum thickness of 75mm soft fill or

1173 of 2461
PAGE 298 of 339
MMRDA
sand extending the full width of the trench. After laying, cables
shall be covered with a further layer of soft fill or sand of
minimum thickness 75mm. All cable bedding shall be well
compacted; power rammers shall not be used for this purpose.
Where more than one horizontal layer of cables is laid, the level
of the upper layer shall be gauged from the bottom of the trench
and marked on the side of the trench at regular intervals to
ensure the correct vertical separation is maintained. Where
high-voltage and low voltage cables are laid in the same trench,
the former shall be laid at the bottom and covered with bedding
material and protective tiles. The low-voltage cables shall be
then laid on a further layer of bedding material at the required
separation distance. During cable laying, sharp metal tools shall
not be used in the trench or placed in such a position that they
may fall into the trench. Cables shall only cross other cables at
junctions at which point clearances between the cables shall be
maintained.
6)
Installation in ducts
Unless otherwise specified or approved by the Engineer, power,

control and instrumentation cables shall not be installed in the
same duct. Cables shall, where necessary, be lubricated to
facilitate drawing in. The lubricant used shall have no
deleterious effect on the cables. Where cables leave duct ends
to enter a trench, a permanent support shall be provided to
reduce the possibility of damage to cables due to ground
settlement.
7)
Excavation of cable trenches
The exact route of each trench shall be approved by the

Engineer before excavation starts. Trenches shall be kept as
straight as possible and shall be excavated in accordance with
IS 1255.Excavated trenches shall be kept free of water and
1174 of 2461
PAGE 299 of 339
MMRDA
protected against damage or collapse. All necessary sheeting,

timbering, strutting and shoring shall be supplied, erected and
subsequently removed to ensure the safety of persons and the
protection of structures, buildings, roads, sewers and other
services from damage. The bottom of all trenches shall be
graded evenly and cleared of loose stones. Where the level of
the trench bottom has to change, the slope shall be gradual and
shall not exceed 1 in 12.After cable installation, trenches shall
be backfilled in layers, and each layer shall be compacted. The
first two layers shall be 100mm deep and shall be compacted by
hand. The remaining layers shall not be greater than 200mm
deep and power compacting may be used. Where applicable,
top soil and turf shall be replaced. Damaged road, hard standing
and paved areas shall be reinstated to an approved standard.
8)
Cable ducts
Cable ducts shall be manufactured from polyethylene and shall

have an internal diameter as specified. Unless otherwise
specified, duct colours shall be as follows:
Electric cables: black;
Telecommunication cables: grey or white;
Proprietary couplings, bends and other accessories shall be

used.
9)
Installation of cable ducts
The route of all ducts shall be approved by the Engineer and

shall be installed and jointed in accordance with the instructions
or recommendations of the manufacturer.
Ducts installed under roads, hard standings and paved areas

1175 of 2461
PAGE 300 of 339
MMRDA
shall extend 1000mm beyond the boundary. The formation and

spacing of ducts for power and auxiliary cables shall be as
specified or agreed with the Engineer. Where site conditions
require a surround of concrete, the thickness shall be not less
than 100mm.After installation; all ducts shall be checked for
alignment and the ends temporarily, but effectively, sealed to
minimize the risk of ingress of water, other materials and vermin.
A polypropylene draw rope with a 6kN breaking strain shall be
installed in each duct.
Draw chambers shall be provided at changes in duct direction

and at intervals along the duct run. The size and spacing of the
chambers shall be determined by cable minimum bending radii
and permitted maximum pulling forces.
10)
Cable-protection tiles and warning tapes
Cable tiles shall be reinforced concrete or clayware complying

with IS 1255. Cable tiles manufactured from other materials
shall not be used without prior approval of the Engineer. The
width of the tile or tiles shall provide a minimum of 50mm
overlap on each side of a cable or group of cables. If more than
one tile is used for covering a group of cables, the tile width shall
be such that the longitudinal joint between tiles is above the
space between the cables and not immediately above a cable.
Cable tiles shall be provided for all high-voltage cables and for
other cables when specified.
Tiles shall be laid directly on the cable-bedding material. A

warning tape shall be placed above individual or groups of
cables and cable ducts. The tape shall be laid at a depth of
300mm below the finished surface level or as otherwise
approved by the Engineer. For groups of cables or ducts where
it is impractical to install individual tapes, a single tape shall be
installed above the each outer cable or duct unless otherwise
1176 of 2461
PAGE 301 of 339
MMRDA
instructed by the Engineer. Warning tapes shall be of polythene

not less than 150mm wide and 0.1mm thick and shall
incorporate a metal foil or braid. They shall be yellow in colour
and shall be continuously marked caution electric cable
below, or similar, in black letters not less than 30mm high.
11)
Marking of buried cables and joints
The route of buried cables shall be permanently identified by

reinforced precast concrete marker posts or blocks of an
approved type with impressed characters HV cable or LV
cable as appropriate. The position of buried cable joints shall be
permanently identified by reinforced precast concrete marker
posts or blocks of an approved type with impressed characters
HV cable joint or LV cable joint as appropriate. Cable marker
posts and blocks shall be located on the precise line of the cable
at regular intervals not exceeding 50m, at changes in direction
and at points of entry into buildings. Marker blocks shall be
installed flush with the finished ground level.
12)
Sealing of cable entries into buildings
Where cables pass through walls below ground level, the point
of entry shall be sealed against the ingress of water by means of
silicon foam or proprietary cable transit system.
13)
Obstructions
When, in the course of the Works, obstructions are encountered

which necessitate diversion of existing service installations,
other underground works, alterations to buildings or foundations
or when conditions require the adoption of a special form of
trench or duct system, the Contractor shall immediately notify
the Engineer, who will instruct the Contractor in writing of the
action to be taken.
1177 of 2461
PAGE 302 of 339
4.8
MMRDA
General Specification of Electric Generators

4.8.1 Diesel Generator Sets Diesel Engine
4.8.1.1
The engine type shall have been in commercial operation

for a period of not less than 3 years.
The engine shall be of the 4-stroke, water-cooled directinjection compression-ignition type with an in-line or veecylinder configuration.
The engine may be naturally
aspirated or turbo-charged. The nominal speed shall not

exceed 1500rpm for 50Hz operation.
The engine shall be rated in accordance with ISO 30461:2002 and shall be capable of continuous operation at
rated output plus a 10% overload for 1 hour in any
12 consecutive hours running.
Unless otherwise specified, fuel oil shall be Class A2 to

BS 2869:1998.
All chain and gear drives shall be located in oil-tight

cases and shall be pressure-lubricated.
The engine and generator shall be mounted on a

common fabricated steel bedplate with anti-vibration
mountings of the multiple neoprene type impervious to
water and oil.
The engine shall accept full-rated load within 20 seconds

from initiation of the starting sequence when starting from
cold at the minimum specified ambient air temperature.
1178 of 2461
PAGE 303 of 339
MMRDA
The initial step load shall be not less than 40% of the fullload value unless otherwise specified.
4.8.1.2
Lubrication
The engine shall have a forced lubricating system

throughout using an integral gear-driven pump with a
coarse strainer on the suction side. A full-flow filter of
nominal micron rating not greater than 10 and having a
pressure-operated by-pass valve shall be provided on the
delivery side. Manual lubrication of any part of the engine
shall not be accepted. The lubrication system shall not
require priming prior to starting the engine.
The engine lubricating oil dipstick shall be easily

accessible and minimum and maximum levels shall be
clearly marked.
The engine sump shall have an easily-accessible drain

point or drain pipe, fitted with a BSP plug.
When
engines
are
specified
to
be
suitable
for
uninterrupted running over a prolonged period, the

following features shall be provided:
(i)
dual in-line lubricating oil filters;
(ii)
dual in-line fuel filters;
(iii)
heavy-duty air filter;
(iv)
Auxiliary lubricating oil tank for installation adjacent

to the engine and fitted with a sight-level gauge;
(v)
an oil circulation system.
1179 of 2461
PAGE 304 of 339
MMRDA
The maximum allowed period of uninterrupted running

shall be stated by the contractor and shall not be less
than the specified period.
4.8.1.3
Cooling
Unless otherwise specified, cooling shall be by means of

a sealed or pressurised radiator of the air-blast type. For
radiators mounted on the generating set baseframe, the
fan shall be driven by vee-belts from the engine
crankshaft. Remote radiators shall be floor-mounted and
shall be complete with motor-driven fan or fans. Remote
radiators shall be suitable for indoor or outdoor location
as specified.
Engine-mounted radiators shall be providing with a flange

for the fitting of flexible ducting.
Engine-driven pump(s) shall circulate the jacket water

and lubricating oil if appropriate through the radiator
sections.
A thermostatically-controlled diverter or by-pass valve

shall be fitted in the engine cooling-water discharge
pipework, with a return to the circulating pump suction, to
maintain the circulating water at the optimum temperature
irrespective of load.
The cooling system shall be provided with plugged valves

as necessary to enable all parts to be drained.
4.8.1.4
Drive Belts
Drive belts shall be of the multiple endless vee-type

1180 of 2461
PAGE 305 of 339
MMRDA
which shall be resistant to fuel and lubricating oils. The

number of belts fitted to each drive shall be one more
than is necessary to transmit the maximum power
requirement.
An accessible belt-tensioning device shall be fitted to

each drive and it shall be possible to change the belt(s)
without major dismantling and re-assembly.
4.8.1.5
Safety Guards
All exposed hot or moving parts and in particular, fans,

belt drives, couplings and flywheels, shall be guarded in
accordance with PD 5304:2000 and to ensure safe
operation.
To permit the adjustment and inspection of drives,

apertures with secured cover plates shall be provided in
the guards at appropriate points.
4.8.1.6
Protection Devices
Devices shall be fitted and arranged to provide visual

alarm indication and automatic engine shutdown under
the following conditions:
(a)
Oil pressure low;
(b)
Oil temperature high;
(c)
Coolant temperature high;
(d)
Over-speed;
(e)
Fuel low.
1181 of 2461
PAGE 306 of 339
MMRDA
A voltage-free set of changeover contacts shall be

provided for each of the above conditions for the initiation
of a remote alarm. The contacts shall be wired to an
enclosed metalclad terminal box.
4.8.1.7
Wiring
Engine-mounted wiring shall be insulated with heat

resistant
insulation
to
CENELEC
Harmonization
Documents HD 21.1 S4:2002 and HD 22.1 S4:2002 and

associated parts thereof for use at temperatures of up to
85C.
Conductors shall be multi-stranded copper of
minimum cross-sectional area 1.5mm excepting special

types such as screened cables.
All wiring, excluding starter cables, shall be shall be

connected to an enclosed metal clad terminal box or
terminal boxes mounted on the base frame.
Starter
cables may be directly connected.
4.8.1.8
Pipework
Fuel pipework shall be produced from seamless steel

tubing with welded or compression-type steel fittings. All
other pipework shall be either seamless copper tubing
with brazed or compression-type gunmetal fittings, or
seamless steel tubing with welded or compression-type
steel fittings.
Flexible sections of pipework shall be synthetic rubber

with stainless steel braided sheaths.
Flexible fuel and
lubricating oil connections shall additionally have flame

resistant sleeves.
1182 of 2461
PAGE 307 of 339
MMRDA
All pipe flanges shall comply with BS 4504-3.3:1989 and

screwed connections with BS 21:1985.
4.8.1.9
Heaters
Oil and water heaters to facilitate cold starting shall be of

the thermostatically-controlled type. The heating surface
loading of oil heaters shall not exceed 7.5kW/m.
4.8.1.10
Instrumentation
Instruments as follows shall be provided:
(a)
lubricating oil pressure gauge;
(b)
lubricating oil temperature gauge;
(c)
cooling water temperature gauge;
(d)
turbo-charged air pressure gauge (if applicable);
(e)
running hours indicator;
(f)
tachometer;
(g)
battery charge ammeter for electric start engines;
(h)
engine stop push-button;
(i)
other instruments as considered necessary by the
engine manufacturer.
The instruments shall be fitted on an engine-mounted

panel supported on anti-vibration mountings. The panel
shall be mounted at a convenient height and position for
1183 of 2461
PAGE 308 of 339
MMRDA
observation and operation.
4.8.1.11
Governing
Engine governing shall be of the electronic type having a

droop characteristic adjustable over the range 0 to 5%.
The governor shall be Type 1 to ISO 3046-4:1997 and
shall be Accuracy Class A1 or better.
The maximum
transient speed change shall not exceed 5% with the

maximum
power-system
step
load
application
as
specified elsewhere.
Provision shall be made for remote adjustment.
4.8.1.12
Exhaust System
Engines shall be provided with a complete exhaust

system comprising rigid and flexible pipework, stainless
steel bellows, silencer(s) and all necessary brackets,
hangers, wall sleeves and plates and sundries for a
complete installation.
Pipe wall thickness shall not be
less than 3mm.
Unless otherwise specified, silencers shall be of the

residential type.
The first section of exhaust from the engine manifold shall

include a flexible bellows unit. The next section of pipe
shall be supported to allow movement without imposing
forces on the manifold.
Exhaust support brackets shall be designed to allow for

pipe expansion and contraction movement.
Bends in the exhaust pipework shall be kept to a

1184 of 2461
PAGE 309 of 339
MMRDA
minimum and shall be of the long radius type.
Where the exhaust pipe passes through a wall, a wall

sleeve and plates shall be fitted.
The annular space
between the pipe and sleeve shall not be less than

25mm. The space between the pipe and sleeve shall be
filled with heat-resistant material.
Exhaust terminations shall not be located in close

proximity to air inlet grills or opening windows were
exhaust gas can re-circulate into the building.
The
exhaust outlet shall be arranged to prevent the ingress of

water.
For
long
exhaust
runs,
water
drain
point
or
condensation trap shall be fitted near to the engine.
Exhaust silencers and pipes, flanges, clips and fixings

shall be sprayed with metallic aluminium paint in
accordance with BS 2569-2:1965 Process D.
Internal sections of the exhaust system shall be

effectively lagged.
The lagging shall be clad with
aluminium sheet secured by stainless steel band clips.
Where it is not practical to lag any part of the internal

section of the exhaust system with which personnel can
come into contact, guards shall be fitted.
4.8.1.13
Starting Systems
Engine starting shall be electric or air systems as

specified and shall comply with the following:
a. Electric:
1185 of 2461
PAGE 310 of 339
MMRDA
The starting battery shall be of the nickel-cadmium or

lead-acid
type
and
unless
otherwise
specified,
installed on an engine bed plate mounted noncorrodible tray or rack and shall have a cover of
insulating material. The battery shall have sufficient
capacity for three consecutive start attempts each of
10 seconds duration.
In addition, the battery shall
have sufficient capacity after the three start attempts

to supply the maximum demand of the control panel
for a minimum period of 24 hours.
The battery charger shall be of the solid-state design

and shall incorporate float and boost charging
facilities. In the float charge mode, the charger shall
automatically maintain the battery in a fully-charged
condition whilst supplying standing loads.
In the
boost charge mode, the charger shall be capable of

fully charging the battery from a fully-discharged
condition in a period not exceeding 7 hours.
The charging characteristics for the nickel-cadmium

vented type battery shall minimise electrolyte gassing.
The charger shall be complete with:
(i) Incoming supply on/off switch;
(ii) Supply on indication;
(iii) Output voltmeter;
(iv) output ammeter;
(v) float/boost charge selector switch;

1186 of 2461
PAGE 311 of 339
MMRDA
(vi) Charger failed relay with voltage-free changeover

set of contacts wired to terminals;
(vii)
Charger failed indication.
The minimum requirement for the charger failed

alarm shall be the detection of ac supply and dc
output failure. The relay shall not operate under a
transient ac supply failure condition.
b. Air
Where applicable, the air starting system shall

comprise
an
compressor,
air
receiver,
hand-start
electric
motor-driven
diesel-driven
standby
compressor, all necessary isolating and pressurerelief valves, interconnecting pipework, gauges, water
traps and drain facilities.
The capacity of the air receiver shall be sufficient for

three consecutive start attempts each of 10 seconds
duration.
The air receiver shall be of the vertically-mounted type

complying with BS 5169:1992 and having a corrosion
allowance not less than 2mm. Fittings shall include:
(i) Pressure gauge;
(ii) Pressure relief valve;
(iii) Manhole;
(iv) Isolating and non-return valves;

1187 of 2461
PAGE 312 of 339
MMRDA
(v) Automatic and manual drain valves;
(vi) Pressure switch for the initiation of a low pressure

alarm.
The capacity and operating pressure of the air

receiver shall be determined by the Contractor.
The air compressors shall be of the air-cooled type

suitably rated to deliver the required quantity of air to
recharge the air receiver from minimum start to
operating pressure in
period
not
exceeding
60 minutes.
Compressor inter and after coolers shall be of finned

or wire wound copper.
The compressor shall be
complete with air filter, silencers, automatic fly-weight

type unloader for no-load start, non-return valve,
pressure gauges, pressure-relief valves and drain
cocks for each stage.
Pressure gauges shall be
mounted on a panel.
The compressor and its driver shall be mounted on a

combination steel baseplate.
The diesel-driven
compressor shall be complete with fuel tank, air intake

filter and exhaust silencer and pipe to atmosphere.
The diesel-driven compressor shall be arranged for

hand starting.
The motor-driven compressor shall be fitted with a

pressure switch for automatic switching of the electric
motor. The electric motor shall be of the three-phase
cage induction type with appropriate IP rating.
1188 of 2461
PAGE 313 of 339
MMRDA
Air piping shall be of the seamless type complying

with BS EN 10217-3:2002.
4.8.1.14
Fuel System
The fuel system shall comprise an engine-driven feed

pump with duplex filters, daily service tank with
supporting structure and drip tray and all interconnecting
pipework including flexible engine connection pipe.
The fuel supply system comprising bulk storage facilities,

fuel transfer system and engine day service tanks shall
be as specified.
When specified, daily service tanks shall be fitted with the

following:
(i)
high, intermediate and low-level float switches

for the control of a fuel oil transfer pump and/or
alarm initiation;
(ii)
a jettison connection fitted with fire valve, the

connection being sized to drain the contents of
the tank in a period not exceeding 5 minutes.
Unless otherwise specified, the capacity of daily service

tanks shall be sufficient for eight hours full-load operation
of its associated generating set.
Fire valves shall be activated from the generator set firedetection system as specified elsewhere.
4.8.2 Diesel Generator Sets Generator
1189 of 2461
PAGE 314 of 339
4.8.2.1
MMRDA
The generator shall be of the salient pole brushless type

complying with BS 5000-3:2006. The generator shall be
flange and foot mounted or foot mounted with open
coupling, with single or twin end-shield bearings.
single-bearing machine shall be directly coupled to the

engine crankshaft.
A two-bearing machine shall be
coupled through an intermediate flexible coupling.
The generator shall be capable of continuous operation at

rated output plus 10% overload for 1 hour in any period of
12 hours without exceeding the temperature rise limits of
the insulation system.
Generator windings shall be of the 2/3 pitch design to

eliminate triple harmonics on the voltage waveform and
fully interconnected damper windings for stable operation
during paralleling.
Generator windings shall be star-connected with neutral

point brought out to the main cable termination facilities
and with provisions for neutral point earthing as specified.
Bearings shall have a minimum life of 40 000 hours and

shall have a re-lubrication interval preferably 8 000 hours
and not less than 4 000 hours. The bearing speed rating
shall not exceed 80% and the bearing outer race
temperature shall not exceed 70C.
The generator enclosure shall provide a minimum

protection classification of IP22 to BS EN 60529:1992,
Oil-lubricated bearings shall be fitted with a clearly visible

1190 of 2461
PAGE 315 of 339
MMRDA
and protected oil-level gauge.
Generators shall be fitted with an anti-condensation

heater.
4.8.2.2
Excitation system
A permanent magnet pilot exciter shall provide power to

the main exciter via the automatic voltage regulator. The
main exciter output shall be fed to the main rotor winding
through a 3-phase full-wave bridge rectifier. The diode
bridge shall be protected against surges and voltage
transients.
The excitation system shall sustain a short-circuit current

of not less than 300% rated current for a minimum period
of 5 seconds to allow external protection to operate.
4.8.2.3
Electrical insulation system
The electrical insulation system shall be Class F or better

to IEC 60085:2004 and the temperature rise shall not
exceed the preceding thermal class.
The generator and exciter stator windings shall be

impregnated with a moisture-resistant, oil-resistant and
acid-resistant polyester varnish with a final coat of antitracking varnish. The generator and exciter rotor windings
shall be impregnated with a high-strength thermo-setting
epoxy resin to withstand rotational forces.
4.8.2.4
Automatic voltage regulator
Automatic voltage regulators shall be of the solid-state

three-phase sensing type with in-built protection against
1191 of 2461
PAGE 316 of 339
MMRDA
sustained over excitation.

the
voltage
regulation
Unless otherwise specified,

shall
be
not
less
than
Grade VR2.21 to BS 4999-140:1987.
With the application of the maximum power system step

load specified elsewhere at any power factor between 0.2
and 0.8 lagging, the initial voltage shall not drop below
85% of the nominal value, recovering to 94% within
1.5 seconds.
Provision shall be made for remote adjustment.
4.8.2.5
Silent D.G Set Container
An acoustic Enclosure shall be designed considering
Adequate Ventilation for GENSET cooling requirement.
Absorbent/Insulating material used shall be fire retardant.
Suitable Thermal lagging to avoid localized heating of

adjoining part of exhaust.
Easy access to service points on GENSET Constructional

Details:
a)
Control norms sound level of 75dB at Silent D.G

Set Container shall be of modular construction with
the provision to assemble & dismantle easily as
per site condition.
b)
The structure shall be fabricated using CRCA

sheets 14/16 SWG. Rockwool slab of suitable
thickness and high density shall be used for
acoustic purpose to reduce the sound level to
1192 of 2461
PAGE 317 of 339
MMRDA
permissible limits i.e. As per Pollution distance of

1mtr from acoustic enclosure.
Acoustic Material:
i)
High density fiber glass.
ii)
To increase life of acoustic material resin coated

fibre glass cloth shall be provided on exposed
surface of rock wool.
4.8.3 Diesel Generator Sets Control System
4.8.3.1
The controls shall be designed to provide the following

facilities:
(a)
automatic starting and stopping of the engine;
(b)
manual starting and stopping of the engine;
(c)
simulated mains failure for testing the automatic

starting and stopping of the engine.
Subject to the approval of the Engineer, the facilities

specified
below
may
be
modified
to
suit
the
manufacturers standard control unit conditional on

compliance with the overall operating concept.
4.8.3.2
Control panel structure
The control panel shall be base frame, wall or floor

mounted
as
specified
and
the
construction
and
components shall generally comply with standards

1193 of 2461
PAGE 318 of 339
MMRDA
specified for switchgear and control gear.
Unless otherwise specified, the control panel shall be

equipped as detailed below.
4.8.3.3
Generator output switchgear
Unless otherwise specified, the generator output shall be

controlled by a three-pole and neutral MCCB/ACB (air
circuit breaker) with overload and short-circuit protection
for control of the generator output. The overload setting
range shall be 0.7 to 1.0. The short-circuit setting range
shall be 2 to 4 times the generator rated current.
4.8.3.4
Indicating instruments
phase ammeters or ammeter with phase selector

switch;
4.8.3.5
voltmeter with phase selector switch;
wattmeter;
Frequency meter.
Control switches
hand / auto / off;
auto-return on / off;
key-operated simulate mains failure / off;
engine heater(s) supply on / off;
1194 of 2461
PAGE 319 of 339
4.8.3.6
4.8.3.7
4.8.3.8
4.8.3.9
MMRDA
generator anti-condensation heater supply on / off.
Push-buttons
engine start / stop;
engine emergency stop
Hand regulating controls
engine speed;
generator voltage
Indicator lights
main supply available;
standby supply available.
Alarm annunciators
engine failed to start;
engine high cooling water temperature;
engine low lubricating oil pressure;
engine over-speed;
engine under-speed;
generator voltage high;
1195 of 2461
PAGE 320 of 339
4.8.3.10
MMRDA
generator voltage low;
generator circuit-breaker auto trip;
fire detection system operated;
emergency stop operated;
battery charger failed;
daily service tank low level;
daily service tank low overflow;
fuel transfer pump fault.
Automatic mains-failure control system
Unless otherwise specified, generator set controls for

single-unit automatic mains failure standby operation
shall comply with the following requirements.
The control system shall initiate the automatic generating

set start-up and shut-down sequences as described
below. The controls shall be designed to operate on an
energise to run and de-energies to stop basis.
4.8.3.11
Automatic start-up and shut-down

With the engine control selection switch in the auto
position, the control system shall operate as follows:
On loss of both main supply and after a preset

adjustable time delay of 0 to 10 seconds, engine
1196 of 2461
PAGE 321 of 339
MMRDA
starting shall be initiated via a mains failure relay

located
in
the
switchboard.
incomer
unit
of
the
associate
Concurrent with the starting of the
engine, the inlet and outlet air louvers shall be opened.
The engine-cranking sequence shall comprise a

maximum of three 10second periods.
The control
system shall provide facilities for adjusting both the

number and duration of the cranking sequence.
On the generating set reaching full speed and voltage

and, after a pre-set adjustable time delay of 0 to
5 seconds, a voltage-free relay contact shall close to
initiate the closing of the associated standby supply
contactor.
Should the main supply be restored before the closing

of the standby supply contactor, the closing of the main
supply contactor shall be initiated and after a pre-set
adjustable time delay of 0 to 5 minutes the engine shall
be shut-down.
On restoration of the main supply with the auto-return

control switch in the on position and after a pre-set
adjustable time delay of 0 to 5 minutes, opening of the
standby supply contactor, closing of the main supply
contactor and engine shutdown shall be automatically
initiated.
The shutdown procedure shall be in
accordance with the engine manufacturers standard

practice.
On restoration of the main supply with the auto-return

control switch in the off position, the generating set
shall continue to supply the load. The automatic shutdown sequence shall be initiated by returning the
1197 of 2461
PAGE 322 of 339
MMRDA
switch to the on position.
4.8.3.12
Simulated mains failure test facility
The facility shall permit the testing of the generating set

automatic start-up sequence under a simulated main
supply failure condition. With the test facility switch in the
simulate mains failure position, the automatic start-up
sequence shall be initiated. The engine shall be stopped
by returning the switch to the off position.
4.8.3.13
Engine lock-out
The engine shall automatically stop and lock-out under

the following conditions:
engine failed to start;
engine high cooling water temperature;
engine low lubricating oil pressure;
engine over-speed;
engine under-speed;
generator voltage high;
generator voltage low;
generator circuit breaker auto trip;
fire detection system operated;
emergency stop operated;
1198 of 2461
PAGE 323 of 339
MMRDA
daily service tank low level.
Alarm and lock-out systems shall be inhibited during

normal starting and stopping operations.
Restarting of the engine shall be prevented until the

alarm has been reset.
4.8.3.14
Emergency stop
The emergency stop shall operate in all control modes.
a) Auxiliary contacts
One set of voltage-free changeover contacts shall be

provided for remote status and alarm indications as
follows:
each alarm condition;
common group alarm for generating set failed

comprising each of the single alarms causing engine
lock-out;
generating set running;
simulated mains failure test selected;
Generating set auto control not selected.
b) External emergency stop
Provision shall be made for the connection of an external

emergency stop push-button or switch. The associated
1199 of 2461
PAGE 324 of 339
MMRDA
terminals shall be fitted with a link.
c) Fire-detection system
Unless otherwise specified, a fire-detection system shall

be installed above the generating set. The system shall
comprise fusible links and tensioned operating wires.
Link fusing shall initiate the operation of the engine fuel

supply fire valve, daily service tank jettison fire valve
when fitted and switches for initiating engine lock-out,
remote alarm and, when installed, fuel transfer pump
stop.
d) Safety
Electrical equipment shall be designed and constructed to

provide a maximum standard of safety for operational and
maintenance personnel.
Mechanical interlocking shall be provided to prevent

access to live equipment and to protect the equipment
and the operator from mal-operation.
Where access to low-voltage enclosures is necessary

with equipment energised from an external source, all
such equipment and terminals shall be shrouded to
prevent accidental contact and warning labels shall be
fitted.
Shrouds shall have a minimum degree of
protection IP30.
Covers fitted to enclosures in which live conductors are

installed shall be fitted with a warning label.
Integral distribution boards shall permit safe access to

1200 of 2461
PAGE 325 of 339
MMRDA
fuse carriers and miniature circuit breakers without the

need for isolation. All live connections when fuse carriers
and plug-in type miniature circuit breakers are removed
shall be fully shrouded AND SHALL BE PROVIDED with
suitable protection against hazardous Environment.
4.9
General Specification of Building Services

4.9.1 Building And External Services Power Distribution
4.9.1.1
Design
Building services installations shall be designed and

installed in accordance with Indian Electricity Rules,
National Building Code and the Chartered Institution of
Building
Services
Engineers
(CIBSE)
Guide,
BS
7671:2008 in concurrence with IS 732:1989.
4.9.1.2
Distribution boards
Distribution fuse boards and miniature circuit breaker

boards, herein referred to as distribution boards, shall
comply with BS EN 60439-1:1999.Distribution board
enclosures shall be fabricated from heavy-gauge sheet
steel with an all-welded construction. Exterior edges and
corners shall be rounded to give a smooth overall
appearance. Assembly bolts, screws or rivets shall not be
visible from the front. Doors shall be lockable. Distribution
boards shall have a minimum degree of protection IP31
to BS EN 60529:1992 when located in clean and dry
rooms. The protection classification for distribution boards
located in other indoor locations shall be IP54. For
outdoor locations, the degree of protection shall be not
less than IPW55.Distribution boards shall be fitted with
removable top and bottom undrilled gland plates, each
1201 of 2461
PAGE 326 of 339
MMRDA
with a brass terminal stud. Phase, neutral and earth bus

bars shall be provided, each clearly identified. The phase
bus bars shall be fully insulated. The bus bar current
rating shall be not less than the sum of the maximum
rated currents of the outgoing ways. The neutral bus bar
shall have a terminal for each outgoing circuit. The earth
bus bar shall be directly connected to the earth terminal
without dependence on the exposed conductive parts of
the enclosure. The earth bus bar shall have a terminal for
each outgoing circuit. Each outgoing circuit including
spare ways shall be controlled by a miniature circuit
breaker as specified. Outgoing circuit terminations shall
be shrouded and covers shall be fitted over all live parts
to prevent accidental contact. Incoming supply terminals,
including the cable socket, shall be enclosed in an
insulating housing which shall extend over the cable
insulation.
Warning labels shall be fitted to all removable covers.

Unless otherwise specified, distribution boards shall be
fitted with a switch disconnector complying with IEC
60947-3:1999 for isolation of the incoming supply. For
three-phase distribution boards, the switch disconnector
shall be four-pole. For single-phase ac and dc distribution
boards, the switch disconnector shall be two-pole.
Outgoing circuits shall be clearly identified. Neutral and
earth bus bar terminals shall be identified as their
respective outgoing way. Embossed plastic and paper
labels will not be accepted. A circuit identification chart in
a clear and durable plastic wallet shall be mounted on the
inside of the door. Distribution boards shall be fitted with
an identification label manufactured from white-blackwhite laminated plastic or rear-engraved Perspex as
specified. The label shall lay flat to the surface and shall
be secured by non-rusting screws. Danger and warning
1202 of 2461
PAGE 327 of 339
MMRDA
labels shall comply with BS 5499-5-2002 in concurrence

with IS 9457:1980.
4.9.1.3
Bulk switching contactors
Bulk switching contactors for the control of lighting and

heating loads shall be of the electromagnetic type
complying with IEC 60947- 4-3:1999. The contactors
shall be rated for uninterrupted duty and shall have
utilization category compatible with the type of load being
controlled. Contactors shall be double-pole for singlephase ac and dc and four-pole for three-phase loads.
Enclosure
construction
shall
be
as
specified
for
distribution boards. 7.20.1.4 Low and extra low voltage

supply transformers Low-voltage and extra-low-voltage
supply transformers shall comply with BS EN 60742:1996
and shall, unless otherwise specified, be of the singlephase type.
Transformers shall be supplied complete with fixing

bracket. The rated output and voltage shall be as
specified.
4.9.1.4
Electrical earth proving and monitoring units
Where supplies are taken to portable tools or appliances

at 240/415V, the supply point shall incorporate electrical
earth
proving
and
monitoring
complying
with
BS
4444:1989. The supply point shall also incorporate

residual-current protection.
The residual-current circuit breaker shall comply with BS

EN 61008-1:2004 and BS EN 61008-2-1:1995.The plug
and socket-outlet shall comply with IS/IEC 309- 2:1989
and shall incorporate pilot contacts.
1203 of 2461
PAGE 328 of 339
4.9.1.5
MMRDA
Building services wiring
Unless otherwise specified, internal services wiring shall

be carried out in heavy-duty hot-dipped galvanized steel
conduit and trunking incorporating 660V grade, single
core PVC-insulated cable. Wiring installation shall comply
with the provisions of IS 732:1989 and SP 30:1985National Electrical Code. Wiring shall be carried out on
the looping-in system. No joints other than at looping-in
points will be allowed. Cable sizes shall be not less than
1.5mm for lighting circuits and 2.5mm for socket outlets,
heating, ventilation and small power circuits. Conduit
systems shall be surface or buried within building
plaster/screed finishes as specified. External services
shall be cabled in multi-core PVC-insulated armoured
cable, surface-run on building structures and steelwork or
direct-buried as appropriate.
4.9.1.6
Building services lighting
General requirements:
The building internal lighting design shall take into

account:
the operating environment;
the type and style of architectural finish;
the activities to be performed in the areas;
access for equipment maintenance;
operating life
1204 of 2461
PAGE 329 of 339
MMRDA
The minimum service illumination levels shall comply with

the minimum recommendations of the CIBSE Code for
the appropriate building area and operational function, or
as otherwise specified. Illumination levels shall apply to
floor levels. In no case shall the illumination be below that
necessary to perform work or other essential activity in
any particular location.
In
areas housing rotating
machinery, lighting shall be arranged on multiple-phase

circuits to prevent stroboscopic effects. Where adjacent
luminaries are connected to different phases of the
supply, a label shall be fitted internally, warning of the
presence of the phase-to phase voltage.
4.9.1.7
General-purpose luminaires
Luminaires shall be of the fluorescent, tungsten or gasdischarge type as specified, and shall comply with BS EN
60598-1:2000.General-purpose
fluorescent
luminaires
shall be manufactured from zinc-coated sheet steel of

minimum thickness 0.7mm with white epoxy polyester
powder or equivalent finish. Luminaires shall be fitted with
a trough reflector or prismatic diffuser as specified.
Luminaires for installation in clean and dry areas shall
have a minimum degree of protection IP20 (without
adiffuser) and IP40 (with a diffuser) to BS EN
60529:1992.Luminaires
for
use
in
corrosive
environment shall have a glass reinforced plastic body

with a prismatic acrylic or polycarbonate diffuser. The
degree of protection shall be IP65 to BS EN 60529:1992.
Covers shall be sealed to the body with a neoprene
gasket and shall be secured using stainless steel fixing
catches. The catches shall be hinged to the body.
Bulkhead luminaires shall be of the heavy-duty type and
shall have a die cast corrosion-resistant Aluminum body
1205 of 2461
PAGE 330 of 339
MMRDA
and front frame with epoxy polyester powder or

equivalent finish, and prismatic cover. Covers fitted to
luminaires located outdoors shall be impact-resistant
polycarbonate. The cover shall be sealed to the body with
a silicon rubber gasket and shall be secured using
stainless steel captive screws.
Retaining hinges shall be stainless steel. Bulkhead

luminaires for indoor location shall have a minimum
degree of protection IP54 and for outdoor location IP65 to
BS EN60529:1992.Floodlighting luminaires shall be of
similar construction to the bulkhead luminaires except
they shall be fitted with a clear toughened glass panel.
Floodlighting luminaires shall be complete with high-purity

anodized Aluminum reflector and
galvanized steel
mounting bracket. Reflector characteristics shall be

selected to suit the floodlight application. Fluorescent
luminaires shall be of the switch-start type unless
otherwise specified.
4.9.1.8
Emergency lighting luminaires
Unless
otherwise
specified,
emergency
lighting
luminaires shall be of the self-contained type complying

with BS 4533-102.1:1990 and shall incorporate a
fluorescent lamp. The rated duration of emergency
lighting luminaires shall be 3 hours. Exit-type emergency
luminaires shall be of the maintained type.
4.9.1.9
Luminaires For hazardous areas
Luminaires for location in Zone 1 and Zone 2 hazardous areas

shall comply with BS EN 50014:1998. The Apparatus Group and
Temperature Class shall be as specified.
1206 of 2461
PAGE 331 of 339
4.9.1.10
MMRDA
Lamps
Tungsten filament lamps shall comply with BS EN

60064:1995+A4:2007 and BS EN 60432-1:2000 and shall
have a minimum rated average life of 2000 hours.
Tungsten
lamps
shall
have
reinforced
internal
construction to provide increased resistance to filament

breakage caused by jolts and vibration. Lamps for special
applications shall be as specified. Tungsten lamps rated
up to and including 150W shall be fitted with a bayonettype lamp cap. For lamp wattage above 150W, the lamp
cap shall be of the Edison-screw type. Lamp caps shall
comply with BS EN 60061-1:1997 in concurrence with IS
6701:1985.Energy-saving fluorescent lamps used as a
direct replacement for tungsten filament lamps shall have
integral control gear and a minimum rated average life of
8000 hours. Fluorescent lamps shall comply with BS
1853-2:1995 in concurrence with IS 2418-Part1:1977 and
shall have caps of the bi-pin type. Unless otherwise
specified, lamps for installation in industrial areas shall
have a correlated colour temperature of 3500K (white
appearance) and for other areas shall have a correlated
colour temperature of 3000K (warm appearance). The
minimum rated average lamp life shall be 3000 hours.
Mercury
discharge
lamps
shall
comply
with
IEC
60188:2001.
4.9.1.11
Ceiling roses
Ceiling roses shall be of insulating material having

ignitability
characteristic
as
specified
in
ISO
5657:1986. Extension flanges shall be fitted to all surface

mounted ceiling roses where the wiring installation is
concealed
in
the
building
1207 of 2461
fabric.
Where
plug-in
PAGE 332 of 339
MMRDA
connections are specified for luminaires, 2A three-pin

outlets and plugs shall be provided which shall be
suitable for mounting on to a circular conduit box. When
specified, the plug shall be retained in the socket by
means of a locking ring.
4.9.1.12
Pendants and chain suspensions
A plain pendant shall comprise a ceiling rose, flexible

cord and lamp holder. Unless otherwise specified, the
flexible cord shall be 0.75mm and the insulation shall be
suitable for a maximum operating temperature of 85C.
Where the lamp holder has a metal exterior, the flexible
cable shall include a protective conductor which shall be
connected to the earth terminal of the lamp holder and
ceiling rose. A tube pendant shall comprise a ball and
socket cover to fit a circular conduit box and steel conduit
not less than 20mm diameter. At the conduit entry to the
luminaire a back nut shall be used. A chain suspension
shall comprise a hook cover fixed to a circular conduit
box and a chain having a load carrying capacity not less
than twice the weight of the luminaire.
4.9.1.13
Supports and fixings
Where fluorescent luminaires 1200mm or more in length

are supported directly by the conduit system they shall be
fixed to two circular conduit boxes both of which shall
form an integral part of the conduit system. Where the
weight of the luminaire is supported by a conduit box or
trunking, the fixing of the conduit box or trunking shall be
adequate for the purpose. Luminaires fitted with tungsten
filament lamps and having metal back plates shall not be
fixed directly to a conduit box in which a thermoplastic
material is the principal load-bearing member. Support of
1208 of 2461
PAGE 333 of 339
MMRDA
luminaires from cable trunking shall be by means of

proprietary clamps or brackets. Where luminaires are
supported from the structure other than by the conduit or
trunking system, they shall be fixed by approved purposemade clamps, bolts, washers and nuts, expanding
anchors or proprietary wall plugs and non-ferrous screws
as appropriate. Luminaires mounted on or recessed into
suspended ceilings shall be independently supported.
4.9.1.14
Wiring connections
Where luminaires, other than tubular fluorescent, are

fixed directly to circular conduit boxes or are supported by
pendants or chains, the final circuit wiring shall terminate
at a terminal block in the conduit box. Where fluorescent
tube luminaires are fixed directly to circular conduit
boxes, the final circuit wiring may be terminated within the
luminaire. The wiring shall enter each luminaire at the
conduit entry nearest to the terminal block and, where a
loop-in wiring system is used, leave by the same entry.
Wiring shall not pass through the luminaire. Where
luminaires are mounted on or recessed into a suspended
ceiling, connection shall be by flexible cord from a plug-in
ceiling rose unless otherwise specified. The plug-in
ceiling rose shall be located not more than 500mm from
the access in the ceiling and shall be firmly fixed. Where
high-bay discharge luminaires are suspended from the
structural ceiling, the connection between the fitting and
fixed wiring shall be by plug and socket. Cables and
flexible cords for final connections to luminaires shall be
suitable for the operating temperature of the luminaire.
Flexible cords for chain suspensions shall have a white
sheath.
Cables and cords passing close to ballast within a

1209 of 2461
PAGE 334 of 339
MMRDA
luminaire shall be suitable for the operating temperature

of the ballast. Where adjacent luminaires are connected
to different phases of the supply, a label shall be fitted
internally; warning of the presence of the phase-to-phase
voltage. A protective conductor shall connect the earth
terminal
of
each
luminaire
to
an
earth
terminal
incorporated in the adjacent conduit box. Where the final

connection is by flexible cord, the protective conductor
shall be integral with the cord.
4.9.2 Building and external services roadway lighting
4.9.2.1
Columns
Roadway lighting columns shall be constructed and

installed in accordance with BS 5649-2:1978. The base
compartment door/cover shall be fitted with a tamperproof
fastening. Columns shall have bolted base mounting
plates for installation on concrete foundation blocks which
shall incorporate bottom-entry cable ducts. Columns shall
be complete with baseboard, fuse unit and wiring
between the fuse unit and luminaire.
The fuse unit shall have a non-hygroscopic plastic case

designed to prevent the ingress of moisture and
condensation, integral double-entry cable termination
chamber with detachable front cover and enclosed-type
fuse complying with IEC 60269-1:1998.
4.9.2.2
Lanterns
All lanterns shall be of the high-pressure mercury or

sodium type fitted with high efficiency lamps and
complete with integral control gear.
1210 of 2461
PAGE 335 of 339
4.9.2.3
MMRDA
Building services sockets and switches
1) Socket-outlets and couplers
Commercial-type socket-outlets shall comply with BS

1363-2:1995 and BS1363-3:1989in concurrence with
IS 1293:1988, and shall be supplied complete with
boxes and fixing screws. Socket outlets shall be white
plastic
or
metalclad
pattern
according
to
the
installation area and as specified. Socket-outlets shall

be of the flush-mounting type in plastered and tiled
areas. In all other areas, socket-outlets shall be of the
surface-mounting type. Industrial pattern socketoutlets and couplers shall comply with IS/IEC 3091:1988
switched
and
IS/IEC
socket
309-2:1989.
outlets
shall
Industrial-type
be
mechanically
interlocked to prevent the plug being inserted or

withdrawn unless the switch is in the off position. It
shall not be possible for the switch to be moved to the
on position unless the plug is completely inserted.
Socket outlets for indoor location in process or damp
areas shall have a minimum degree of protection IP55
to BS EN 60529:1992. For outdoor locations, the
degree
of
protection
shall
be
not
less
than
IP65.Socket-outlets for locations in chemical-handling

areas shall have plastic enclosures resistant to the
particular chemical. In office and control room areas,
socket-outlets shall be installed at 0.5m above floor
level. In plant areas, socket-outlets shall be installed
at 1.2m above floor level. The height of socket-outlets
shall only be changed with the approval of the
Engineer. Residual-current circuit breakers fitted to
socket-outlets shall comply with BS EN 61008-1:2004
and BS EN 61008-2:1995 and shall have a tripping
sensitivity of 30mA with an operating time not
1211 of 2461
PAGE 336 of 339
MMRDA
exceeding 30ms.
2)
Switches
Switches shall comply with BS EN 60669-1:2000

in concurrence with IS 3854:1997 and shall be
supplied complete with box, cover plate and fixing
screws.
Switches shall be
white
plastic or
metalclad type according to the installation area

and as specified. At multi-switch positions for
lighting, the switches shall be contained in multigang boxes. Multi-phase switch assemblies shall
be phase-segregated and a separate cover shall
be fitted over each phase section. The phase shall
be marked on the covers and a label warning of
the presence of a three-phase supply shall be
fitted. Switches shall be of the flush-mounting type
in plastered and tiled areas. In all other areas,
switches shall be of the surface-mounting type.
External lighting switches shall have rotary switch
action and, unless otherwise specified, a hotdipped galvanized cast-iron enclosure with tapped
spouted entry. Switches for indoor locations in
process or damp areas shall have a minimum
degree of protection IP55 to BS EN 60529:1992.
For outdoor locations, the degree of protection

shall be not less than IP65.Switches for locations
in chemical-handling areas shall have plastic
enclosures resistant to the particular chemical.
Switches shall be installed 1.4m above floor level.
The Contractor shall include for the design, supply,

delivery to Site, off-loading, storage, erection,
testing and setting to work the complete building
1212 of 2461
PAGE 337 of 339
MMRDA
services installations at the sites Waste water

pump houses. As a minimum, the Contractor has
to provide the following:
Internal main and emergency lighting;
External walkways and floodlighting;
Small power;
Air conditioning;
Ventilation and ceiling fans;
Telephone lines and telephone handsets;
The building services installation shall comply with

Standard Specification and the following clauses
herein. Where the standard specification, particular
specification and drawings differ, the Standard
specification shall take precedence.
Lighting
Illumination level
Location
lux
Hall Area
200
Switch room
300
Control room
350
Workshop area
300
Offices
300
Staff room
200
Corridors
75
1213 of 2461
PAGE 338 of 339
MMRDA
Location
lux
toilet& washroom
100
Outdoor lighting
25
Ventilation
Mechanical ventilation shall be provided as follows:
Location:
Air changes/hour
(ACH):
Pump room
6
Toilets and washrooms
Mess rooms and kitchen
Electrical switch rooms
10
Ancillary Services
Power supply to instrumentation and automation system

shall be provided. Telephone intercom wiring shall be as
required.
1214 of 2461
PAGE 339 of 339
SUB-SECTION 6B.4-B: ELECTRICAL WORKS (UNDER MSETCL SUPERVISION)
1215 of 2461
MMRDA
Table of Contents
1216 of 2461
MMRDA

SECTION I
TECHNICAL SPECIFICATION FOR

SUB-STATION WORKS
Scope:
The scope of work broadly includes the design, engineering, manufacturing, testing at
the manufacturers work and supply of all the equipments/materials for EHV Substation/End bays, execution of the necessary civil works as specified/as required
according to site conditions, erection, testing and commissioning of the equipments/
materials for the following EHV Substations.
1.2
The equipments to be supplied and erected against this specification are required
for vital installations where continuity of service is very important. The design,
materials and manufacture of the equipments as well as the erection work shall
therefore be of the highest order/standard to ensure continuous and trouble free
service over the years.
1.2. a)
The equipments to be supplied (as per annexure I) shall be complete with all parts
necessary for their effective, trouble-free operation. Such parts will be deemed
to be within the scope of the bidder irrespective of whether they are specifically
indicated in the commercial order/Price Schedule or not.
SECTION 6B4_B: ELECTRICAL WORKS UNDER MSETCL SUPERVISION
1217 of 2461
PAGE 1 of 358
1.3
MMRDA
The equipment shall be suitable for the system whose particulars are as follows:
a. Nominal system voltage
132kV
b. Highest system voltage
145kV
c. Basic Insulation level
650kV
d. Ground clearance (Minimum)
4.6 M
e. Sectional clearance (Minimum)
3.5 M
f. Frequency
50Hz 3%
g. Number of phases
h. Neutral earthing
1.4
Solidly Effectively Earthed.

SERVICE CONDITIONS
Equipment to be supplied against this specification shall be suitable for

satisfactory operation under the following tropical conditions:
i.
Maximum ambient temperature
50 Deg C
ii.
Maximum temperature in shade
iii.
Minimum temperature in shade
3.5 Deg C
iv.
Maximum daily average temperature
40 Deg C
v.
Relative Humidity
10% to 100%
vi.
Maximum annual rainfall
1450 mm
vii.
Maximum wind pressure
viii.
Maximum altitude above mean sea level
ix.
Isoceraunic level
50 days / year
x.
Seismic level (Horizontal acceleration)
0.3 g
xi.
Moderately hot and humid tropical climate, conducive to rust and
45 Deg C
150 kg/ m sq.

:
1000 Mtrs.
fungus growth.
xii.
The climatic conditions are prone to wide variations in ambient

conditions and the equipment offered shall be suitable for installation
at any of the stations in the (Maharashtra) State.
1.5
STANDARDS
Unless otherwise specified elsewhere in this specification, the equipments
supplied and erected against this specification shall conform to the latest revision
of the following standards:
1.
Aluminium
conductor
for
overhead
- IS 398
transmission purposes. (ACSR./AAAC)
1218 of 2461
PAGE 2 of 358
2.
MMRDA
Conductor and earthwire accessories for
- IS 2121
overhead power lines.

3.
Design and construction of foundations for
- IS 4091
transmission line towers and poles.

4.
Hot dip galvanized coatings on round steel
- IS 4826
wires.
5.
Hot dip galvanized coatings on structural steel
- IS 4759
and allied products.

6.
Porcelain insulators for overhead power lines

with a nominal voltage greater than 1000V.
7.
Solid core insulators
- IS 2544
- IS 5350
- IS 13134
8.
Electric Power connectors
- IS 5561
9.
Method of testing weights, thickness &
- IS 2633
uniformity on H.D.S. articles.

10.
Recommended
practices
for
hot-dip
- IS 2629
Insulator fittings for overhead power lines
- IS 2486
galvanizing of Iron & Steel.

11.
with a nominal voltage greater than 1000V.

12.
Use
of
structural
steel
in
overhead
- IS 802
Rolled steel, beams, channel and angle
- IS 808
transmission lines.
13.
sections.
14.
Technical supply conditions for nuts and
- IS 1367
threaded fasteners.
15.
Specification for high tension structural steel.
- IS 961
16.
Hexagonal bolts for steel structures.
- IS 6639
17.
Specification for washers:
a) Spring
- IS 3063
b) Plain
- IS 2016
c) Heavy
- IS 6610
18.
- IS 1821
Dimensions for clearance holes for metric

bolts.
1219 of 2461
PAGE 3 of 358
19.
MMRDA
Specification for hot dip galvanized coatings
- IS 5358
on fasteners.
20.
Wrought aluminium and aluminium alloy
- IS 5082
bars, rods, tubes and sections for electrical

purpose.
21.
Supply of pipes and tubes.
- IS 5561
- IS 1239
22.
Dimensions for wrought aluminium and

aluminium alloy tubes.
a) drawn type
- IS 2678
b) extruded type
- IS 2673
23.
Specification for H.V.A.C. circuit breakers.
- IS 13118
24.
Degree of protection provided for enclosures
- IS 2147
for low voltage switchgear and control gear.

25.
Specification for 3 phase induction motor.
- IS 325
26.
High pressure cylinder in which SF6 gas is
- IS 4379/
transported and stored at site.
- IS 7311
27.
Specification for current transformers.
- IS 2705
28.
Specification for high voltage porcelain
- IS 2099
bushings.
29.
Method of high voltage testing.
- IS 2071
30.
Insulation co-ordination of highest voltages
- IS 2165
for equipments of 100kV and above.

31.
Specification
for
insulating
oil
for
- IS 335
transformers and switchgear.

32.
Specification for voltage transformer.
- IS 3156
33.
Code of practice for climate proofing of
- IS 3202
electrical equipment.
34.
35.
Specification for Alternating current isolators
- IS 1818/
(disconnectors) and earthing switches.
- IS 9921
Specification for marking and arrangement
- IS 375
for switchgear, busbar main connection &

auxiliary wirings.
1220 of 2461
PAGE 4 of 358
36.
37.
MMRDA
Specification for Surge arrestors without gap
- IEC 99-4
for AC system.
- IS 3070
Specification for large hollow porcelain for
- IS 5621
use in electrical installation.

38.
Specification
for
stationery
cells
and
- IS 1651
batteries, lead acid type (with tubular

positive plates).
39.
Specification for synthetic separators for
- IS 6071
lead acid batteries.

40.
Specification for hard rubber containers for
- IS 1146
lead-acid storage batteries.

41.
Specification for sulphuric acid.
- IS 366
42.
Specification for water for storage batteries.
- IS 1069
43.
Specification for sealing compound for lead
- IS 3116
acid batteries.
44.
Specification for rectifier equipment in
- IS 3895
general.
45.
Specification for HRC fuses.
- IS 9224
46.
Specification for indicating instruments.
- IS 1248
- IS 2419
47.
Specification
conductor
for
monocrystalline
rectifier
assemblies
semi-
- IS 4540
and
equipments.
48.
Specification for transformers.
- IS 2026
49.
Specification for printed circuit boards.
- IS 5921
50.
Specification
for
AC
contactors
for
- IS 2959
Specification for Air breaks switches and
- IS 4064
voltage not exceeding 1000V.

51.
fuses combination units.

52.
Specification for colour for ready mix paints.
- IS 5
53.
Safety code for semi-conductor rectifier
- IS 6619
equipment.
1221 of 2461
PAGE 5 of 358
54.
MMRDA
General requirement for switchgear and
- IS 4237
control gear for voltage not exceeding

1000V.
55.
Specification for Electrcial relays for power
- IS 3231/
system protection.
- IS 225 /
- BS 142
56.
Specification for static protective relays.
- IS 8686
57.
Dimensions of mechanical structures of the
- IS 297
19 (482.6mm) series.
58.
Specification for Energy meters, control
- IS 722
switches.
59.
Specification for PVC insulated cables upto
- IS 1554
and including 1000 Volts.

60.
Code of practice for phosphating iron and
- IS 6005
steel.
1.6
The equipments/work covered under this specification shall also comply with the
requirements of Indian Electricity Act and the Indian Electricity Rules and any
other applicable statutory provisions, rules and regulations.
2.0
Requirement and Quantity:
2.1
The scope and quantity of work covered in this specification are broadly indicated
in the scope of work/Bill of quantity (BOQ) .The works involved comprise of the
following:
A) Design, engineering, manufacturing, testing at the manufacturers works and
supply of all materials as specified in BOQ required for the Substations as
specified at clause no. 1.2 above
B) Supply of materials and execution of civil works as specified in the scope of
work and BOQ, including foundations, , along with construction of cable trenches,
control room (including electrifications, false ceiling and air conditioning as per
civil schedule) and the roads within the switchyard.
C) Erection, Testing and commissioning of all equipments.
1222 of 2461
PAGE 6 of 358
2.2
MMRDA
Item-wise quantities required and scope of work are indicated in the Bill of
Quantity at Annexure-I. The Bill of Quantity shall be considered as the datum
for preparation of bids. In case there are any changes in quantity/ scope (during
execution) vis--vis the Bill of Quantity, the price implication (addition/deletion)
shall be worked out by operating the unit rates. As such, unit rates of all the items
including various lamps & fixtures for indoor/ outdoor installation shall be
available/indicated in the offer.
2.3
Minor items like, cable glands, lugs, clamps for supporting the earthing strips/
earthwires, caution boards, etc are not included in the BOQ but required for the
completion of the project. Such minor items, though not specifically listed out in
BOQ, is included in the scope of bidder.
2.4
Total weight of structural steel required includes a) Wt. of S/S gantry structures,
b) Wt. of lighting & lighting mast structures, c) Wt. of foundations bolts required,
d) Wt. of all equipments support structures except Circuit Breaker, Isolator,
Coupling Capacitor & Wave trap..
3.0
Drawings and Data:
3.1
The earthmat design shall be in bidders scope. However, the successful bidder
shall take the soil resistivity of the switchyard area and design the earthmat. The
earthmat design calculation, earthmat layout, equipment earthing details and soil
resistivity report shall be furnished to Design, Contracts & Monitoring for approval.
Also, the laying of earth mat as per the earth mat drawings, the equipment
earthing and connection to the earth mat will be in the bidders scope.
3.2
Detailed design drawings in respect of all the structures and similar materials to
be supplied by the bidder as also the control room details will be furnished
separately to successful bidder. All such materials shall be procured as per these
drawings. Wherever necessary, the inspection of materials at the respective
manufacturers works will be done by the MMRDA representative and the
dispatch clearance will be issued if the materials are found to be in order.
3.3
The switchyard is designed for a short circuit level of 40kA for 3 seconds. The
power connectors and hardware shall be suitable for withstanding a short circuit
level of 40kA for 1 second.
4.0
Principle Technical Particulars:
1223 of 2461
PAGE 7 of 358
4.1
MMRDA
The Principle technical particulars in respect of the various equipments to be

supplied against this specification are furnished at Annexure III A to U. Materials
not covered by above PTP Shall conform to relevant IS amended to upto date.
4.2.1
Drawings for approval: The successful tenderer(s) shall submit all the relevant
drawings for approval within 30 days from the date of issue of Letter of Award
(LOA). The drawings mentioned in Annexure-A shall be submitted to Design,
Contracts & Monitoring Section in Corporate Office. The all other drawings other
than in Annexure-A shall be submitted to concern filed office for approval. The
approval / comments on the drawings will normally be conveyed within 4 weeks
from the date of submission/ receipt whichever is later
4.2.2
Gantry Structure & Equipment support structure:

A) The proto inspection of the gantry & equipment structure to be used for the
subject work should be carried out by Corporate Office, Mumbai, at
manufacturers site.
If the proto inspection of the required (as per approved layout) gantry & equipment
support structure is not carried out by Corporate Office:
i)
Proto inspection of gantry & equipment structure call shall be offered

to Corporate Office, Mumbai.
ii)
If contractor is not using standard MSETCL drawing/making or any

changes in gantry & equipment structures. Contractor will take
approval from Corporate Office, Mumbai & offer proto inspection call to
Corporate Office, Mumbai
The gantry & equipment structure for which proto inspection for particular vendor
is already carried out and approved by Corporate Office, the BOQ of the same
shall be submitted for approval to concerned field office.
4.3
4.3.1
B) Contractual Drawings & Manuals:

The manufacturing of each equipments shall be strictly in accordance with the
approved drawings and no deviation will be permitted without the written approval
of the Planning/Design & Engineering department. All manufacturing work which
is not as per approved drawing shall be at the suppliers risk and shall be liable
for rejection.
1224 of 2461
PAGE 8 of 358
4.3.2
MMRDA
The supplier shall submit detailed packing list of each equipment, gantry,
structure for approval. After approval, copies of these approved drawings,
Technical literature, commissioning manuals, packing list shall be forwarded to
the consignees along with the consignment. Copies of packing list shall also be
submitted to the General Manager (SB), MSETCL, along with bill for payment.
a) After commissioning the supplier shall furnish sets of approved drawings,
including Bill of Quantity and wiring schedules, sets of technical literature and
4.3.3
commissioning manuals in case of substation equipments/ relay panels in

suitable files. These shall be six sets for each equipment & shall be furnished to
the Transmission Project department.
b) In addition to above supplier shall also furnish to the Transmission Project
Department one complete set of PVC reproducible of the relevant drawings (i.e.
switchyard drawings, schematic drawings, internal wiring drawings, external
cable connection drawings, wiring, termination of marshalling boxes drawing.
Control room & switchyard electrification drawing) along with 2 CDS each of as
built drawings and literatures/ commissioning manuals.
5.0
Delivery period:
All the works against this specification shall be completed within 12 months,
including monsoon from the date of LOA. Time being the essence of the contract;
timely completion of the work is imperative. Any delay in completion may lead to
penalty on the defaulter.
6.0
Type Tests:
6.1
Each equipment offered for supply against this specification shall be of a design,
which is already, type tested as per the relevant standards and the requirements
specified in MSETCL specification.
6.2
The type tests, already conducted, shall not be more than five (5) years old as on
the date of opening of the bids.
1225 of 2461
PAGE 9 of 358
6.3
MMRDA
Type test reports as per 6.2 above for equipments manufactured by any of the
approved vendors need not be submitted along with the offer, provided that an
undertaking is furnished to submit type test reports, if already conducted, for
approval of the owner, or to conduct the type tests in the presence of owners
representative and submit it before dispatch of the equipments. In case the type
test of any equipment is more than five year old, the bidder shall indicate only the
date of type testing already carried out, and shall not submit copies of such (more
than five year old) test reports.
6.4
If the type tests are more than five year old, the bidder has to arrange for type
testing the equipment at no cost to the purchaser, and an undertaking in this
regard shall be furnished, in the enclosed Schedule-E, along with the offer, failing
which the offer may be rejected.
6.5
In the case of control and relay panels, the type tests clauses as above are mainly
applicable for protective relays.
6.6
Not-withstanding anything stated above, the purchasers decision regarding type

tests will be final and binding on the bidder.
7.0
Land Development and facilities at site:
7.1
Land leveling/development for the augmentation shall be arranged by MMRDA.
7.2
Space for construction of covered and open stores within the owners premises
will be identified by the owner so as to enable the contractor to construct his own
site store/ storage yard.
7.3
Water supply for construction work shall be arranged by the contractor at his own
cost. Aux. power supply shall be arranged by MSETCL. Necessary deposit and
energy charges shall be borne by the contractor.
8.0
Deviations from Specification:

In case the bidder desire to deviate from this specification on any account, details
of such deviations along with the reasons and justifications thereof shall be
brought out clearly in the Schedule of Deviations (Schedule- F). Unless brought
out specifically in the schedule of Deviations, the offer shall be treated to be
conforming to the requirements of the specification in all respects.
1226 of 2461
PAGE 10 of 358
MMRDA
Technical Specifications for Bay Controllers
Tech. Specifications for BCU based Control & Protection Scheme
Control and Protection System for 132kV substations
1.0
Bay Controller Concept :
1.1
In the bay controller concept, conventional control and relay panels are not
envisaged. Instead, bay level IEDs for bay control functions and bay protection
functions are to be supplied and installed along with the SCADA/ substation
automation system. Conventional control panels are not envisaged. All the
controls, indications, alarms, metering etc are required to be made possible
through/available in the SCADA system. It is therefore envisaged to provide
Bay controller IED/bay control unit (BCU), in place of the conventional control
panel. Thus Bay protection unit (BPU) & Bay control unit with discrete
multifunction meters shall be offered. For substation where the highest system
voltage is 400 kV or above these cubicles/units are to be installed in small
kiosks (mini control rooms) in the switchyard. The switchyard wise size of mini
control room (in the S/Y) shall be as follows :
i)
In case of substations where highest system Voltage is upto 220kV,

dedicated mini control rooms (Bay Control Rooms) in the switchyard are
not envisaged. For Substations upto 220kV level, C&R panels are to
be installed in the Main Control Room itself.
1.2
Since all the cables for CT/(CVT/PT)/CB/aux. supply circuits will be connected
to the bay level cubicle i.e. Bay protection and bay control unit, only optical fiber
cable shall be laid between the various bay level IEDs/relays/meters and the
SCADA in the main control room.
1.3
Dedicated Bay Control Units and Bay Protection Units (BPU) shall be provided
for each bay for Control and protection functionality in compliance with IEC61850 standard. The offered protection and control unit shall comply with the
logical node structure as per IEC-61850 and the trip and priority messages viz.
1227 of 2461
PAGE 11 of 358
MMRDA
interlocking data shall be on GOOSE. Combined Bay Protection and Control

Unit shall not be acceptable. The required Control functions in BCU and
Protection functions in BPU shall be as per the details given in this specification.
1.4
For the substation where the highest system voltage is 220 kV or below, Bay
controller concept with centralized architecture is envisaged. For 220 kV or
below, Bay controller and Bay protection IEDs duly mounted on suitable
panel shall be installed in the main control room itself & it is not intended
to construct mini (bay) control room (kiosk) in the switchyard for installing
bay controller cum bay protection panel.
2.0
Bay Control Units (BCU)
One Bay Control Unit shall provide complete functionality for one bay. Each set
of BCUs shall have sufficient digital inputs to acquire the status of each and
every circuit breaker, isolator, earth switch, non-communicable supervisory
relay etc. of that bay. Similarly the digital output shall be sufficient to control all
the switchgears and also for functions like resetting of relays etc. in one bay.
3.0
Bay Protection Unit (BPU)
Each Bay Protection Unit shall comprise one or more numerical relays to meet
the protection requirements specified for each type of feeder.
Bay Protection Units of various bays shall interact with BCUs over inter bay
Network Bus to share information related to Bay Level Interlocking, fault data,
alarms/events etc. However, the trip commands from Bay Protection Units shall
be hard-wired directly (through suitable trip relay) to appropriate switchyard
equipment. Also, critical interlocking data between Bay Protection Units and
Bay Control Units, including the substation level interlocks such as bus earth
switch; bus bar protection trip etc. shall also be hard-wired to ensure complete
bay level functionality even in case of failure of substation LAN. The interlocking
information to be hard-wired between Bay Protection Units and Bay Control
Units shall be decided by Owner during detailed engineering stage.
1228 of 2461
PAGE 12 of 358
MMRDA
Contact Multiplication Relays (CMR) shall be provided for all isolators in

respective Bay Control and Protection Panels. CMRs shall have provision for
Manual operation in case of non-operation of auxiliary contacts of field
equipments.
4.0
Protective Relays:
4.1
All the protective relays shall be fully programmable digital (numerical) with
Protection elements realized using software algorithm. Hardware based/Analog
measurement shall not be acceptable.
4.2
The relay should have high immunity to electrical and electromagnetic

interference. It should be compatible with all the relevant IS/IEC standards.
4.3
All the protective relays shall be subjected to tests listed at 6.10 to establish
compliance with IEC 61850 for EHV substation equipment installed in sheltered
area in the outdoor switchyard and specified ambient conditions.
4.4
The offered relay shall have a comprehensive local MMI for interface. It shall
have the following minimum elements so that the features of the relay can be
accessed and setting changes can be done locally.
4.5
Alphanumeric backlit LCD display unit Fixed LEDs for indication of trip, relay
available and relay out of service. Keypad for browsing, setting the relay
parameters The relays should have at least two communication ports viz. Front
Ethernet RJ45 port for local communication for relay settings, modifications,
extraction and analysis of fault/event/disturbance records by means of a laptop
and a Rear fiber optic port on IEC61850 standard for remote communication to
SCADA system.
4.6
The relays shall have the following tools for fault diagnostics
4.7
Fault record The relay shall have the facility to store fault records with
information on cause of trip, date, time, trip values of electrical parameters.
1229 of 2461
PAGE 13 of 358
4.8
MMRDA
Event record The relay shall have the facility to store time stamped event
records with 1 ms resolution. Disturbance records At least 10 sec of
disturbance records shall be provided in the offered Numerical relays. Each
record shall store data from 8 analogue channels and 32 digital channels. The
data from DR function shall be available in IEEE/COMTRADE format and shall
be compatible with the relay test kit being supplied under this contract.
4.9
It shall be possible to store this information in the event of an auxiliary supply

failure with the help of a battery back up.
4.10
The relay settings shall be provided with password protection.
4.11
It shall be possible to change the relay setting from the front panel using the
keypads.
4.12
The relay shall have comprehensive self-diagnostic feature. This feature shall
continuously monitor the healthiness of all the hardware and software elements
of the relay. Any failure detected shall be annunciated through a output
watchdog contact. The fault diagnosis information shall be displayed on the
LCD and also through the communication port.
4.13
The Numerical Relays shall be provided with 1 set of common support Windows
based software, which will allow easy settings of relays in addition to
downloading of event, fault, disturbance records, and measurements. The relay
settings shall also be changeable from local or remote using the same software.
4.14
Trip contact of the protective relay shall not be directly connected for energizing
CB trip coil. Suitable fast operating type trip relay with adequate numbers of
output contact shall be used between the numerical relays and CB trip coils.
Hand operated relays wherever the applicable shall be electrically reset able
type. Push button required for this shall be included in the scope.
5.
LINE DIFFERENTIAL PROTECTION
This protection shall:

1230 of 2461
PAGE 14 of 358
[I]
MMRDA
FOR SHORT LINES
i)
Shall be of numerical type, working on the current differential principle

and suitable for Single/Multimode Fiber.
ii)
Be fast operating type
iii)
Be suitable for two terminal EHV lines.
iv)
Have provision to supervise the pilots continuously.
v)
Be capable of operating correctly for all types of internal faults.
vi)
Remain immune to power swings and external faults.
vii)
Have pilot supervision scheme which will energies appropriate alarm

under the following conditions:
a)
Pilots are opened.
b)
Pilots are shorted.
c)
Pilots are cross connected.
viii)
Have minimum 5 KV insulation between pilots and other circuits.
ix)
Have the required number of output contacts to meet the scheme

requirement (through contact multiplication relay, if required)
x)
Include one electrically reset trip relay with 10 N/O plus 2 N/C contacts
for tripping the circuit breaker and for various inter-locks.
[II]
132 KV FEEDER PROTECTION :
(A)
MAIN PROTECTION : This protection shall :
i)
Be similar to the distance protection scheme specified for 220KV feeders

under I.A except that the tripping design to be adopted will be 3 phase.
(B)
AUTO RECLOSE SCHEME :
This shall be similar to that for 220 KV feeders, specified under I (B) except for
the following changes:
i)
The relay shall be suitable for only three phase reclosure.
ii)
The selector switch shall be a 2-position switch to select A.R IN /
1231 of 2461
PAGE 15 of 358
MMRDA
A.R.OUT.
(C)
BACK-UP PROTECTION :
This shall be similar to I(C) specified for 220 KV feeders.
(D)
STUCK-BREAKER PROTECTION :
The LBB protection shall be similar to that specified for 220kv lines under I (D).
(E)
LINE DIFFERENTIAL PROTECTION (FOR SHORT LINES) :
This protection shall be similar to that for 220 KV feeders, specified under I (E).
[III]
220KV/132KV/110KV/100KV TRANSFORMER PROTECTION:
(A)
DIFFERENTIAL PROTECTION: This relay shall:
i)
Be a percentage biased differential current relay with high set trip
feature.
ii)
Be fully programmable numerical relay having built-in facility for CT ratio

and phase angle correction/selection.
iii)
Have operating time not more than 60 ms inclusive of trip relay operating
time during all types of faults within the protected zone.
iv)
Be a 2-input relay to protect three phase two winding or auto transformer

and 3 input relay to protect three phase three-winding T/F.
v)
Be immune to magnetizing in-rush currents, but shall operate correctly

in the event of an internal fault during in-rush condition.
vi)
Be a triple pole relay capable of detecting all types of faults within the
protected zone.
vii)
Have an adjustable bias setting.
viii)
Have adequate output contacts (with aux. relays if necessary) to meet

the scheme requirement.
(B)
RESTRICTED EARTHFAULT PROTECTION: This protection shall:
1232 of 2461
PAGE 16 of 358
MMRDA
i)
Be a single pole, circulating current differential relay.
ii)
Be connected between the HV bushing CTs and HV neutral CT in the

case of 2/3 winding transformers and across the HV bushing CTS, LV
bushing CTs and neutral CTs in the case of an auto-transformer (ICTs)
iii)
Be high speed type.
iv)
Be tuned to power frequency only, and shall be immune to harmonics.
v)
Have adequate number of output contacts (with aux. relays if necessary)

to meet the scheme requirements.
(C)
BACK-UP PROTECTION HV SIDE/LV SIDE : This protection shall
i)
Be similar to the back-up protection specified under I.C. for 220KV

feeders.
(D)
STUCK-BREAKER PROTECTION :
This shall be similar to that specified for 220 KV lines under I.D. and shall be
provided for both HV and LV breakers.
(E)
OVERLOAD PROTECTION :
The overload protection relay to be connected to CTs on LV1 and LV2 of 3Wdg. T/f shall :
i)
Be definite time over current relays
ii)
Have variable setting range 50%-200% of the rated current.
iii)
Have variable time setting range of 2.5 seconds to 25 seconds.
iv)
Have minimum 3 N/O + 1 N/C contacts (through external Aux. relay) for
trip/alarm duties.
[IV]
BUSBAR PROTECTION :
The bus-bar protection scheme shall be similar to that specified under 4.4
[V]
BACK-UP PROTECTION FOR 220KV/132KV TRANSFER BUS-COUPLER /
1233 of 2461
PAGE 17 of 358
MMRDA
BUS SECTIONALIZER / MAIN BUS COUPLER:

This relay shall be similar to that specified under [I] C for 220KV feeders.
[VI]
UNDER FREQUENCY PROTECTION :
The relay meant for Under Frequency protection shall be an Under Frequency
cum Frequency Trend relay. The relay shall:
1.
Be of microprocessor based design and shall be suitable for operation

on 50Hz power system.
2.
Be fully programmable and communicable type numerical relay having

built-in disturbance recorder and events recorder.
3.
Be suitable for graded load shedding of the power system.
4.
Have 4 independently adjustable tripping stages out of which two stages

shall have rate of change of frequency (df/dt) function and the remaining
two shall have under frequency function.
5.
Have accuracy of the order of +/- 0.03 Hz at 50 Hz.
6.
Have wide setting range, say from 45Hz to 55Hz for under / over
frequency operation.
7.
Have facility for setting the pick-up values in steps of 0.1 Hz for under /
over frequency detection.
8.
Shall have wide setting range 0.2 Hz/sec. to 9.0 Hz/sec. For rate of
change of frequency (df/dt) operation at least in the range of 0.2 Hz/sec.
To 1.0 Hz/sec.
9.
Remain unaffected by voltage fluctuations.
10.
Remain insensitive to harmonics and transients in the system.
11.
Be suitable for operation with 110V, 50Hz, AC supply (Un) from bus
connected PTs and have operating range from 0.6 Un to 1.2 Un.
12.
Have timer setting range 0.1 to 5 sec. In steps of 0.1 sec. For the under
frequency units.
13.
Have a suitable tripping delay for accurate sensing in case of rate of

change of frequency (df/dt) operation.
14.
Be suitable for 110V / 220V DC auxiliary supply from station battery.
Note : 4 nos. of fast operating, electrical reset type trip relays, one per stage,
with 3N/O + 1N/C contacts shall be supplied along with each relay / scheme.
1234 of 2461
PAGE 18 of 358
MMRDA
6.0
SUBSTATION AUTOMATION SYSTEM
6.1
GENERAL
6.1.1 The Substation Automation System (SAS) shall be designed & installed so as
to control and monitor all the substation equipments from each bay control unit
as well as from the main control room (SCADA).
The SAS shall comprise of the following main functional parts:

o
IEC 61850 standard compliant.
Bay control Intelligence Electronic Devices (IEDs) for control and
monitoring.
o
Redundant Station human machine interface (HMI)on hot standby
mode.
o
Managed switched Ethernet switches (complying with IEC 61859

standard requirements) for each bay/marshalling cubicle complying with
IEC-61850 standard requirements.
Peripheral equipment like printers, display units, key boards, Mouse etc.
The S/S Automation System(SAS) for the s/s including work stations, mimic
display, control room furniture and all other equipments required for the SAS
for the s/s shall be as defined in this specification.
6.1.2 It shall enable local station control via a PC by means of human machine
interface (HMI) and control software package, which shall contain an extensive
range of supervisory control and data acquisition (SCADA) function.
6.1.3 It shall include intelligent electronic devices (IED) for bay control and inter IED
communication infrastructure. An architecture drawing for SAS shall be
furnished by the bidder along with the offer.
6.1.4 The bay level intelligent electronic devices (IED) for protection and control shall
provide direct connection to the switchgear without the need of interposing
components and perform control, protection, and monitoring functions. Further,
1235 of 2461
PAGE 19 of 358
MMRDA
the protection and control IEDs shall be connected to the Ethernet switches
independently and both shall support horizontal communication (goose
messages).
6.2
General System design
6.2.1 The Substation Automation System (SAS) shall be suitable for operation and
monitoring of the complete substation including future extensions, if any.
6.2.2 The system shall be of state-of-the art design suitable for operation under
electrical environment present in Extra high voltage substations, follow the
latest engineering practice, ensue long-term compatibility requirements and
continuity of equipment supply and the safety of the operating staff.
6.2.3 The offered SAS shall have facility to support remote control and monitoring
from Remote Control Centers via gateways, if required in future.
6.2.4 The system shall be designed such that personnel without any background
knowledge in microprocessor based technology are able to operate the system.
The operator interface shall be intuitive such that operating personnel shall be
able to operate the system easily after having received some basic training.
6.2.5 The system shall incorporate the control, monitoring and protection functions
specified, self- monitoring, signaling and testing facilities, measuring as well as
memory functions, event recording and evaluation of disturbance records.
6.2.6 Maintenance, modification or extension of components shall not cause a

shutdown of the whole substation automation system. Self-monitoring of
components, modules and communication shall be incorporated to increase the
availability and the reliability of the equipment and minimize maintenance.
6.2.7 Bidder shall offer the Bay level unit (a bay comprises of one circuit breaker and
associated Disconnector, earth switches and instrument transformer), bay
mimic along with relay and protection panels (described in other sections of
technical specifications) housed in air-conditioned room suitably located in
1236 of 2461
PAGE 20 of 358
MMRDA
switchyard, and Station HMI in Control Room building for overall optimization
in respect of cabling and control room building. For substations upto 220kV
level, Bay Control & Protection Panels are to be housed in the Main Control
Room itself.
6.3
System architecture
The SAS shall be based on a decentralized architecture and on a concept of

bay-oriented, distributed intelligence.
Functions shall be decentralised, object-oriented and located as close as

possible to the process.
The main process information of the station shall be stored in distributed

databases. The typical SAS architecture shall be structured in two levels i.e.
station and bay level.
At bay level, the IEDs shall provide all bay level functions regarding control,
monitoring and protection, inputs for status indication and outputs for
commands. The IEDs should be directly connected to the switchgear without
any need for additional interposition of transducers. However, all the commands
extending for control of switchgear shall be routed through suitable trip/ aux.
Relays.
Each bay control IED shall be independent from each other and its functioning
shall not be affected by any fault occurring in any of the other bay control units
of the station.
The data exchange between the electronic devices on bay and station level
shall take place via the communication infrastructure. This shall be realized
using fiber optic cables, thereby guaranteeing disturbance free communication.
The fiber optic cables shall be run in suitable conduit pipes. Data exchange is
to be realized using IEC 61850 standard with a external managed switched
Ethernet communication infrastructure in decentralized ring configuration.
1237 of 2461
PAGE 21 of 358
MMRDA
All the numerical IEDs must be fully IEC 61850 compliant and must have the
following features.
o
Peer-to-peer communication using GOOSE messages (IEC 61850) for

interlocking.
Inter-operatability with third party IEC 61850 compliant devices
Generate XML file for integration/engineering with vendor independent

SCADA systems.
Should be directly connected to the inter bay bus on IEC 61850 without
the use of any gateways. Connections of bay protection IEDs to the IEC
61850 bus through the bay control units is not acceptable.
The communication shall be made in 1+1 mode, excluding the links

between individual bay IEDs to switch, such that failure of one set of fiber
shall not affect the normal operation of the SAS. However, it shall be
alarmed in SAS. Each fiber optic cable shall have adequate spare fibers.
At station level, the entire station shall be controlled and supervised from the
station HMI. It shall also be possible to control and monitor the bay from the
bay level equipment at all times.
Clear control priorities shall prevent operation of a single switch at the same
time from more than one of the various control levels, i.e. station HMI, bay level
or apparatus level. The priority shall always be on the lowest enabled control
level.
The station level contains the station-oriented functions, which cannot be

realized at bay level, e.g. alarm list or event list related to the entire substation
etc.
The GPS time synchronizing signal (as specified elsewhere) for the
1238 of 2461
PAGE 22 of 358
MMRDA
synchronization of the entire system shall be provided.
6.4
FUNCTIONAL REQUIREMENTS
6.4.1 Operation Philosophy:
The high-voltage apparatus within the station shall be operated from different
places:
Station HMI
Local Bay Controller IED (in the bays)
Operation shall be possible by only one operator at a time.
The operation shall depend on the conditions of other functions, such as

interlocking, synchro check etc. (see description in "Bay control functions")
6.4.2 Select-before-execute
For security reasons the command is always to be given in two stages; selection
of the object and command for operation under all mode of operation except
emergency operation. Final execution shall take place only when selection and
command are actuated.
6.4.3 Command Supervision
6.4.3.1 Bay/station interlocking and blocking
Software interlocking is to be provided to ensure that inadvertent incorrect

operation of switchgear causing damage and accidents in case of false
operation does not take place.
In addition to software interlocking hardwired interlocking are to be provided for

Bus earth switch interlocking.
1239 of 2461
PAGE 23 of 358
MMRDA
It shall be a simple layout, easy to test and simple to handle when upgrading
the station with future bays. For software interlocking the bidder shall describe
the scenario while an IED of another bay is switched off or fails.
A software interlock override function shall be provided which can be enabled

to bypass the interlocking function.
6.4.3.2 Run Time Command cancellation
Command execution timer (configurable) must be available for each control

level connection. If the control action is not completed within a specified time,
the command should get cancelled.
6.4.3.3
Self-supervision
Continuous self-supervision function with self-diagnostic feature shall be

included.
User Configuration
The monitoring, controlling and configuration of all input and output logical
signals and binary inputs and relay outputs for all built-in functions and signals
shall be possible both locally and remotely.
It shall also be possible to interconnect and derive input and output signals,
logic functions, using built-in functions, complex voltage and currents, additional
logics (AND-gates, OR gates and timers).(Multi-activation of these additional
functions should be possible).
The Functional requirement shall be divided into following levels.
a.
Bay (a bay comprises of one circuit breaker and associated

disconnected, earth switches and instrument transformer) Level
Functions
1240 of 2461
PAGE 24 of 358
b.
MMRDA
System Level Functions
6.4.4 Bay level functions
In a decentralized architecture the functionality shall be as close to the process

as possible. In this respect, the following functions can be allocated at bay level:
*Bay control functions including data collection functionality
*Bay protection functions
Separate IEDs shall be provided for bay control function and bay protection
function.
6.4.4.1
Bay control functions
6.4.4.1.1 Overview
Functions
o
Control mode selection
Select-before-execute principle
Command supervision:
Interlocking and blocking
Double command
Synchro check, voltage selection
Run Time Command cancellation
Transformer tap changer control i.e. manual control from HMI (for power
transformer bays)
Operation counters for circuit breakers
Operating pressure supervision
Display of interlocking and blocking
Breaker position indication per phase
Alarm annunciation
1241 of 2461
PAGE 25 of 358
MMRDA
Measurement display
Local HMI (local guided, emergency mode)
Interface to the station HMI
Data storage for at least 200 events
Extension possibilities with additional I/Os inside the unit or via fiberoptic communication and process bus
6.4.4.1.2 Control mode selection
Bay level Operation:
As soon as the operator receives the operation access at bay level the
operation is normally performed via bay control IED. During normal operation
bay control unit allows the safe operation of all switching devices via the bay
control IED.
6.4.4.1.3
EMERGENCY mode
Control authority in this mode is given to a higher level (Control Room) and
the installation can be controlled only remotely. Control operation from lower
levels shall not be possible in this operating mode.
6.4.4.1.4
Synchronism and energizing check
The synchronism and energizing check functions shall be bay-oriented and

distributed to the bay control and/or protection devices. These features are:
Settable voltage, phase angle, and frequency difference Energizing for dead
line live bus, live line dead bus or dead line dead bus with no synchrocheck function Synchronizing between live line and live bus with synchro
check function.
6.4.4.1.5
Voltage Selection
The voltages relevant for the Synchro check functions are dependent on the
1242 of 2461
PAGE 26 of 358
MMRDA
station topology, i.e. on the positions of the circuit breakers and/or the
isolators. The correct voltage for synchronizing and energizing shall be
selected automatically by the bay control and protection IEDs.
Raise and lower operation of OLTC taps of transformer shall be facilitated

through Bay Controller IED by using the contacts of BCU.
6.4.4.2
Bay protection function
6.4.4.2.1 General
The protection functions are independent of bay control function. The

protection shall be provided by separate protection IEDs (numerical relays)
and other protection devices indicated separately.
IEDs shall be connected to the communication infrastructure for data sharing

and shall meet the real-time communication requirements for automatic
functions. The data presentation and the configuration of the various IEDs
shall be compatible with the overall system communication and data
exchange requirements.
6.4.5 System level functions
6.4.5.1
Status supervision
The position of each switchgear e.g. circuit breaker, isolator, earthing switch,
transformer tap changer etc. shall be supervised continuously. Every detected
change of position shall be immediately displayed in the single line diagram
on the station HMI screen, recorded in the event list, and a hard copy printout
shall be produced. Alarms shall be initiated in the case of spontaneous
position changes.
The switchgear positions shall be indicated by two auxiliary switches,

normally closed (NC) and normally open (NO), which shall give ambivalent
signals. An alarm shall be initiated if these position indications are inconsistent
1243 of 2461
PAGE 27 of 358
MMRDA
or if the time required for operating mechanism to change position exceeds a

predefined limit.
The SAS shall also monitor the status of sub-station auxiliaries. The status
and control of auxiliaries shall be done through separate one or more IED and
all alarm and analogue values shall be monitored and recorded though this
IED. Necessary interfacing devices / transducers shall also be included in
order to integrate station auxiliaries with SAS.
6.4.5.2
Measurements
Analogue inputs for voltage and current measurements shall be connected

directly to the voltage transformers (VT) and the current transformer (CT)
without intermediate transducers. The values of active power (W), reactive
power (VAR), frequency (Hz), and the rms values for voltage (U) and current
(I) shall be calculated.
The measured values shall be displayed locally on the station HMI and in the
control center. The abnormal values must be discarded. The analogue values
shall be updated every 2 seconds.
Threshold limit values shall be selectable for alarm indications.
Substation Automation System (SAS) shall have provision for computation of

Monthly, Fortnightly & Daily Energy Audit. Depending upon Bus configuration,
It shall be possible for Bus-wise, Section-wise Energy Audit as well. All the
necessary reports in this regard shall be generated automatically by the
System.
6.4.5.3
Event and alarm handling
Events and alarms are generated either by the switchgear, by the control
IEDs, or by the station level they shall be recorded in an event list in the station
HMI. Alarms shall be recorded in a separate alarm list and appear on the
screen. All or a freely selectable group of events and alarms shall also be
1244 of 2461
PAGE 28 of 358
MMRDA
printed out on an event printer. The alarms and events shall be time-tagged
with a time resolution of 1 ms.
6.5
Station HMI
6.5.1 Substation HMI Operation
On the HMI the object has to be selected first. In case of blocking or if the
interlocking conditions are not met, the selection shall not be possible and an
appropriate alarm annunciation shall occur. If a selection is valid the position
indication will show the possible direction, and the appropriate control
execution button shall be pressed in order to close or open the corresponding
object.
Control operation from other places shall not be possible in this operating
mode.
6.5.1.1
Presentation and dialogues
General
The operator station HMI shall be a redundant system, with hot standby and
shall provide basic functions for supervision and control of the substation. The
operator shall give commands to the switchgear on the screen via mouse
clicks or keyboard commands.
The HMI shall give the operator access to alarms and events displayed on
the screen. Aside from these lists on the screen, there shall be a printout of
alarms or events in an event log.
An acoustic alarm shall indicate abnormalities, and all unacknowledged

alarms shall be accessible from any screen selected by the operator.
The following standard screens shall be available from the HMI.
1245 of 2461
PAGE 29 of 358
MMRDA
Single line diagram showing the switchgear status and measured values.
Control dialogues with interlocking and blocking details. This control

dialogue shall tell the operator whether the device operation is permitted
or blocked.
Measurement dialogues
Alarm list, station/bay oriented
Event list, station/bay oriented
System status
In the MIMIC diagram colour identification shall be given to different voltage

circuits. The colour should change when the circuit is disconnected from
active circuit.
6.5.2 HMI design principles
Consistent design principles shall be adopted with the HMI concerning labels,
colours, dialogues and fonts. Non-valid selections shall be dimmed out.
The object status shall be indicated using different status colours for
Selected object under command
Selected on the screen
Not updated, obsolete values, not in use or not sampled
Alarm or faulty state
Warning or blocked
Update blocked or manually updated
Control blocked
Normal state
1246 of 2461
PAGE 30 of 358
MMRDA
6.5.3 Process status displays and command procedures
The process status of the substation in terms of actual values of currents,

voltages, frequency, active and reactive powers as well as the positions of
circuit breakers, isolators and transformer tap changers shall be displayed in
the station single line diagram.
In order to ensure a high degree of security against undesired operation, a

"select-before-execute" command procedure shall be provided. After the
"selection" of a switch, the operator shall be able to recognize the selected
device on the screen, and all other switchgear shall be blocked. As
communication between control center and device to be controlled is
established, the operator shall be prompted to confirm the control action and
only then final execute command shall be accepted. After the "execution" of
the command the operated switching symbol shall flash until the switch has
reached its new position.
The operator shall be in a position to execute a command only, if the switch

is not blocked and if no interlocking condition is going to be violated. The
interlocking statements shall be checked by the interlocking scheme
implemented at bay and station level. After command execution, the operator
shall receive a confirmation that the new switching position has been reached
or an indication that the switching procedure was unsuccessful with the
indication of the reason for non-functioning.
6.5.4 System supervision & display
The SAS system shall be comprehensively self-monitored such that faults are
immediately indicated to the operator, possibly before they develop into
serious situations. Such faults are recorded as a faulty status in a system
supervision display. This display shall cover the status of the entire substation
including all switchgear, IEDs, communication infrastructure and remote
communication links, and printers at the station level etc.
6.5.5 Event list

1247 of 2461
PAGE 31 of 358
MMRDA
The event list shall contain events that are important for the control and
monitoring of the substation.
The event and associated time (with 1 ms resolution) of its occurrence has to
be displayed for each event.
The operator shall be able to call up the chronological event list on the monitor
at any time for the whole substation or sections of it.
The events shall be registered in a chronological event list in which the type
of event and its time of occurrence are specified. It shall be possible to store
all events in the computer for at least one month. The information shall be
obtainable also from a printed event log.
The chronological event list shall contain:
Position changes of circuit breakers, isolators and earthing devices
Indication of protective relay operations
Fault signals from the switchgear
Indication when analogue measured values exceed upper and lower

limits. Suitable provision shall be made in the system to define two level
of alarm on either side of the value or which shall be user defined for
each measured.
Loss of communication
Filters for selection of a certain type or group of events shall be available.

The filters shall be designed to enable viewing of events grouped per:
Date & time
Bay
1248 of 2461
PAGE 32 of 358
MMRDA
Device
Function e.g. trips, protection operations etc.
Alarm class
6.5.6 Alarm list
Faults and errors occurring in the substation shall be listed in an alarm list and
shall be immediately transmitted to the control center. The alarm list shall
substitute a conventional alarm tableau, and shall constitute an evaluation of
all station alarms. It shall contain unacknowledged alarms and persisting
faults.
The date and time of occurrence shall be indicated.
The alarm list shall consist of a summary display of the present alarm
situation. Each alarm shall be reported on one line that contains.
The date and time of the alarm
The name of the alarming object
A description text
The acknowledgement state
Whenever an alarm condition occurs, the alarm condition must be shown on

the alarm list and must be displayed in a flashing state along with an audible
alarm. After acknowledgement of the alarm, it should appear in a steady (i.e.
not flashing) state and the audible alarm shall stop. The alarm should
disappear only if the alarm condition has physically cleared and the operator
has reset the alarm with a reset command. The state of the alarm shall be
shown in the alarm list (Unacknowledged and persistent, Unacknowledged
and cleared, Acknowledged and persistent).
Filters for selection of a certain type or group of alarms shall be available as

1249 of 2461
PAGE 33 of 358
MMRDA
for events.
6.5.7
Object picture
When selecting an object such as a circuit breaker or isolator in the single line
diagram, the associated bay picture shall be presented first. In the selected
object picture, all attributes like
Type of blocking
Authority
Local/Remote control
SAS control
Errors
Etc.,
Shall be displayed.
6.5.8 Control dialogues
The operator shall give commands to the system by means of mouse pointing
the object pointing the object diagram. It shall also be possible to use the
keyboard for command activation. Data entry is performed with the keyboard.
Dedicated control dialogues for controlling at least the following devices shall
be available.
6.6
Breaker and Disconnector(when Disconnector is motor operated type)
Transformers tap changer.
User-authority levels
It shall be possible to restrict activation of the process pictures of each object

(bays, apparatus) within a certain user authorization group. Each user shall
then be given access rights to each group of objects e.g.:
Display only
Normal operation (e.g. open/close of switchgear)
1250 of 2461
PAGE 34 of 358
MMRDA
Restricted operation (e.g. by-passed interlocking)
System administrator
For maintenance and engineering purposes of the station HMI, the following
authorization levels shall be available:
Display only
Normal operation (e.g. open/close of switchgear)
Restricted operation (e.g. bypassed interlocking)
System administrator
For maintenance and engineering purposes of the station HMI, the following
authorization levels shall be available:
No engineering allowed
Engineering/configuration allowed
Entire system management allowed
The access rights shall be defined by passwords assigned during the login
procedure. Only the system administrator shall be able to add/remove users
and change access rights.
6.7
Reports
The reports shall provide time related follow-ups of measured and calculated
values. The data displayed shall comprise:
Trend reports:
Day (mean, peak)
Month (mean, peak)
Semi-annual (mean, peak)
Year (mean, peak)

Historical reports of selected analogue Values:
Day (at 15 minutes interval)
Week
1251 of 2461
PAGE 35 of 358
MMRDA
Month
Year
It shall be possible to select displayed values from the database in the process
display on line. Scrolling between (e.g. days) shall be possible. Unsure values
shall be indicated. It shall be possible to select the time period for which the
specific data are kept in the memory.
Following printouts shall be available from the printer and shall be printed on
demand.
i.
Daily voltage and frequency curves depicting time on X-axis and the
appropriate parameters on the Y-axis. The time duration of the curve is
24 hours.
ii.
Weekly trend curves for real and derived analogue values.
iii.
Printouts of the maximum and minimum values and frequency of

occurrence and duration of maximum and minimum values for each
analogue parameter for each circuit in 24 hr period.
iv.
Provision shall be made for logging information about breaker status like
number of operation with date and time indications.
v.
Equipment operation details shift wise and during 24 hours.
vi.
Printout of adjustable time period as well as of demand for MW, MVAR,

Current, Voltage on each feeder and transformer as well as Tap
Positions, temperature and status of pumps and fans for transformers.
vii.
Printout of adjustable time period as well as of demand system

frequency and average frequency.
Viii Substation Automation System (SAS) shall have provision for

computation of
Monthly, Fortnightly & Daily Energy Audit. Depending
1252 of 2461
PAGE 36 of 358
MMRDA
upon Bus configuration, It shall be possible for Bus-wise, Section-wise

Energy Audit as well. All the necessary reports in this regard shall be
generated automatically by the System
6.7.1 Trend display (Historical data)

It shall be possible to illustrate all types of process data as trends input and
output data, binary and analogue data. The trends shall be displayed in
graphical form as column or curve diagrams with a maximum of 10 trends per
screen. Adjustable time span and scaling ranges must be provided.
It shall be possible to change the type of value logging (direct, mean, sum or
difference) on-line in the window. It shall also be possible to change the
update intervals on line in the picture as well as the selection of threshold
values for alarm purposes.
6.7.2 Automatic disturbance file transfer
All recorded data from the IEDs with integrated disturbance recorder systems
shall be automatically uploaded (event triggered once per day) to a station
HMI database. A dedicated computer as relay engineers console (EWS) shall
be offered for analysis of records additionally.
6.7.3 Disturbance analysis
The PC based workstation shall have necessary software to evaluate all the
required information for proper fault analysis.
6.7.4 IED parameter setting
It shall be possible to access all protection and control IEDs for reading the
parameters (settings) from the station HMI or from a dedicated monitoring
computer. The setting of parameters or the activation of parameter sets shall
only be allowed after entering a password.
1253 of 2461
PAGE 37 of 358
MMRDA
Automatic sequences
The available automatic sequences in the system should be listed and

described (e.g. sequences related to the bus transfer). It must be possible to
initiate pre-defined automatic sequences by the operator and also define new
automatic sequences.
6.8
System hardware:
6.8.1 Redundant Station HMI, HMI View Node and Disturbance Recorder Work
Station:
6.8.1.1
The contractor shall provide redundant station HMI in hot standby mode.
It shall be capable to perform all functions for entire substation including future
requirements as indicated in the SLD. It shall use industrial grade
components. Processor and RAM shall be selected in such a manner that
during normal operation not more than 30% capacity of processing and
memory are used. RAM of capacity of Min. 8 GB shall be provided. Supplier
shall demonstrate these features.
The capacity of hard disk shall be selected such that the following requirement
should occupy less than 50% of disk space:
1.
Storage of all analogue data (at 15 minutes interval) and digital data
including alarm, event and trend data for thirty (30) days.
2.
Storage of all necessary software
3.
500GB space for MMRDA use.
Supplier shall demonstrate that the capacity of hard disk is sufficient to

meet the above requirement.
HMI (Human Machine Interface)

1254 of 2461
PAGE 38 of 358
MMRDA
The VDU shall show overview diagrams (Single Line Diagrams) and complete
details of the switchgear with a colour display. All event and alarm
annunciation shall be selectable in the form of lists. Operation shall be by a
user-friendly function keyboard and a cursor-positioning device. The user
interface shall be based on WINDOWS concepts with graphics and facility for
panning, scrolling, zooming, decluttering etc.
6.8.1.2
Visual Display Units with TFT (Thin Film Technology)
The contractor shall provide two display units, one for station HMI and another
one for redundant HMI. These shall have high resolution and reflection
protected picture screen. High stability of the picture geometry shall be
ensured. The screen shall be at least 21" diagonally in size and capable of
colour graphic displays.
The display shall accommodate resolution of 1280 x 1024 pixels.
The HMI shall be able to switch the keyboard and cursor-positioning device,
as unit among all the monitors at a console via push button or other controls.
6.8.1.3
Printer
It shall be robust and suitable for operation with a minimum of 132 characters
per line. The printing operation shall be quiet with a noise level of less than
45 dB suitable for location in the control room. Printer shall accept and print
all ASCII characters via master control computer unit interface.
The printer shall have in built testing facility. Failure of the printer shall be
indicated in the Station HMI. The printer shall have an off line mode selector
switch to enable safe maintenance. The maintenance should be simple with
provisions for ease of change of print head, ribbon changing, paper insertion
etc.
All printers mounted in the control room shall be provided with a separate
printer enclosure each. The enclosure shall be designed to permit full
1255 of 2461
PAGE 39 of 358
MMRDA
enclosure of the printers at a convenient level. Plexiglas windows shall be

used to provide visual inspection of the printers and ease of reading. The
printer enclosures shall be designed to protect the printers from accident
external contact and each should be removable from hinges at the back and
shall be provided with lock at the front.
All reports and graphics prints shall be printed on A3 size colour laser printer.
One dot matrix printer shall be exclusively used for hourly log printing.
All printers shall be continuously online.
6.8.1.4
Mass Storage Unit
The mass storage unit shall be built-in to the Station HMI. All operational
measured values, and indications shall be stored in a mass storage unit of
CD-ROM/DVD-ROM with 700 MB or more capacity. The unit should support
at least Read (48X), Write (24X) and Re-write (10X) operations, with MultiSession capability. It should support formatting and use under the operating
system provided for Station HMI. The monthly back up of data shall be taken
on disc. The facility of back up of data shall be inherent in the software.
Switched Ethernet Communication Infrastructure:
The bidder shall provide the redundant switched optical Ethernet

communication infrastructure for SAS. The bidder shall keep provision of
100% spare capacity for employer use. The Ethernet switch, compliant with
IEC-61850 standard, shall have dual power supply and of managed type. One
switch shall be provided to connect all IEDs in one diameter of the 400kV yard
and for two bays of 220kV yard to communication infrastructure.
6.8.2 Bay level unit
The bay unit shall use industrial grade components. The bay level unit, based
on microprocessor technology, shall use numerical techniques for the
calculation and evaluation of externally input analogue signals. They shall
1256 of 2461
PAGE 40 of 358
MMRDA
incorporate select-before-operate control principles as safety measures for

operation via the HMI. They shall perform all bay related functions, such as
control commands, bay interlocking, data acquisition, data storage, event
recording and shall provide inputs for status indication and outputs for
commands. They shall be directly connected to the switchgear. The bay unit
shall acquire and process all data for the bay (Equipment status, fault
indications, measured values, alarms etc.) and transmit these to the other
devices in substation automation system. In addition, this shall receive the
operation commands from station HMI. The bay unit shall have the capability
to store all the data for at least 24 hours.
One number Bay level unit shall be provided for supervision and control of
bay (a bay comprises of one circuit breaker and associated disconnector,
earth switches and instrument transformer). The bay level unit shall be
equipped with analogue and binary inputs/outputs for handling the control,
status monitoring and analogue measurement functions. All bay level
interlocks are to be incorporated in the Bay level unit so as to permit control
from the Bay level unit/local bay mimic panel, with all bay interlocks in place,
during maintenance and commissioning or in case of contingencies when the
station HMI is out of service.
The Bay level unit shall meet the requirements for withstanding
electromagnetic interference according to relevant parts of IEC 61850. Failure
of any single component within the equipment shall neither cause unwanted
operation nor lead to a complete system breakdown.
6.8.2.1
Input/Output (I/O) modules
The I/O modules shall form a part of the bay level unit and shall provide
coupling to the substation equipment. The I/O modules shall acquire all
switchgear information (i.e. data coming directly from the switchgear or from
switchgear interlocking devices) and transmit commands for operation of the
switchgear. The measured values of voltage and current shall be from the
secondaries of instrument transformers. The digital inputs shall be acquired
by exception with 1 ms resolution. Contact bouncing in digital inputs shall not
1257 of 2461
PAGE 41 of 358
MMRDA
be assumed as change of state.
6.8.2.2
Air-conditioned Room
In case of 400kV substation, air-conditioned Bay Control Room for

accommodating bay controllers, protection panels etc. for each diameter shall
be provided. The room dimensions shall be as stated above.
6.8.3 Extensibility in future
Offered substation automation system shall be suitable for extension in future

for additional bays. During such requirement, all the drawings and
configurations, alarm/event list etc. displayed shall be designed in such a
manner that its extension shall be easily performed by the employer. During
such event, normal operation of the existing substation shall be unaffected
and system shall not require a shutdown. The contractor shall provide all
necessary software tools along with source codes to perform addition of bays
in future and complete integration with SAS by the user. These software tools
shall be able to configure IED, add additional analogue variable alarm list,
event list, modify interlocking logics etc. for additional bays/equipment, which
shall be added in future.
6.9
Software structure
The software package shall be structured according to the SAS architecture

and strictly divided in various levels. Necessary firewall shall be provided at
suitable points in software to protect the system. An extension of the station
shall be possible with lowest possible efforts. Maintenance, modification or an
extension of components of any feeder may not force a shut down of the parts
of the system, which are not affected by the system adaptation.
6.9.1 Station level software
6.9.1.1
Human-machine interface (HMI)
1258 of 2461
PAGE 42 of 358
MMRDA
The base HMI software package for the operator station shall include the main
SAS functions and it shall be independent of project specific hardware version
and operating system. It shall further include tools for picture editing,
engineering and system configuration. The system shall be easy to use, to
maintain, and to adopt according to specific user requirements. Systems shall
contain a library with standard functions and applications.
6.9.2 Bay level software
6.9.2.1
System software
The system software shall be structured in various levels. This software shall
be placed in a non-volatile memory. The lowest level shall assure system
performance and contain basic functions, which shall not be accessible by the
application and maintenance engineer for modifications. The system shall
support the generation of typical control macros and a process database for
user specific data storage. In case of restoration of links after failure, the
software along with hardware shall be capable of automatically synchronizing
with the remaining system without any manual interface. This shall be
demonstrated by contractor during integrated system test.
6.9.3 Application software
In order to ensure robust quality and reliable software functions, the main part
of the application software shall consist of standard software modules built as
functional block elements. The functional blocks shall be documented and
thoroughly tested. They form part of library. The application software within
the control/protection devices shall be programmed in a functional block
language.
6.9.4 Network Management System
The contractor shall provide a Network Management System (NMS)

software for following management functions.
1259 of 2461
PAGE 43 of 358
a.
Configuration Management
b.
Fault Management
c.
Performance Monitoring
MMRDA
This system shall be used for management of communication devices and

other IEDs in the system. This NMS can be loaded in DR workstation and
shall be easy to use, user friendly and menu based. The NMS shall monitor
all the devices in the SAS and report if there is any fault in the monitored
devices. The NMS shall
a)
Maintain performance, resource usage, and error statistics for all
managed links and devices and present this information via displays,
periodic reports and on demand reports
b)
Maintain a graphical display of SAS connectivity and device status
c)
Issue alarms when error conditions occur.
d)
Provide facility to add and delete addresses and link
The contractor shall provide each software in two copies in DVD to load into
the system in case of any problem related with Hardware/Communication etc.
6.10
TESTS
The substation automation system offered by the bidder shall be subjected to

following tests to establish compliance with IEC 61850 for EHV substation
equipment installed in sheltered area in the outdoor switchyard and specified
ambient conditions.
6.10.1 Type Tests:
Type tests shall be carried out as per relevant IS/IEC standard.
6.10.1.1 Control IEDs and Communication Equipment: shall be subjected to the

1260 of 2461
PAGE 44 of 358
MMRDA
following type tests
a.
Power Input (burden)
i) Auxiliary Voltage
ii) Current Circuits
iii) Voltage Circuits
iv) Indications
b.
Accuracy Tests
i) Operational Measured Values

ii) Currents
iii) Voltages
iv) Time resolution
c.
Insulation Tests:
i) Dielectric Tests
ii) Impulse Voltage withstand Test
d.
Influencing Quantities
i) Limits of operation
ii) Permissible ripples
iii) Interruption of input voltage
e)
Electromagnetic Compatibility Test

i) 1 MHZ, burst disturbance test
ii) Electrostatic Discharge Test
iii) Radiated Electromagnetic Field Disturbance Test
iv) Electrical Fast transient Disturbance Test
v) Conducted Disturbances Tests induced by Radio Frequency Field
vi) Magnetic Field Test
vii) Emission (Radio Interference level) Test
viii) Conducted Interference Test
1261 of 2461
PAGE 45 of 358
f)
MMRDA
Function Tests
i) Indication
ii) Commands
iii) Measured Value Acquisition
iv) Display Indications
g)
Environmental Tests
i) Cold Temperature
ii) Dry Heat
iii) Wet heat
iv) Humidity (Damp heat Cycle)
v) Vibration
vi) Bump
vii) Shock
6.10.2 Factory Acceptance Tests:
The supplier shall submit a test specification for factory acceptance test (FAT)
and commissioning tests of the station automation system for approval. For
the individual bay level IEDs, applicable type test certificates shall be
submitted.
The manufacturing phase of the SAS shall be concluded by the factory

acceptance test (FAT). The purpose is to ensure that the Contractor has
interpreted the specified requirements correctly and that the FAT includes
checking to the degree required by the user. The general philosophy shall be
to deliver a system to site only after it has been thoroughly tested and its
specified performance has been verified, as far as site conditions can be
simulated in a test lab. If the FAT comprises only a certain portion of the
system for practical reason, it has to be assured that this test configuration
contains at least one unit of each and every type of equipment incorporated
in the delivery system.
If the complete system consists of parts from various suppliers or some parts
1262 of 2461
PAGE 46 of 358
MMRDA
are already installed on site, the FAT shall be limited to sub system tests. In
such a case, the complete system test shall be performed on site together
with the site acceptance test (SAT).
6.10.3 Integrated Testing:
The integrated system tests shall be performed as detailed in subsequent

clauses as per following configuration:
12.2
Redundant station HMI, DR works station, two switches (i.e. for two
diameters) along with all IEDs for the printers.
All other switches for complete substation as detailed in section

project shall be simulated as needed.
6.10.3.1
Hardware Integration Tests:
The hardware integration test shall be performed on the specified systems to

be used for Factory tests when the hardware has been installed in the factory.
The operation of each item shall be verified as an integral part of system.
Applicable hardware diagnostics shall be used to verify that each hardware
component is completely operational and assembled into a configuration
capable of supporting software integration and factory testing of the system.
The equipment expansion capability shall also be verified during the hardware
integration tests.
6.10.3.2
Integrated System Tests:
Integrated system tests shall verify the stability of the hardware and the
software. During the tests all functions shall run concurrently and all
equipment shall operate a continuous 100 Hours period. The integrated
system test shall ensure the SAS is free of improper interactions between
software and hardware while the system is operating as a whole.
6.10.4 Field Tests:

1263 of 2461
PAGE 47 of 358
MMRDA
The field tests shall completely verify all the features of SAS hardware and
software.
6.11
SYSTEM OPERATION
6.11.1 Substation Operation
6.11.1.1
NORMAL OPERATION
Operation of the system by the operator from the Control Room shall take
place via industry standard HMI (Human Machine Interface) subsystem
consisting of graphic colour VDU, a standard keyboard and a cursorpositioning device (mouse).
The colour screen shall be divided into 3 fields:
i)
Message field with display of present time and date
ii)
Display field for single line diagrams
ii)
Navigation bar with alarm/condition indication
For display of alarm annunciation, lists of events etc. a separate HMI View
note, shall be provided.
All operations shall be performed with mouse and/or a minimum number of

function keys and cursor keys. The function keys shall have different
meanings depending on the operation. The operator shall see the relevant
meanings as function tests displayed in the command field (i.e. operator
prompting). For control actions, the switchgear (i.e. circuit breaker etc.)
requested shall be selectable on the display by means of the cursor keys. The
switching element selected shall then appear on the background that shall be
flashing in a different colour. The operator prompting shall distinguish
between:
Prompting of indications e.g. fault indications in the switchgear and
1264 of 2461
PAGE 48 of 358
MMRDA
Prompting of operational sequence e.g. execution of switching
operations
The summary information displayed in the message field shall give a rapid
display of alarm/message of the system in which a fault has occurred and
alarm annunciation lists in which the fault is described more fully.
Each operational sequence shall be divided into single operation steps, which
are initiated by means of the function keys/WINDOW command by mouse.
Operator prompting shall be designed in such a manner that only the
permissible keys are available in the command field related to the specific
operation step. Only those switching elements shall be accessed for which
control actions are possible. If the operation step is rejected by the system,
the operator prompting shall be supported by additional comments in the
message field. The operation status shall be reset to the corresponding
preceding step in the operation sequence by pressing one of the function
keys. All operations shall be verified. Incorrect operations shall be indicated
by comments in the message field and must not be executed.
The offer shall include a comprehensive description of the system. The above
operation shall also be possible via WINDOWS based system by mouse.
6.12
POWER SUPPLY
Power for the substation automation system shall be derived from station
auxiliary supply. In case of failure of station auxiliary supply, substation DC
system (220 volt) shall feed the SAS.
Inverter of suitable capacity shall be provided for station HMI and its
peripheral devices e.g. printer etc. In the event of Power failure, necessary
safeguard software shall be built for proper shutdown and restart.
6.13
Maintenance
1265 of 2461
PAGE 49 of 358
MMRDA
6.13.1 Maintenance Responsibility during the Guaranteed Availability Period
During Guaranteed Availability Period, the Contractor shall take continual

actions to ensure the guaranteed availability and shall make available all the
necessary resources such as specialist personnel, spare parts, tools, test
devices etc. for replacement or repair of all defective parts and shall have
prime responsibility for keeping the system operational.
6.14
RELIABILITY AND AVAILABILITY
The SAS shall be designed so that the failure of any single component,
processor, or device shall not render the system unavailable. The SAS shall
be designed to satisfy the very high demands for reliability and availability
concerning:
Mechanical and electrical design
Security against electrical interface (EMI)
High quality components and boards
Modular, well-tested hardware
Thoroughly developed and tested modular software
Easy-to understand programming language for application programming
Detailed graphical documentation and application software
Built-in supervision and diagnostic functions
After Sales Service
Security
- Experience of security requirements

- Process know-how
- Select before execute at operation
- Process status representation as double indications
Distributed solution
Independent units connected to the local area network
Back-up functions
Panel design appropriate to the harsh electrical environment and
ambient
conditions
Panel grounding immune against transient ground potential rise
1266 of 2461
PAGE 50 of 358
6.15
MMRDA
Outage terms
(a) Outage
The state in which substation automation system or a unit of SAS is

unavailable for Normal Operation as defined in the clause 6.11.1 due to
an event directly related to the SAS or unit of SAS. In the event, the owner
has taken any equipment/system other than substation Automation
System for schedule/-forced maintenance, the consequent outage to SAS
shall not be considered as outage for the purpose of availability.
(b) Actual outage duration (AOD)
The time elapsed in hours between the start and the end of an outage.
The
time shall be counted to the nearest 1/4th of an hour. Time less
than 1/4th of
an hour shall be counted as having duration of 1/4th of an
hour.
(c) Period Hours (PH)
The number of hours in the reporting period. In a full year the period hour
are 8760 h (8784 h for a leap year).
(d) Actual Outage hours (AOH)
The sum of actual outage duration within the reporting period AOH = "
AOD
(e) Availability
Each SAS shall have a total availability of 99.98% or better i.e. the ratio
of
6.16
total time duration minus the actual outage duration to total time duration.
Guarantees Required
1267 of 2461
PAGE 51 of 358
MMRDA
The availability for the complete SAS shall be guaranteed by the Contractor.
The contractor shall demonstrate the availability guaranteed by conducting
the availability test on the total substation automation system as a whole after
commissioning of total substation automation system. The test shall verify the
reliability and integrity of all sub-systems. Under these conditions the test shall
establish an overall availability of 99.98%. After the lapse of 1000 Hours of
cumulative test time, test records shall be examined to determine the
conformance with availability criterion. In case of any outage during the
availability test, the contractor shall rectify the problem and after rectification,
the 1000 hours period start after such rectification. If test object has not been
met the test shall continue until the specified availability is achieved.
The contractor has to establish the availability in a maximum period of three

months from the date of commencement of the availability test.
After the satisfactory conclusion of test both contractor and employer shall
mutually agree to the test results and if these results satisfy the availability
criterion, the test is considered to be completed successfully. After that the
system shall be taken over by the employer and then the guarantee period
shall start.
6.17
Spares
6.17.1 Consumables:
All consumables such as paper, cartridges shall be supplied by the contractor

till the SAS is taken over by the owner.
6.17.2 Availability Spares:
The bidder is required to list the spares, which may be required for ensuring
the guaranteed availability during the guaranteed availability period. The final
list of spares shall form part of scope of supply and accordingly the price
thereon shall be quoted by the bidder and shall be considered in the
1268 of 2461
PAGE 52 of 358
MMRDA
evaluation of the bids. During the guaranteed availability period, the spare
parts supplied by the Contractor shall be made available to the Contractor for
usage subject to replenishment at the earliest. Thus, at the end of availability
period the inventory of spares with the Employer shall be fully replenished by
the Contractor. However, any additional spares required to meet the
availability of the system (which are not a part of the above spares supplied
by the Contractor) would have to be supplied immediately by the Contractor
free of cost to the Employer.
6.18
LIST OF EQUIPMENTS
Quantity of equipments shall be decided by bidder in order to achieve

guaranteed reliability and availability as declared by bidder.
i)
Station HMI
ii)
Redundant Station HMI (in Hot-stand by mode)
iii)
Bay level units with bay mimic
iv)
Disturbance Recorder Work Station (Maintenance HMI)
v)
A3 size Colour Laser Printer 1 No. (For Reports & Disturbance records)
vi)
Dot matrix printers (one each for Alarms and log sheets)
vii) Communication infrastructures between Bay level units, Station HMI,

printers, redundant LAN etc. as required.
viii) Any other equipment as necessary.
Viii) Gateways (Main & Standby) for remote communication with SLDC over
IEC-60870 101 and 104.
8.
DC DISTRIBUTION & DC SUPERVISION:
8.1
The Sub Station having highest System voltage of 245 KV / 145 KV & below
shall be of 220 V, 2 wire ungrounded DC supply respectively.
b)
The Sub Station having highest System voltage of 420 KV shall have
two
separate 220 V, 2 wire ungrounded DC supply (i. e. source I &
source II)
shall be provided.
1269 of 2461
PAGE 53 of 358
8.2
MMRDA
DC distribution for the protection panels shall be such that separate subcircuits with suitable MCBs & DC Supervision relays are provided for each of
the following.
8.3
i)
Isolator/Earth switch control/interlock.
ii)
Indication/annunciation.
iii)
Breaker/Isolator auxiliary contact multiplication.
iv)
Metering (48 VCD).
v)
DC supervision (48 VCD).
vi)
Circuit breaker closing/tripping.
vii)
Main I protection.
viii)
Main II protection.
ix)
Back up/LBB protection.
Two trip coils of each main & tie/TBC circuit breaker shall be energized
through trip contact of 400 kV protections by using two separate
D.C.
sources (source I and source II)
8.4
DC Supervision shall be provided to continuously supervise the DC supply for

all the above circuits. For 400kV system, DC monitoring of the two sources
can be achieved through criss-cross method. However in case of
conventional C&R panels housed in the control room, the scheme shall be
suitable to be monitored on 48 VDC supply from the station PLCC battery.
The DC Supervision Scheme shall have provision for alarm in the SAS
8.5
Auxiliary relays used in various panels for the DC supervision scheme shall
have adequate number of elements with suitable self reset type operation
indicators wherever applicable. If required, two elements of these relays shall
be of 48 V DC rating and the remaining shall be of 220 V D.C.
9.0
9.1
SUPERVISION RELAYS FOR CIRCUIT BREAKER
Auxiliary relays of appropriate rating shall be provided for monitoring the

following problems in EHV circuit breakers.
1270 of 2461
PAGE 54 of 358
MMRDA
i)
Loss of SF6 - alarm condition
ii)
Loss of Oil/air - alarm condition
iii)
Loss of N2 (Nitrogen)-alarm condition
iv)
SF6 low- lockout condition
v)
Oil/air low - lockout condition
vi)
N2 (Nitrogen) low-lockout condition
9.2
The auxiliary relays for all the above functions shall be self resetting
type,
(having hand-reset operation indicators flags). Each element shall have

minimum 3 pairs of N/O contacts to cater to the following functions:
10.0
10.1
i)
For Data Acquisition System (DAS)
ii)
For SCADA/DR
VT SELECTION SCHEME
In the case of sub-stations having two main bus arrangements there will be
two sets of bus PTs, each set connected to one main bus.
It is, therefore, necessary to provide suitable VT selection scheme through

which the PT circuits of each line/transformer panel will be connected to the
appropriate PT secondary, depending on whether the line/transformer circuit
is connected to Main bus I or Main bus II.
10.2
The VT selection shall be automatic and shall be initiated by the operation of

the bus I/ bus II isolator of the concerned feeder/transformer bay.
10.3
The VT selection relays shall have adequate number of contacts to

changeover all the VT secondary sub-circuits simultaneously. These relays
shall be rated for 220V DC supply from the station battery.
10.4
V.T. selection scheme shall have provision to announce the VT selection

failure" through suitable annunciation.
11.0
BUS CONFIGURATION & BUS TRANSFER SCHEME
1271 of 2461
PAGE 55 of 358
MMRDA
1) Bus-bar arrangement will be:
a)
11.0
One Main (with Bus Sectionaliser) + One Auxiliary bus (2 Bus)
TRIP CIRCUIT SUPERVISION:
(i)
Trip circuit supervision scheme shall be provided for each circuit
breaker.
The scheme shall be capable of continuously monitoring
the healthiness of the breaker trip circuits.
(ii)
Number of trip circuit supervision relays required per breaker will
be as per
the number of trip coil. The standard adopted in general
will be
(a)All other breakers (for upto 132kV) 1 + 1 = 2 nos.
trip coils.
(iii) The trip circuit supervision scheme shall be capable of monitoring the trip
circuits irrespective of whether the breaker is open or close.
(iv) The scheme shall be such that it is possible to monitor the continuity of the
cable connection between the relay panel and the circuit breaker.
(v) The relays shall be suitable to work on 220V DC supply, and shall give
visual as well as audible annunciation through the SAS in the event of any
break in the trip circuit/loss of battery supply.
12.0
12.1
MULTIFUNCTION ELECTRICITY METER (MFE):
Multi-function electricity meter shall be four quadrants measuring type with

Time of Day (TOD) facility and shall be provided on the control panels for
indicating the Instantaneous parameters like voltage, current, frequency,
power factor, apparent power, reactive power, active power, etc. and the
integrated parameters like Mwh, Mvarh, etc. The meter shall have an
accuracy of 0.2, and shall be capable of recording import and export
parameters separately for lead and lag power factor. The four quadrants shall
1272 of 2461
PAGE 56 of 358
MMRDA
be as follows:
Quadrant
Mode
Active power
Reactive power
PF
Q1
Import
A+
R+
Lag
Q2
Export
A-
R+
Lead
Q3
Export
A-
R-
Lag
Q4
Import
A+
R-
Lead
A single meter capable of recording both import and export of energy and the
various system parameters like, voltage, current, frequency, power factor,
active power, reactive power etc. shall be provided on each panel where
export and import of energy are required to be recorded. The meter shall have
not less than three TOD slots. It shall be possible to programme the time slots
as per the site requirement.
Multi function meters shall be microprocessor based compact units having

suitable port(s) for interface with local computer/Data Acquisition system. In
case any specific software or other accessories like cables etc. are required
for this purpose, the same shall be included in the bidders scope.
12.2
The meters shall have digital unit. The digits shall be clear and bright. The nit
shall have number of digits not less than six (6). The meter shall be direct
reading type, that is, without involving any external multiplying factor. It shall
be possible to programme the meter, at site, to suit the actual CT and PT
ratios. However, inadvertent resetting/changing of the selected CT/PT ratio
shall be prevented through suitable software or hardware interlock.
12.3
M.F.E. meter shall be flush mounting type having all connections from the
rear. Provision shall be available for in-situ testing/calibration of the meter.
12.4
Meters shall be suitable for 50 Hz AC systems with 1A CT secondary and

110V PT secondary rating and shall be 4-wire 3-element type capable of
reading
correctly
even
when
used
for
unbalanced
loads.
No
transducer/external interfaces shall be included between the instrument

transformer (secondary) and the meter.
1273 of 2461
PAGE 57 of 358
12.5
MMRDA
Feather-touch push buttons shall be provided on the meters for enabling

selection of various system parameters to be read. The parameter being
displayed shall be identified on the display unit. Normal scroll mode shall also
be available, and the parameters to be displayed shall be programmable.
12.6
MFE meters shall preferably be self-powered type. Meters shall have nonvolatile memory using ELPROM so as to retain the recorded parameters
during power failure/storage. In case the meter is having built-in selfchargeable type battery back up to support the retention of energy recording
during storage/aux. Supply failure, the same shall have a life not less than 10
years.
12.7
The meter shall be tamper-proof, having suitable locking arrangement.

Locking by method of password may also be offered to prevent tempering by
unauthorized persons.
12.8
Test terminal block of 3 phase, 4 wire type shall be provided for enabling on
line testing of MFE meter.
12.9
Dedicated MFM shall be provided for each CT.
13.0
TIME SYNCHRONISATION EQUIPMENT
13.1
The Time synchronization equipment shall receive the co-ordinate Universal

Time (UTC) transmitted through Geo Positioning Satellite System (GPS) and
synchronize equipments to the Indian Standard Time in substation. The times
synchronization shall be realized using the SNTP protocol at inter bay bus.
13.2
Time synchronization equipment shall include antenna, all special cables and
processing equipment etc.
13.3
It shall be compatible for synchronization of Event Loggers, Disturbance

recorders and SCADA at a substation through Ethernet realized through optic
fiber bus.
1274 of 2461
PAGE 58 of 358
13.4
MMRDA
Equipment shall operate up to the ambient temperature of 50 degree

centigrade and 100% humidity.
13.5
The synchronization equipment shall have 2 micro second accuracy.

Equipment shall give real time corresponding to IST (taking into consideration
all factors like voltage and temperature variations, propagation and
processing delays etc.)
13.6
Equipment shall meet the requirement of IEC 60255 for storage and operation.
13.7
The system shall be able to track the satellites to ensure no interruption of

synchronization signal.
13.8
The output signal from each port shall be programmable at site for one hour,
half hour, minute or second pulse, as per requirement.
13.9
The equipment offered shall have six (6) output ports. Various combinations
of output ports shall be selected by the customer, during detailed engineering,
from the following:
13.10
RS232C
3 Nos. of Ethernet RJ45 port with link/activity and 10/100 Mbps.
The equipment shall have a periodic time correction facility of one second
periodicity.
13.11
Time synchronization equipment shall be suitable to operate from 220V/110V

DC available at substation.
13.12
Equipment shall have real time digital display in hour, minute, second (24 hour
mode) and have a separate time display unit (100 mm display high) at a
suitable height in the control room.
Principle technical parameters for Bus post and disc Insulators

1275 of 2461
PAGE 59 of 358
MMRDA
1.0
Bus Post Insulators:
1.1
The Bus Post Insulators (BPI) shall be suitable for outdoor service and it shall
be solid core. The insulator shall be made of homogeneous and vitreous
porcelain of high mechanical and di-electric strength. Glazing of the porcelain
shall be of uniform brown or dark brown color, with a smooth surface arranged
to shed away rain water.
1.2
The Bus Post Insulators shall be provided with a completely galvanized steel
base designed for mounting on the support structure. The base and mounting
shall be such that the insulator will be rigid and self supporting, and no guying
or cross- bracings between phases shall be necessary. All the ferrous (metal)
parts shall be duly hot dip galvanized.
1.3
The Bus Post Insulators shall be provided with cap of high grade malleable
steel casting. It shall be machine-faced and hot dip galvanized. The casting
shall be free from blow holes, cracks and other defects.
1.4
All necessary nuts, bolts, washers, etc. required for the assembly of the
insulator stack shall be supplied alogwith the insulator. All these fasteners shall
be hot dip galvanized.
1.6
The basic technical parameters of Bus Post Insulators are as follows:
Sr.
Particulars
132/100 KV
No.
1)
Voltage Rating
145 KV
2)
Height
1500 mm
3)
Min.Nominal Creepage
3625 mm
Distance
4)
Bending Strength (min.)
4 KN
5)
Torsional Strength (min.)
460 Kgm
6)
Impulse Withstand
650 KVp
1276 of 2461
PAGE 60 of 358
MMRDA
Voltage
7)
No. of Tapped holes
4/4
(Top / Bottom).
8)
Tapped Dia. (Top)
M16
9)
Hole Dia. (Bottom)
18 mm
10)
PCD (Top/Bottom)
127/184 mm
2.0
Disc Insulators
2.1
The insulator strings shall consist of standard Porcelain or Glass discs for a
three phase 50 Hz, effectively 132 KV systems The discs shall be cap and pin,
ball and socket type. All the disc insulators shall be of antifog type.
2.2
The number of insulators to be used for suspension and tension locations, their
electromechanical strength alongwith hardware fitting shall be as follows:
Sr.
Particulars
No.
132 KV
2.3
Tension String
120 KN
Suspension string
70 KN
No. of Insulators for
Tension String
10
Suspension string
The size of disc insulator, minimum creepage distance shall be as follows:
Sr.
EMS of
Type of
Size of Disc insulator
Min. Creepage
No.
insulator
insulator
(mm)
distance (mm)
(Dia. x Height)
1
70 KN
120 KN
255 x 145
320
AF
280 x 145
430
255 x 145
320
AF
280 x 145
430
1277 of 2461
PAGE 61 of 358
MMRDA
Sr.
EMS of
Type of
Size of Disc insulator
Min. Creepage
No.
insulator
insulator
(mm)
distance (mm)
(Dia. x Height)
3
160 KN
280 x 170
320
AF
305 x 170
430
NOTE: Details applicable for items covered in BOQ only be considered.
2.4
All raw materials to be used in the manufacture of insulators shall be subject to

strict raw material quality control and to stage testing/quality control during
manufacturing stage to ensure the quality of the final end product.
Manufacturing shall conform to the best engineering practices adopted in the
field of extra high voltage transmission.
2.5
The porcelain used for manufacturing the porcelain discs shall be ivory white,
non-porous and having very high dielectric, mechanical and thermal strength.
The porcelain shall remain unaffected by climatic conditions, ozone, acid, alkali,
zinc or dust. The manufacturing shall be by wet process, and impervious
character obtained by thorough vitrification.
2.6
The glass used for manufacturing the shells of Glass disc insulator shall be
sound, free from defects such as flaws. bubbles, inclusions etc. and be of
uniform toughness over its entire surface. All exposed glass surfaces shall be
smooth.
2.7
The insulator surfaces that come in contact with cement shall be made rough
by sand glazing. All other exposed surfaces shall be brown glazed. The
thickness of the glaze shall be uniform throughout the working temperature
range.
2.8
The insulator caps shall be made of good quality malleable cast iron and shall
be annealed. Ball-pins shall be made of drop-forged steel. The ferrous parts
(caps, pins, etc.) shall be duly hot dip galvanized. The security clips shall be
made of phosper bronze or stainless steel.
2.9
Cement used as a filler material shall be quick setting, fast curing, port land
1278 of 2461
PAGE 62 of 358
MMRDA
cement. It shall not cause fracture by expansion or loosening by contraction.

Cement shall not react chemically with metal parts in contact with it, and its
thickness shall be as small and as uniform as possible.
2.10
The dimensions of Ball & Socket for 70 KN disc shall be 16 mm and of 120/160
KN disc 20 mm in accordance with the standard dimensions stated in IS2486(II).
3.0
IDENTIFICATION MARK:
3.1
The shell of insulator shall be legibly and indelibly marked with the trade
mark/name of the manufacturer, the month and year of manufacture, country
of manufacture, guaranteed electro-mechanical strength in Kilo-Newtons
abbreviated by 'KN' to facilitate easy identification and proper use. The marking
shall be printed and not impressed and the same shall be applied before firing.
3.2
The metal cap of each disc insulator shall bear the name of manufacturer by
embossing. The identifying letters shall be at least 5 mm high. The characters
shall be distinct, durable, and conspicuous after galvanizing.
4.0
Type Tests:
4.1
All the type tests as specified for Buspost insulators and Disc insulators
(unit/string) in MSETCL Technical Specification for the respective items and
conducted within last 5 years from the date of opening of tender shall be
submitted.
4.2
In case, the tests have been conducted earlier than 5 years or if there is any
change in the manufacturing process, material or design in the equipment
since after earlier passing of the type tests, the respective type test(s) shall be
carried out by the successful tenderer, after award of contract, in presence of
purchaser's representative, free of cost.
5.0
Acceptance Tests:
1279 of 2461
PAGE 63 of 358
MMRDA
The following acceptance tests shall be conducted on 70 KN, 120 KN and 160
KN disc insulators in presence of purchasers representative for the purpose of
acceptance of a lot:
Sr.
Particulars of test
Reference
No.
Standard
a)
Visual examination
IS:731
b)
Verification of dimensions
IS:731
c)
Temperature cycle test
IS:731
d)
Galvanising test
IS:731
e)
Mechanical performance test
IEC:60575
f)
Test on locking device for
IS:2486(IV)
ball and socket coupling
Eccentricity test (Axial & Radial
IEC:60383/60168
g)
Runout)
h)
Electro-mechanical strength test
IS: 731
i)
Puncture test
IS: 731
IS: 731
IEC:60383
(Only for Porcelain Disc insulators)
j)
Porosity test
(Only for Porcelain Disc insulators)
k)
Thermal shock test

(Only for Glass Disc insulators)
l)
Steep wave front test/Puncture test
specification
1280 of 2461
As per MSETCL
PAGE 64 of 358
m)
n)
6.0
MMRDA
Mechanical failing load Test
As per MSETCL
specification
Power frequency voltage
IEC: 60383
withstand test (Dry)
Routine Tests:
The following routine tests shall be conducted on each insulator and results
certified by the manufacturer:
Sr.
Particulars of test
Reference
No.
Standard
a)
Visual Inspection
IS: 731
b)
Mechanical routine test
IS: 731
c)
Electrical routine test
IEC: 60383
d)
Thermal shock routine test
IEC: 60383
As per MSETCL
(for glass insulator only)

e)
Polarised Light Inspection

(for glass insulator only)
specification
Principle technical parameters for Circuit Breakers
1.
CIRCUIT BREAKER
1.0
General Technical Requirements:
1.1
The circuit breakers shall be porcelain-clad type suitable for outdoor

installation. The porcelain housing for the interrupter shall be of a single-piece
construction, without any joint. The breaker unit shall be mounted on insulator
columns, each column consisting of not more than three insulators.
1.2
All ferrous parts, including fasteners of size M10 and above, exposed to air,
1281 of 2461
PAGE 65 of 358
MMRDA
shall be hot dip galvanized. Nut-bolts of size less than M10 shall be made of
stainless steel.
1.3
The terminal pads for take-off shall be made of aluminum. If the terminal pad
is made of any material other than aluminum, it shall be silver painted. The
current density adopted for the terminal pad shall not be more than 1.0A per
Sq. mm for Al. / 1.6A per sq. mm for copper.
1.4
The circuit breaker for 132 kV shall be SF6 type. Each breaker shall be
provided with a minimum of 10 N/O + 10 N/C auxiliary contacts. The contacts
shall be adequately rated for the various duties stipulated.
1.5
Similar parts of the breaker, especially the removable ones, shall be freely
interchangeable without any modification at site.
1.6
The support structure may be lattice type or tubular type, and shall be made out
of hot-dip galvanized steel. The foundation bolts and other associated nuts,
washers, spring washer, etc. shall also be hot-dip galvanized. The foundationdrilling plan shall be as per the enclosed drawings.
1.8
The circuit breaker shall also be capable of:
i) Interrupting line/cable charging current as per IEC without use of opening

Resistors.
ii) Clearing short line fault (Kilometric faults) with source impedance behind the
bus equivalent to symmetrical fault current specified.
iii) Breaking 25% of the rated fault current at twice rated voltage under phase
voltage opposition condition.
2.0
The circuit breakers shall meet the following Principle technical particulars/
requirements:
Sr.No.Particulars
1282 of 2461
PAGE 66 of 358
MMRDA
132kV
1.Rated voltage of the CB
145kV
2. Continuous
2000A
current rating
3.Rated short circuit capacity

a) Breaking
(RMS)
40kA
(3 seconds)
b)Making (peak)
100kA
4.Auxiliary supply
220V/110 v
a) DC
(-15% to +10%)
b) AC 3 phase
OR
415V
( + / - 10%)
c) AC 1 phase
240 V
(+/-
10%)
5. Minimum height of the lowest part of the support insulator
from ground level.
2500mm
6. Minimum creepage distance of support insulator.
3625mm
7.Tripping design
3 pole mechanically coupled

(MGO).
8. Auto-reclosing duty.
9. Operating duty.
3 phase (for lines only)
10. First Pole to clear factor
1.5
11.Max. Closing time (ms)
150
12. Operating mechanism.
Spring/Spring
13. Maximum breaking time at rated breaking.
60ms
14. One minute power frequency withstand voltage.
275kV
15. Number of trip coils.
1283 of 2461
PAGE 67 of 358
MMRDA
16. 1.2/50 micro second impulse withstand voltage
i)To earth
(kV peak)
650
ii) Across open contacts

Impulse on one terminal, power frequency voltage on 650
opposite terminal (Kvp)
17. 250/2500 microsecond switching impulse withstand
voltage:
i)to earth (KVP)
ii)Across open contacts:

Impulse on one terminal
Power Frequency voltage of
opposite polarity on other

terminal (KvP/+KvP)
18. Out of Phase breaking capacity
25%
of
rated
breaking
capacity
19. Rating of Aux. contacts
10A at 220V
DC
continuously
20. Breaking capacity of aux. contacts
2 Amps DC with ckt. Time

constant of not less than 20
ms
21. Max. radio interference voltage
(micro volts)
22. Rated breaking current capacity for rated small inductive 0.5 to 10A without switching
current (Amps)
overvoltage exceeding 2.0

per unit
23. i) Line charging current at rated voltage
(The
breaker shall be able to interrupt the rated line charging current

with test voltage immediately before opening equal to product
400 A
of U/3 * 1.4 as per IEC 62271-100 (where U is the rated

voltage of the circuit breaker)]
ii) 420kv Shunt reactor switching capacity
iii) Short time withstand current
40
a) AC component (KA rms)

1284 of 2461
PAGE 68 of 358
MMRDA
b) Percentage of DC component
Corresponding to minimum
opening
time
standard
c) Duration of
short circuit
24.Permissible limit of
25.
Max.
3sec
temperature rise
acceptable
difference
in
the
instants
of
closing/opening of contacts
i)
within a pole (ms)
ii)
between poles (ms)
26. Phase to phase spacing in the switchyard i.e. inter pole

spacing for breaker (mm)
a) If both terminals are not in the horizontal plane
4300
b) If both terminals are in the horizontal plane
4300
27. Height of concrete plinth above ground level (to be provided

by the purchaser) (mm)
300
28. Period for withstanding rated Phase to ground voltage by

gap between open contacts at zero gauge pressure of SF 6
8 Hours
gas due to leakage

29. Dielectric stress withstand across breaker imposed on it at
lockout pressure continuously
30. Thickness of silver plating for terminal
pads (other than aluminum)
2 pu
25 microns
31. Shade of Paint

32. Dry film thickness of prime and finished coats of paint
0.0762 mm
33. SF6 gas leakage per year
<1%
34. Sheet Steel thickness of operating
3 mm
mechanism cabinet
35. Thickness of neoprene gasket for control cabinet
15 mm
36. Rating of push button:

i)
For 240 V AC
6 Amps
ii)
For 220 V DC
2 Amps
37. Size and type of wiring for control circuits
2.5 Sq.mm.,
Copper
Stranded
1285 of 2461
PAGE 69 of 358
as
per
MMRDA
38. Single phasing protection for auxiliary

motors shall be built in the thermal
Yes
overload protection
39. Mechanical indication shall be provided
to show open and close position of
Yes
breaker easily visible from ground level
40. Operation Counter shall be provided to

register the cumulative number of breaker operations
41. Breaker shall be provided with local manual control for
emergency tripping
42. Percentage range of rated voltage for
Correct operation of closing coil (%)
43. Percentage range of rated voltage for correct operation of
trip coil (%)
44. Class of
Breaker
Yes
Yes
85 to 110
70 to 110
3.0
TECHNICAL SPECIFICATIONS FOR CIRCUIT BREAKERS
Notes :
1. Provision shall be made for attaching an operation analyzer at site for timing test
on breaker without opening any gas compartment.
2. Provision for circuit breaker ready status using spring charge and pressure switch
contact for each pole for 132kV breakers shall be available.
3. D.C. changeover scheme should be for indication ckt., Annunciation ckt, pressure
switch and pole discrepancy only.
4. Inclusion of Contact Resistance and DCRM measurement for 400KV and 245KV
Circuit Breakers and Leakage test for each breaker shall be done as a part of
Routine Tests. Physical documents with actual graphs should be provided at the
time of delivery.
5. The foundation drilling plan shall be maintained as per circuit breaker
manufacturers recommendations.
6. OPERATING MECHANISM AND ASSOCIATED EQUIPMENTS:
1286 of 2461
PAGE 70 of 358
The
MMRDA
operating mechanism shall be of spring charging
operation type operated by
type or Pneumatic
electrical control under normal operation. The
mechanism shall be adequately
designed for the specified tripping
and
reclosing duty. The entire operating mechanism, control circuitry, individual

spring charging motor etc., as required, shall be housed in an out-door type steel
enclosure, hot dip galvanized/spray galvanized/Epoxy painted as per shade of
IS 5. This enclosure shall conform to the degree of protection IP-55. The enclosure
shall be invariably mounted on a concrete plinth of 300mm height.
7.
Measurement of pre-insertion resistor (PIR) value for breakers supplied with

PIR.
8.
For more details and approved drawings please visit MSETCLs website.
9.
For detailed specifications please refer to Specification no :
1)
MSETCL/TR. PROJ./D&E-S3/CB-1B/0411 For 145kV CB LIST OF

STANDARDS
SR
NO
TITLE
STD. REF. NO.
IEC 62271-100
Specification for alternating current circuit breaker.
IEC 376
Specification and acceptance of new supply of sulphur

hexafluoride.
IEC 529/IS 2147 Degree of protection provided for enclosures for low
voltage switchgear and control gear.
IS 325
Specification for 3 phase induction motor
IS 2629
Recommended practice for hot dip galvanizing of iron and

steel.
IE C- 2331
High voltage porcelain bushings
IE C 60
High voltage test techniques
IEC- 71-
Insulation co-ordination, Terms, definitions, principles and
Part I & II
rules
CIGRE Working
Switching over-voltages in EHV and UHV systems with
group-Report
special reference to closing and
No. 13-02-1973
Reclosing transmission lines
IEC 270
Partial discharge measurements
10
1287 of 2461
PAGE 71 of 358
11
MMRDA
Indian Electricity Rules
12
13
IS 4379}
High pressure cylinder in which SF 6 gas is transported
IS 7311}
and stored at site
IS 1893
Seismic Test
(Part I) 2002
14
IS 2516
Specification for Circuit Breakers
15
IS 2147
Degree of protection provided for enclosures for
low
voltage switchgear and control gear

16
IS 5621
Hollow insulator for high voltage equipments
17
IS 13118
Specification for HVAC Circuit Breakers
18
IS 7285
Specification for gas cylinders
19
IS-2825
Specification for pressure vessels
20
IS-13947
Specification for Degree of Protection
21
IS 5
Colour for ready mixed paints and channel.
22
BS 162
Specification for compressed air piping
LIST OF TYPE TEST REPORTS
SR.
LIST OF TYPE TEST
NO.
NAME OF
REF. NO.
REFERENCE
TESTING
AND DATE
NO OF
LABORATORY
OF TYPE
ACCEPTANCE
AND DATE OF
TEST
LETTER BY
TYPE
REPORT
C.E. (TR. PR.)
TESTING
A) Type Tests (Report to be submitted along with offer)
Dielectric Tests:
a) Lightning impulse voltage

1
test
b) Switching impulse voltage

test (Wet)
1288 of 2461
PAGE 72 of 358
SR.
LIST OF TYPE TEST
NO.
MMRDA
NAME OF
REF. NO.
REFERENCE
TESTING
AND DATE
NO OF
LABORATORY
OF TYPE
ACCEPTANCE
AND DATE OF
TEST
LETTER BY
TYPE
REPORT
C.E. (TR. PR.)
TESTING
c) Power frequency voltage
test
2
Mechanical endurance Test
Short circuit test

(Test duties 1 to 5)
Short line fault test
Out of phase switching test
7
8
9
Line charging breaking current

test
Reactor current switching Test
Radio interference Voltage
(RIV) test
10
Corona extinction Voltage test
11
Seismic withstand test
12
Thermal test on closing

resistor
13
IP 55 test
Principle technical parameters for Insulator ,Hardware & Conductor/Earthwire

Accessories
1.0
GENERAL REQUIREMENTS:
a)
The material offered shall be of best quality, well finished workmanship, latest
design and confirming to the best modern practices adopted in the Extra high
voltage field. All drop forged parts shall be free from flaws, cracks or other
1289 of 2461
PAGE 73 of 358
MMRDA
defects and shall be smooth, close grained and of true forms and dimensions.
All machined surface shall be true, smooth and well finished.
b)
Metal fittings of specified material for string hardwares, are required to have
excellent mechanical and electrical properties such as strength, toughness,
mobility, high electrical conductivity, low power losses, freedom from corona
formation or discharges likely to cause interference to tele-transmission of
signals of any kind and high corrosion resistance.
c)
All components shall be clean, free from indents, cracks, shrinks, slender, air
holes, burrs or rough edges and shall have smooth finished surface throughout.
All current carrying parts shall be designed to have minimum contact resistance
and shall be smooth finished. Adequate bearing area between fittings shall be
provided and 'Point' or 'Line' contacts shall be avoided.
d)
All steel components shall be made of forged steel of Class IV grade by drop
forging method and normalized. They shall be smooth finished with rounding
off the edges. The minimum failing load shall be as indicated in the approved
drawing. The component shall bear the name of manufacturer by embossing.
e)
Special attention shall be paid in the manufacture of aluminum dead end

clamps and jumper to ensure that the finished material is free from surface
defects like laminations, rough, jagged and imperfect edges, deep scratches,
cracks and any other harmful defects. The jumper shall be uniformly and
adequately pressed so as to be free from air gaps. The contact surface between
clamp and jumper shall be straight to ensure full contact area between them.
After machining the clamps and jumper shall be made free from dint, oil, grease
etc. The steel sleeve shall be made of forged steel of Class II grade by drop
forging method and normalized.
f)
No component shall be made by joining, welding, shrink fitting or any other

process from more than one piece of material except for Corona Control Ring.
g)
The Suspension and tension hardwares shall be suitable for insulators with
nominal pin shank diameter of 16 mm and 20 mm respectively of IS: 2486 Part
1290 of 2461
PAGE 74 of 358
MMRDA
II 1989 for 220/132 KV system.
h)
All forged and cast components shall necessarily bear identification mark of the
manufacturer by Embossing.
i)
Both suspension and tension type hardwares shall be of ball and socket type
and should invariably be with 'R' type security clip of stainless steel conforming
to IS:2486 (Part III & IV).
j)
Unless specifically mentioned, the tension clamps shall be of compression

type and shall have a steel sleeve to be compressed on the steel core end of
the ACSR conductor.
k)
The suspension clamp (envelop type and drop type) shall be suitable for
supporting respective ACSR and AAA conductors without armour rods.
The clamps shall be corrosion resistant, light in weight and easy to handle. The
clamps shall be designed, manufactured and finished to give it a suitable shape
without sharp angles at the ends and shall have such radius of curvature so
as to avoid any possibility of hammering between the clamp and conductor due
to vibrations. It should, however, have sufficient contact surface to minimise
damage due to fault currents. If dissimilar materials are used for suspension
clamp suitable precautions shall be taken to minimise electrolytic corrosion.
l)
The purchaser reserves the right to insist upon the Supplier for proving the
composition and the quality of the material at any stage, either during or after
the execution of the contract.
m)
All bolts, nuts shall conform to IS:1367-1991. Bolt heads and nuts shall be
locked in an approved manner. The threads in nuts and tapped holes shall be
cut after galvanizing and shall be well lubricated or greased. All other threads
shall be cut before galvanizing. The bolt threads shall be under-cut to take care
of increase in diameter due to galvanizing. Rivet type arrangement shall not be
used for any item.
1291 of 2461
PAGE 75 of 358
MMRDA
n)
The mechanical strength of the insulator hardware strings shall be as under:
i)
132 KV Single suspension string (with straight / Drop clamp) for

Single/Twin/Quad Conductors - 70 KN
ii)
132 Single Tension string for Single/Twin/Quad Conductors -120 KN
2.0
LOCKING DEVICES:
I)
SECURITY CLIPS
a)
The security clips to be used as locking device for ball and socket coupling
shall be R shaped hump type to provide for positive locking of the coupling
as per IS:2486 (Part III & IV). The legs of the security clips shall allow for
spreading after installation to prevent complete withdrawal from the socket.
The locking device shall be resilient, corrosion resistant and of sufficient
mechanical strength. There shall be no possibility of the locking device to be
displaced or be capable of rotation when placed in position and under no
circumstances shall it allow separation of insulator units and fittings.
b)
The hole for the security clip shall be countersunk and the clip shall be of such
design that the eye of the clip may be engaged by a hot line clip puller to
provide for disengagement under energised conditions. The force required for
pulling the clip into its unlocked position shall not be less than 50 N (5 Kgs) or
more than 500 N (50 Kgs).
II)
SPLIT PINS
The split pin to be used as locking device for Bolt and Nut shall be R shaped
hump type to prevent disengagement of Nut from the bolt. The split pin shall of
stainless steel grade AISI 304. The legs of the split pin shall allow for spreading
after installation to prevent complete withdrawal from the bolt. The split pin
shall be resilient, corrosion resistant and of sufficient mechanical strength. The
dimensions of split pin shall confirm to requirements given in IS:2486 (Part III &
IV).
1292 of 2461
PAGE 76 of 358
MMRDA
3.0
BOLTS, NUTS AND PLAIN / SPRING WASHERS :
a)
Bolts and nuts shall conform to latest edition of IS:1363, IS:1367, IS:2614 and
IS:12427. The mechanical properties shall conform to class 8.8 and 5.6 for bolts
and class 5 for nuts.
b)
Spring washers shall confirm to latest edition of IS:3063, IS:6821 and IS:1586
and shall be electro-galvanized in accordance with IS:1573 (1986) service
condition IV.
c)
Plain washers shall confirm to IS:2016.
4.0
COMPONENT ASSEMBLY:
The insulator string hardwares shall be in general conformity with the MSETCL
drawings and each suspension and tension hardware set shall comprise of
components indicated therein.
The manufacturer may however, offer any other suitable type of insulator
hardware / component which is more efficient / suitable than the MSETCL
standard drawing. However, in such a case the decision of MSETCL regarding
suitability of the same for the intended purpose shall be final.
5.0
GALVANIZING:
a)
After
all
shop work is complete, all
ferrous
parts
of hardwares and
accessories shall be hot dip galvanized in conformity with IS:2629 and IS: 2633.
Before galvanization, the steel section shall be thoroughly cleaned of any paint,
grease, rust, scale, acid/alkali or such other foreign matters as are likely to
interfere with the galvanizing process or with the quality and durability of the
zinc coating. Pickling shall be very carefully done and shall be proper.
b)
The zinc used for galvanizing shall be of grade Zn 98 (% of zinc 99.95%) as

per IS:209. The mass of zinc coating on various components shall be as follows:
1293 of 2461
PAGE 77 of 358
MMRDA
Sr.
Thickness of
Mass of
Thickness of
No.
steel article
zinc coating
zinc coating
1)
5 mm and above
610 gm/m2
86 microns
2)
Below 5 mm
460 gm/m2
64 microns
3)
Fasteners
300 gm/m2
42 microns
4)
Spring washers
272 gm/m2
38 microns
1 gm/m2 = 0.14 Microns
c)
The galvanized surface shall consist of continuous and uniformly thick

coating of zinc, firmly adhering to the surface of steel. The finished surface
shall be clean and smooth and shall be free from defects like discolored
patches, bare spots, unevenness of coating, spelter which is loosely attached
to the steel, globules, spiky deposits, blistered surface, flaking or peeling off
etc. The presence of any of these defects noticed on visual or microscopic
inspection shall render the material liable to rejection.
d)
There shall be no flaking or loosening when struck squarely with a chisel faced
hammer. The galvanized components shall withstand minimum four one
minute dips in standard copper sulphate solution as per IS:2633.
e)
All bolts, nuts, plain washers etc. shall be hot dip galvanized conforming to
IS 5358. Spring washers shall be electro-galvanized in accordance with IS
1573(1986) service condition IV. Excess spelter from bolts, nuts, etc. shall be
removed by centrifugal spinning. Rethreading of bolts after galvanizing shall
not be done. Nuts however, may be tapped, but this should not cause
appreciable recking of the nuts on the bolts.
6.0
RIGID SPACER (TWIN & QUADRUPAL):
The spacer shall be manufactured in one piece without any loose parts, by
gravity die casting from aluminium alloy grade 4600. In case any other material
is used it shall be ensured that it is non-corrosive. All ferrous metal parts shall
be galvanised conforming to IS:2633, 2629.
1294 of 2461
PAGE 78 of 358
MMRDA
The spacer shall be of simple design. Installation of units shall be simple and
achieved without use of special tools.
Spacer shall firmly grip the conductors without causing any damage to the
conductor strands. Also it shall not be damaged when subjected to vibrations
during service.
Spacer shall have sufficient resilience to allow longitudinal, vertical and

torsional movements of the conductors relative to each other and shall maintain
their correct separation, with no lubrication and maintenance, of 450 mm and
350 mm without any wear and tear.
No rubbing, other than conductor clamp hinges or clamp swing bolts, shall take
place between any part of the spacer.
7.0
EARTH WIRE ACCESSORIES
Accessories suitable for 7/3.66 mm earthwire shall be offered.
7.1
TENSION CLAMP
Suitable compression type tension clamps shall be used to hold earthwire. 16

mm diameter anchor shackle shall be supplied which shall be suitable for
attaching the tension clamp to strain plate. The anchor shackle shall be made
of forged steel of Class IV grade by drop forging method and normalised. The
same shall be smooth finished with rounding off the edges.
The clamp shall be made of Mild steel/Forged steel of class II grade for G.I.
earthwire by drop forging method and normalized. The same shall be smooth
finished with rounding off the edges and corners. The clamp shall also be
provided with an aluminium cover and filler tube.
The tension clamp shall have a jumper plate, for attaching jumper terminal to it.
The same shall be attached with 2xM12 size bolts, nuts and plain washers of
mild steel and spring washer of spring steel. The length of one of the bolts shall
1295 of 2461
PAGE 79 of 358
MMRDA
be more than the other for connecting earth bond to the tower body.
The clamp shall have adequate area of bearing surface to ensure positive
electrical and mechanical contact. The clamp shall not permit any slippage of
earthwire under working tension and vibration. The electrical resistance of the
clamp when compressed on the earthwire shall be less than 75% of measured
resistance of equivalent length of earthwire. The slip strength of the assembly
shall not be less than 95% of the ultimate tensile strength of the earthwire. The
angle of jumper terminal shall be 30o with respect to the vertical line.
The clamp shall be complete with all the components including anchor
shackle, bolt, nuts, washers, split pin, jumper arrangement etc.
7.2
EARTH BOND
The earth bond shall be made of E.C. grade (% of Copper 99.8%) tinned
flexible copper cable of size 37/7/0.417 mm with 8.757 mm diameter and
copper area equivalent of 34 mm2. Two tinned copper lugs having suitable
holes for 12 mm & 16 mm diameter bolts shall be press jointed at either ends
of the copper cable. One 45 mm long galvanised Mild Steel bolt with nut and
plain, spring washer shall also be provided. This shall be suitable for providing
proper bondage between earthwire, suspension/tension clamp and gantry. The
pulloff load shall not be less than 300 kg.
8.0
Type Tests:
a) Test Reports for all the type tests as specified in MSETCL Technical
Specification, conducted within last 5 years from the date of opening of tender
shall be submitted.
b) In case, the tests have been conducted earlier than 5 years or if there is any
change in the manufacturing process, material or design in the equipment
since after earlier passing of the type tests, the type test(s) shall be carried out,
after award of contract, in presence of purchaser's representative, free of cost.
1296 of 2461
PAGE 80 of 358
9.0
MMRDA
Acceptance Tests:
The following acceptance tests shall be conducted in presence of purchasers

representative for the purpose of acceptance of a lot:
Sr.
Particulars of test
Reference standard
No.
I)
Suspension hardwares:
1)
Visual examination
2)
Verification of Dimensions
3)
Mechanical strength test
on clamp and components
Mechanical strength test on
Corona control rings
welded joints
6)
Galvanising/Electroplating test
II)
Tension hardwares:
1)
Visual examination
2)
3)
on components
Mechanical/slip strength
test on dead end assembly
Corona control rings
welded joints
7)
III)
Tests on locking devices(Security clip):
1)
Verification of resistance
to bending
4)
5)
4)
5)
6)
As per MSETCL specification.
As per IS:2486(IV)
1297 of 2461
PAGE 81 of 358
MMRDA
2)
Hardness test
3)
Operation test
IV)
Conductor accessories:
a)
Rigid Spacer
1)
Visual examination
2)
3)
Clamp slip test
4)
Clamp bolt torque test
5)
Tension Compression test
Sr.
Particulars of test
Reference standard
No.
V)
Earthwire accessories:
a)
Tension clamp
1)
Visual examination
2)
3)
on components
4)
Slip strength test on clamp
5)
Hardness test
6)
VI)
Earth Bond
1)
Visual examination
2)
3)
Slip strength test
9.0
ROUTINE TESTS:
This shall mean those tests, which are to be carried out on each item to check
the requirements which are likely to vary during production. The same shall be
as per relevant IS.
1298 of 2461
PAGE 82 of 358
MMRDA
Principle Technical Particulars for Clamps & connectors.
1.0
The Bus- support clamps, spacers, T-connectors and various equipment

connectors shall be supplied as per the enclosed drawings. The material used
for these items shall be generally as follows:
Sr.No.
(a)
Application
Material
Bolted Type Connection:
1) For connection to ACSR/ AAAC/
Aluminum Alloy conforming
Morculla Aluminum terminal.
to designate A6 as per IS617.
2) For connection to copper terminals,
Electrolytic grade copper,
with crimping facility to connect
forged & tinned.
ACSR/AAAC/Morculla jumper.
(b) Crimping Type Connection:
i) For connection to ACSR/ AAAC/
EC grade aluminum.
Morculla jumper.
2.0
The connector/ jumper terminal intended for crimping type connection shall be
manufactured by the drop-forging method. Other types of clamps and
connectors (which are not meant for crimping type connection) shall be gravity
die-cast and normalized.
3.0
The material shall be of the best workmanship, and all the sharp edges and
corners shall be rounded off. The thickness of tinning, whenever applicable,
shall be not less than 10 microns. The minimum thickness of pads made of
Copper shall be 10mm and those made out of Aluminum/ Aluminum Alloy shall
be 12 mm, unless otherwise indicated in the enclosed drawings.
4.0
All the clamps and connectors shall be designed to carry a continuous current
1299 of 2461
PAGE 83 of 358
MMRDA
not less than 120% of the rated current of the conductor (twin/ single as the
case may be)/ equipment terminal to which these are to be connected.
Temperature rise of the connector under the above condition shall not be more
than 50% of the temperature of the main conductor/ equipment terminal.
5.0
All the fasteners (i.e. nuts, bolts, washers, check-nuts etc.) used in the clamps
and connectors shall be non magnetic stainless steel. The straight bolts shall
be fully threaded, and the U-bolts shall be threaded unto 30mm from the ends.
For connectors made out of Aluminum/ Aluminum Alloy, the bolts shall be of 12
mm diameter, and for copper connectors the bolts shall be 10 mm diameter.
6.0
The clamps and connectors meant for 0.4 ACSR (Zebra/ Moose) and AAAC
(525 sq mm) shall have the same crimping dimensions. It shall be possible to
use the same clamp/ connector for 0.4 ACSR or AAAC 525 sq mm, as would
be required, without any modification/ change at site.
7.0
The length of the bolt shall be chosen such that after fully tightening the nut and
check-nut, minimum 5 (five) threads of the bolt shall project outside the nut/
check-nut.
8.0
Standards:
The clamps & connectors shall conform to the latest Indian Standards including
follwong:
IS-2121
Fittings for Aluminium & Steel cord Aluminium conductors for

overhead power lines.
IS-5561
Electric Power connectors.
IS-2633
Method of testing weights, thickness & uniformity of coating on hot
dip
9.0
galvanized articles.
Type Tests:
List of type tests to be carried out

i)
Short time current rating test for 50kA for 3 sec.
ii)
Temperature Rise Test for full rated current
1300 of 2461
PAGE 84 of 358
10.0
MMRDA
Routine/Acceptance Tests:
i) Visual & Dimensional Check

ii) Tensile strength test
iii) DC Resistance test
11.0
Drawings:
Drawings in respect of various types clamps & connectors are enclosed.

Principle technical parameters Air break disconnectors
(Isolators)
Technical Specification for 145 Isolators
1.0
SCOPE:
1.1
This specifications covers the design, manufacture, assembling & testing at

manufacturers works, inspection, packing and delivery of the 145kVHorizontal
double break, center post rotating, triple pole mechanically gang operated
outdoor type air break disconnector (isolators) alongwith relevant accessories
and auxiliary equipments for installation in various substations in Maharashtra
State (India).
1.2
It is not the intent to specify completely herein all details of the design and
construction of equipments. However, the equipment shall conform in all
respects to high standards of engineering, design and workmanship and shall
be capable of performing in continuous commercial operation upto the expected
life of 25 years in a manner acceptable to the purchaser, who will interpret the
meanings of drawings and specification, and shall have the powers to reject
any work or material which, in his judgment, is not in accordance therewith. The
equipment offered shall be complete with all components necessary for its
effective and trouble free operation alongwith associated structure equipments,
interlocks, protection schemes etc. Such components shall be deemed to be
within the scope of suppliers supply, irrespective of whether those are
1301 of 2461
PAGE 85 of 358
MMRDA
specifically brought out in this specification and / or the commercial order or not.
All similar parts, particularly the removable ones, shall be interchangeable.
2.0
SERVICE CONDITIONS:

Satisfactory continuous operation under the following tropical conditions.
Maximum
2.2.1 ambient temperature
(c)
50
Maximum
2.2.2 temperature in shade
(c)
45
Minimum
2.2.3 temperature of air in shade
(c)
3.5
Relative
2.2.4humidity
(%)
10 to 100
Maximum
2.2.5 annual rainfall
(mm)
1450
Maximum
2.2.6 wind pressure
(Kg/sq.mm)
150
(Meters)
1000
(days/year)
50
(g)
0.3
Maximum
2.2.7 altitude above mean sea level
Isoceraunic
2.2.8 level
2.2.9
Climate
Moderately hot & humid

tropical climate conducive to
rust and
fungus growth
3.0
STANDARDS:
Sr. No.
Standard No.
Title
1.
IS : 9921- 1982
Alternating current isolators (disconnectors) and

earthing switches
2.
IS : 1239
Standard for Electric Resistance Welded (ERW)

pipes.
3.
IEC : 129
High Voltage Switchgears
4.
IS : 2544
Tests on Indoor and Outdoor post insulators
5.
IEC : 168
-- do --
6.
IS : 2147
Degree of protection provided by enclosures for

Low voltage switchgear and control gear.
1302 of 2461
PAGE 86 of 358
7.
IS : 4691
MMRDA
Degree of protection provided by enclosures for

Rotating electrical machinery
8.
IS : 325
Three phase induction motors.
9.
IS : 4722
Rotating electrical machines.
10.
IS : 2629
Recommended practice for hot dip galvanizing of

iron and steel.
11.
IS : 4759
Hot dip Zinc coating on structural steel.
12.
IS : 2633
Method of testing weight, thickness and uniformity

of coating on fasteners.
13.
IS : 1573
Electro plated coating of zinc on iron and steel.
14.
IS : 3033
Spring washers.
15.
IS : 2016
Plain washers.
16.
IS 5561
Power Connectors
17.
IS 1554
PVC Cables
18.
IS 375
Marking and arrangement for switch gear busbar

main connectors and auxiliary wirings.
19.
IS 3961
Recommended current rating for PVC insulated &

PVC sheathed heavy duty cables.
20.
IS 8263
Method for Radio Interference voltage (RIV) test

on high voltage insulators.
21.
3.1
IEC 437
Radio Interference voltage (RIV) test.
Unless otherwise specified elsewhere in this specification, the rating as well as

performance and testing of the disconnector shall conform to the latest
revisions of all the relevant standards available at the time of tender/placement
of order.
3.2
Equipments meeting with the stipulations of other authoritative International

standards like IEC, ANSI, CSA, DIN, etc., which ensure equal or better quality
than the standards listed above, shall also be acceptable. In such case the
tenderer should submit alongwith his offer, two copies of such standards, in
authentic English translation, if the language of the standards is other than
English. In case of dispute, the stipulations in the English translation, submitted
by the tenderer, shall prevail. Stipulation of IS shall prevail however, MSETCL
decision will be final and shall be binding on bidder/manufacturer.
1303 of 2461
PAGE 87 of 358
3.3
MMRDA
The equipment should be designed to suit mounting of the base channel and
allied components including main drive & earthing mechanism on the lattice
type structure standardized by the MSETCL as indicated in the attached
drawings no. 06.776, 06.775 & 06.774.
4.0
PRINCIPAL TECHNICAL PARAMETERS:
The equipments covered in this specification shall meet the technical

Requirements listed in Annexure A, B & C.
5.0
GENERAL TECHNICAL REQUIREMENTS:
5.1
Type of disconnectors:
5.1.1
The disconnectors shall be of three phase mechanically gang operated

horizontal double break design, having turn and twist type moving blades and
with or without gang operated vertical break earth blades as per requirement.
The disconnectors shall be motor operated (remote/local operation) with
manual operation facility whenever required.
5.2
Current carrying parts:
5.2.1 Material of earthing blades and contacts shall be the same as those of main
switch moving blades and contacts respectively. Cross sectional area of
earthing blades and contacts shall not be less than 50% of cross sectional area
of main blades and contacts. The earthing blades shall have the same short
time current rating (thermal and dynamic) as that of main switch.
5.3
Current density:
Current density to be adopted for the current carrying parts of isolator shall not
exceed the following limits:
a) Hollow tube sections
- Copper
- 2.0 A/sq. mm.
b) Other sections
- Copper
- 1.6 A/sq. mm.
1304 of 2461
PAGE 88 of 358
5.4
MMRDA
Insulators:
5.4.1 Solid core insulators only shall be used for isolator. The insulators shall have
cantilever strength not less than 4 KN.
5.4.2 The insulators shall be provided with a completely galvanized steel base design
for mounting on the support. The base and mounting arrangement shall be such
that the insulators are rigid and self- supporting and no guying or cross bracing
between phases shall be necessary.
5.4.3 The insulator shall be made of homogenous and vitreous porcelain of high
mechanical and dielectric strength. It shall have sufficient mechanical strength
to sustain electrical and mechanical loading on account of wind load, short
circuit forces, etc. Glazing of the porcelain shall be of uniform brown or dark
brown colour with a smooth surface arranged to shed away rain water. The
porcelain shall be free from lamination and other flaws or imperfections that
might affect the mechanical or dielectric quality. It shall be thoroughly vitrified,
tough and impervious to moisture. The porcelain and metal parts shall be
assembled in such a manner and with such material that any thermal differential
expansion between the metal and porcelain through the range of temperature
specified in this specification shall not loosen the parts or create undue internal
stresses which may affect the mechanical or electrical strength or rigidity. The
assembly shall not have excessive concentration of electrical stresses in any
section or across leakage surfaces. The cement used shall not give rise to
chemical reaction with metal fittings. The insulator shall be suitable for water
washing by rain or artificial means in live/service conditions (hot line washing).
5.4.4 Cap to be provided on top of the insulator shall be of high grade cast
iron/malleable steel casting or Aluminum alloy. The casting shall be free blow
holes, cracks and such other defects. It shall be machine faced and hot dip
galvanized. The post insulators shall have a creepage distance of 25mm per
kV of highest system voltage.
Voltage Level
Top PCD (mm)
1305 of 2461
Bottom PCD (mm)

PAGE 89 of 358
36kV
MMRDA
76
76
The holes shall be suitable for bolts with threads having anticorrosive
protection. The effective depth of threads shall not be less than the nominal
diameter of the bolt. The top and bottom PCDs for the 245KV, 145KVand the
36kV insulators shall be as shown in the table above.
5.4.5 All the ferrous parts shall be hot dip galvanized smoothly as per, IS 2629 or any
other equivalent authoritative standard. The material shall be galvanized only
after shop operations have been completed. The metal parts, before
galvanization, should be thoroughly cleaned of any paint, grease, rust, scales
or any foreign deposits which are likely to come in the way of galvanization
process. The coating (galvanizing) shall withstand minimum four one-minute
dips in copper sulphate solution as per IEC-168.
5.4.6 The insulator unit shall be assembled in a suitable jig to ensure correct
positioning of the top and bottom metal fittings relative to one another. The
faces of the metal fittings shall be parallel and at right angle to the axis of the
insulator and corresponding holes in the top and bottom metal fittings shall be
in a vertical plane containing the axis of the insulator.
5.4.7 It shall be the sole responsibility of the supplier/manufacturer to carry out

thorough inspection and quality checks on the insulators at the insulator
suppliers works before offering the insulators for purchaser's inspection.
5.5
Operating Mechanism:
5.5.1
A)
Three- phase 415V AC Motor operated mechanism shall be
provided for the main switch. Manual mechanism, gang operated

through a crank and reduction gear, shall also be provided for the main
switch.
B)
Manual operated mechanism gang-operated through a lever/handle on
1306 of 2461
PAGE 90 of 358
MMRDA
operating shaft shall be provided for earth switch. The mechanism box
for both the drives shall be suitable for mounting on the MSETCLs
standard support structure.
5.5.2 Motor:
5.5.2.1
Motor shall be suitable for 3-phase 415V AC supply with variations as

specified in this specification.(Clause 7.2.2)
5.5.2.2
Motor shall be squirrel cage induction motor suitable for direct-on-line (DOL)
starting and shall generally conform to IS 325.
5.5.2.3
Motor shall be totally enclosed surface cooled (TESC) type, with
IP - 67
protection class after mounting on actuator.
5.5.2.4
It shall be possible to separate the motor from the lubricant filled gearing of
actuator allowing easy replacement of motor without loosing any lubricant
regardless of mounting position.
5.5.2.5
Motor shall be of minimum class F insulation, with temperature rise

restricted to class B.
5.5.2.6
The motor shall withstand, without damage, stalled torque for at least three
times the duration of tripping device.
5.5.2.7
Motor shall be suitable for intermittent duty with following duty rating:
open/close duty actuators capable of 20starts/hour.
5.5.2.8
The operating mechanism shall provide quick, simple and effective

operation. The main switch shall close or open with about 20 (TWENTY)
revolutions of the crank. The earth switch shall close or open by rotation of
lever/handle through 90 degrees. The operating mechanism shall be such
that the main switch or earth switch, once operated, will remain stay-put in
closed or opened position till the next command (operation) is given by the
operating personnel. This feature is important to prevent inadvertent
1307 of 2461
PAGE 91 of 358
MMRDA
operation by gravity, wind, short circuit forces, seismic acceleration,

vibration, shock, accidental touching, etc.
5.6
Control Cabinet :
5.6.2 The control cabinet of operating mechanism shall be made out of stainless steel
of minimum thickness 2mm. Alternatively, mechanism box made of minimum
3mm thick aluminum plate or casting duly powder coated may be offered.
Control cabinet shall be provided with hinged doors having suitable gasket,
locking arrangement, etc. to achieve the desired ingress protection (IP-67)
rating. Sloping rain hood shall be provided to cover all sides. 15 mm thick
neoprene or better type of gaskets shall be provided to ensure degree of
protection of not less than IP-67 as per IS 2147. The cabinet shall be suitable
for fixing on MSETCLs standard support structure with adjustment for vertical,
horizontal and longitudinal alignment. Details of the arrangement proposed for
such adjustment as well as for sealing shall be furnished in the drawings.
5.6.3 The gear box enclosure should be made of Malleable Cast Iron (MCI) or Ductile
Cast Iron (DCI) so as to avoid any misalignment of gears. The disconnector
may be required to operate only occasionally, with considerably long idle
intervals. Special care shall therefore be taken for selection of material for gear
and lubrication of gears to meet this requirement. The gears shall be made of
aluminum, bronze or any other better material and lubricated for life with
graphite or better quality non-draining and non-hardening grease. Complete
details of components, material, grade, self lubricating arrangement, grade of
lubricants, details of jig, fixtures and devices used for quality check shall-be
furnished by the tenderer in his offer.
5.6.4
Padlocking arrangement:
The isolator and earthing switch shall be provided with padlocking arrangement
to permit locking of the isolator main switch and earthing switch in both fully
open and fully closed positions.
5.7
Gland plate and glands:
1308 of 2461
PAGE 92 of 358
MMRDA
A removable cable gland plate of 3mm thickness, duly powder coated tp

prevent rusting, with double compression type brass cable glands, shall be
provided with each operating mechanism for terminatin all the cables entering
form bottom.
5.8
Auxiliary switch:
5.8.1
The operating mechanism for main switch shall be equipped with eight nos.
each of NO and NC contacts and two numbers of MBB contacts for 132kV
isolators. Operating mechanism for earth switch shall be equipped with four
Nos. of NO and NC contacts. These auxiliary switches shall be extremely
reliable, and are exclusively for purchaser's interlocking and protection scheme.
The auxiliary switch shall be shaft mounted snap type. The purchaser shall use
these switches either directly or through contact multiplication relays for various
protection/interlock schemes.
5.8.2
The auxiliary switches and auxiliary circuits shall be capable of carrying a

current of atleast 10 Amps continuously. Auxiliary switches shall be capable of
breaking atleast 2A in a 220 V DC circuit with a time constant of not less than
20 milliseconds.
5.8.3
The main requirement of the Aux. contacts of the Isolator is that Aux. contacts
should close before the primary (Main) contact closes and open only after the
primary contact opens. The auxiliary switches shall be actuated by a cam or
similar arrangement directly mounted on the isolator shaft without any
intermediate levers, linkages etc. to ensure fool-proof operation.
5.9
Terminal block and wiring:
Each operating mechanism box shall be provided with 1100V grade stud type
terminal block. All auxiliary switches, interlocks and other terminals shall be
wired upto the terminal block. The terminal block shall have at least 20 percent
extra/spare terminals. All wiring shall be carried out with 1100V grade PVC
(Polyvinyl Chloride) insulated 2.5 Sq.mm copper conductor. Maximum
1309 of 2461
PAGE 93 of 358
MMRDA
conductor temperature shall be as per IS: 3961.
5.10 Interlocking:
Operation of isolator Main switch and earth switch is required to be interlocked

with associated switchgear/breaker and protection schemes of the purchaser so
that it will not be possible to operate the isolator and/or the earth switch when
the switchgear/ breaker is in closed position. Further, mechanical interlocking
between main switch and earth switch shall also be provided to ensure that the
earth switch can be closed only after the main blade is open and vice-versa. Any
modifications to scheme suggested by the purchaser on scrutiny of the offered
drawing shall be acceptable to the tender.
5.11 Limit Switch
Limit switches to cut off power supply to motor at each end of travel shall be
provided to prevent damage to the drive mechanism/ motor. This shall be reliable,
and independent for each end of travel. Ordinary auxiliary switch shall not be used
as limit switch. Details of make, rating and type of limit switch shall be furnished
in the offer/drawings.
5.12 Overload and Single Phasing Preventer
Suitable relay/device shall be provided to prevent over-loading of the motor.

Single phase preventer shall be provided to detect open circuiting of any phase
and trip off the motor under such condition. Complete details of the devices shall
be furnished in the offer/drawings.
5.13
Contactor
Contacts of the contactor shall be suitable for making and breaking stalled
motor current. The contactor coil shall be suitable for 220 V DC or 110V DC
suitable inter-locking D.C. relay to cut off A.C. supply to the motor in accordance
with the interlocking scheme shall also be provided. Two Nos. of contactors
shall be provided for each motor for OPEN and CLOSE operation respectively.
1310 of 2461
PAGE 94 of 358
MMRDA
Make, type, rating and other details of the contactor shall be furnished in the
offer.
5.14
Space heaters
Space heater suitable for 1 phase 240V A.C. supply shall be provided for each
mechanism box to prevent condensation. Suitably rated MCBs and control
switches also shall be provided for the heaters.
5.15
Interior (cubicle) illumination
A switch, HRC fuse and holder suitable for a 10W, 240V CFL lamp shall be
provided in mechanism box of isolators.
5.16
Power socket
A 15A, 240V AC rated power socket along with MCB/fuses and switch shall be
provided in the mechanism box.
5.17
Control and Auxiliary Supply
A 3 phase control switch along with HRC fuses for phases and link for neutral
shall be provided for motor power supply and a 2 way switch with HRC fuses
shall be provided for control supply in the motor operated mechanism.
Alternatively, suitably rated MCB may be provided in place of the switch and
HRC fuses for both functions.
6.0
Accessories:
The accessories to be provided on the isolator shall include but not be limited
to the following:
6.1
Position Indicator:
A mechanical position indicator to show whether the isolator is in ON or OFF

1311 of 2461
PAGE 95 of 358
MMRDA
position needs to be provided for each isolator.
6.2
Counter Balance Springs:
Counter balance springs, cushions etc. shall be provided to prevent impact at

the end of travel both on opening and closing of the isolator. The springs shall
be made of durable and non-rusting type alloy.
7.0
Name Plates
The disconnector shall be provided with a name plate of thickness 2 mm. The
nameplate shall be weather proof and corrosion-proof. It shall be mounted in
such a position that it shall be visible in the position of normal service and
installation. It shall carry the following information duly punched or engraved on
it.
7.1.1 Isolators base:

MSETCL:
Name of manufacturer
A/T No & Name of S/S or Project,
Type, Designation
Serial Number:
Rated voltage:
Rated normal current:
Rated short time current
M.S.
E.S
M.S.
E.S
(In kA rms and duration in sec)

Rated short time peak current (kA p):
Weight:
7.1.2 Operating Device:

MSETCL:
Name of manufacturer:
A/T No.:
Type Designation
Reduction gear ratio
1312 of 2461
PAGE 96 of 358
MMRDA
A. C. Motor.
i)
Rated auxiliary voltage
ii)
Starting current
iii)
Designation of AC motor as per IS: 4722:
iv)
Starting torque at 80'% of supply voltage.
v)
Over travel in degrees after cutting off supply
Total operating time in seconds

i)
CLOSE operation
Electrical
Manual
ii)
OPEN operation
Electrical
Manual
Space heater
Rated voltage and power
Auxiliary contacts
i)
Rated current (Amps)
ii)
Time constant (ms)
iii)
No. of contacts used (NC & NO)
iv)
No. of free contacts (NC & NO)
Terminal blocks & wiring

i)
Rated current
ii)
Voltage grade and type.
7.1.3 Interlocking device
7.2
i)
Type/ Make
ii)
Voltage
iii)
Wattage: Whether continuously rated?
iv)
Any other particulars
Auxiliary Power Supply:
7.2.1 Auxiliary electrical equipment shall be suitable for operation on the following
supply systems:
1313 of 2461
PAGE 97 of 358
MMRDA
AC control & protective devices,
240V, single phase 2 wire, 50Hz
lighting fixtures & space heaters
A.C. supply with one point

grounded.
DC alarm, control & protective
220V or 110V, 2 wire ungrounded
devices
DC supplies from station

batteries.
Motor driving mechanism
415V, 3-phase, 50Hz AC
7.2.2 Above supply voltages may vary as follows:
AC supply
: Voltage variation:
(+) or (-) 10%
Frequency variation: (+) or (-) 5%

Both variation may occur either simultaneously or independently
DC supply:
(-) 15% to (+) 10%
Each of the foregoing supplies will be made available by purchaser at one

terminal point for each isolator.
7.3
Signaling:
Signaling of the close position shall not take place unless the movable contact
has set in a position in which the rated normal current, the peak withstand
current and the short time withstand currant can be carried.
7.3.1 Signaling of open position shall not take place unless the movable contact has
reached the position such that the clearance between the contacts is at least
80% of the isolating distance
7.4
Earthing
Flexible copper connections shall be provided between rotating earth blades

and the frame. These flexible connections shall have adequate cross sectional
area and shall be tinned or suitably treated against corrosion.
The frame of each disconnector and earthing switch shall be provided with two
reliable earthing terminals and clamping screw suitable for carrying the
1314 of 2461
PAGE 98 of 358
MMRDA
specified short time current for connection to the purchasers earthing

conductor / flat. The diameter of clamping screw/ nut-bolt shall be at least 12
mm. The connecting point shall be marked with earth symbol.
7.5
Design and construction:
7.5.1 The manufacturer shall have experience of minimum five years in the design,
manufacture and supply of equipment similar to that offered. Full particulars of
design, manufacture, jigs, template and quality control devices developed for
manufacture of the equipments offered in respect of the following items shall
be furnished with drawings and descriptions alongwith the tender.
i)
Contacts, material, current density, etc.
ii)
Design of contact pressure
iii)
Contact support and fixing arrangement on Insulators,
iv)
Turn and twist mechanism, clamps, locks, etc.
v)
Bearings, housing of bearings, bushes, etc.
vi)
Balancing of heights
vii)
Coupling pipes, joints, connection adjustments
viii)
Base plates
ix)
Down pipe, guides joints.
x)
Brass bushes and bearings at various joints
xi)
Operating mechanism type, thickness of material of box, degree of

protection, glands, etc.
xii)
Nuts, bolts and fasteners
xiii)
Interlocking devices/arrangements
7.5.2 Offers without the above information or with incomplete information may be
rejected.
7.5.3 All live parts shall be designed to have smooth surfaces without any sharp
points, edges and other corona producing surfaces so as to eliminate corona
at specified extinction voltage.
7.6
Fasteners:
1315 of 2461
PAGE 99 of 358
MMRDA
Nuts, bolts and washers of size M16 and higher shall be hot dip galvanized.
The bolts used on tapped holes of insulator cap shall be galvanized by
centrifuge process to avoid excess deposition of zinc on threads. Nuts, bolts
and washers of less than M16 size shall be of stainless steel, when used on
live parts, and nickel plated brass in other parts.
7.7
Contacts:
Contacts shall be made out of hard drawn electrolytic grade copper. Arcing
contacts wherever provided shall close first and open last. The contact surface
shall be silver plated to 15 micron thickness. Fabrication shall be done with
suitable jig to avoid deviations during production. Details of size and shape of
contacts, spring, back plate, fixing arrangements, design of contact pressure,
life of contacts, limit of temperature rise etc. shall be furnished alongwith the
tender.
7.8
Terminal Pad
The Terminal pad shall be made out of electrolytic grade copper silver plated
to 15 micron thickness. Dimensions of the terminal pad shall be furnished in the
tender/drawing. Earth switch terminal pad shall also be made of electrolytic
grade copper.
7.9
Mounting of contacts:
Fixed contacts shall be mounted on a block or channel welded to 10 mm thick

M.S. plate with holes for fixing on the insulators. Slots shall be provided for
marginal adjustment of height of contacts. The contacts shall rest on a brass
block.
7.9.1
Main contacts:
The isolator shall have heavy-duty self-aligning and high-pressure contacts of

modern design. The contacts of the isolator shall be in the form of reverse loop
so that during passage of short circuit current they exert additional pressure on
1316 of 2461
PAGE 100 of 358
MMRDA
the moving contacts. The blades of the isolator shall be of rotating type at its
longitudinal axis by the turn and twist mechanism provided in the moving
contact assembly. The moving and fixed contact assemblies shall be so
designed as to ensure:
a) Electro dynamic forces withstand ability during short circuit without the risk
of dislodging of moving contact from the fixed contact.
b) Ability to withstand Thermal stress during short circuits.
c) Constant contact pressure even when the live parts of the insulator stacks
are ubjected to tensile stress due to liner expansion of connected bus bar
conductor, either because of temperature variation or strong winds.
d) Wiping and self-cleaning action during closing and opening of contacts.
e) Self- aligning of contacts, ensuring smooth closing of the isolator.
7.9.2
Earthing switch contacts:
1) The earthing switch shall be manually operated type.
2) The moving contact and blade shall be made of high-conductivity electrolytic

copper of adequate strength to withstand all thermal and bending stresses at
the time of short circuits. The bimetallic arrangement (moving blade of
aluminum /Cast iron and contact tip of copper) shall not be accepted.
3) The fixed contacts shall be identical to the main isolator fixed contacts except
for silver plating.
4) The earthing of the moving contact shall be effected by flexible copper braids
having adequate cross-section to safely carry the short circuit current specified.
5) The earthing switch for all poles of the isolator shall be mounted on the same
shaft and operated by a single and common operating handle, which shall be
1317 of 2461
PAGE 101 of 358
MMRDA
distinct and separate from that used for operating the main blade of isolator.
7.10
Moving Blades:
Moving blade shall be made of electrolytic grade copper. Contact surface of

moving blades shall be silver plated to 15 micron thickness. The design shall
be such that contact surfaces shall automatically be wiped during closing and
opening operations to remove any film, oxide coating, etc. Wiping action shall
not cause scouring or abrasion of surfaces. The moving contact pipe should be
supported with self-greased Teflon /Brass bushes at the rotating points for
smooth operations.
7.11
Turn and twist Mechanism:
Turn and twist mechanism shall be provided with suitable self-locking property
to avoid inadvertent opening or closing of contacts by wind, short circuit force,
etc. on moving blade. The contact holding springs shall be made out of stainless
steel or phosphor bronze or any other better material to have adequate strength
and resilience and shall be encased with grease to avoid exposure in rain. The
clamps and plates shall be made out of M.S. Plate or flat having at least 10mm
thickness. Fasteners with lock nuts shall be used wherever necessary.
Vulnerable parts shall be fabricated by tubular gas cutting or milling. The entire
mechanism shall be fabricated in suitable jig and template to avoid
deviations/errors during production. The Turn & twist assembly of moving
contact should be provided with sealed double ball bearing.
7.12
Bearings:
Rotating - insulator shall be mounted on housing with bearings. The housing

shall be made of gravity die cast Aluminum with smooth surfaces and suitably
machined for seating the bearings. Two no. of bearings with adequate shaft
diameter and distance between the bearings shall be provided to avoid
wobbling during operations. The bearings shall be of at least 75 mm internal
diameter for 145kV class rating and. The bearings shall be of reputed make
and lubricated for life. All other friction locations shall be provided with suitable
1318 of 2461
PAGE 102 of 358
MMRDA
bearings of stainless steel or brass bushes. The bearings, bushes, joints,

springs, etc. shall be so designed that no lubrication shall be required during
the service. Complete details of bearings, bushes, housing, greasing, etc. shall
be furnished with the tender/drawings.
7.13
Balancing of height:
Fixed insulators shall be provided with elevator base plate with four studs for
balancing of heights. Thickness of plate and diameter of stud shall be 10mm
and 25mm respectively for isolators of rated voltage of 145 kV and above.
Adequate numbers of nuts, lock nuts and washers shall be provided. Taper
washer shall be provided to match inclined surface of steel sections
7.14
Tandem Pipe:
Tandem pipes shall be of at least 32mm ID and class B for isolators of 145kV
class. Two nos of tandem pipes shall be used for phase coupling of double
break isolators. Base plate of insulators for connection of tandem pipe shall be
made out of one piece of M.S. Plate of at least 10mm thickness. Bolt and
shackle device shall be used to connect tandem pipe to the base plate.
Wherever unavoidable, sliding clamps may be used. These clamps shall be
made out of at least 10 mm thick M.S. Flat with four nos. of nuts and bolts. A
grub screw shall be provided for securing connection on tandem pipes.
7.15
Down Pipe:
50mm ID class B pipe shall be used for the operating rod of disconnects. The
pipe shall be terminated into a suitable swivel or universal type joint between
the insulator bottom bearing and the operating mechanism to take care of
marginal angular misalignment at site. All brackets, guides, etc. shall be
mounted on the base of the isolator. Arrangement of mounting any guide,
bracket, etc. on support structure, except the operating mechanism and the
base, shall not be accepted.
7.16
Base:
1319 of 2461
PAGE 103 of 358
MMRDA
Each phase of isolator shall be provided with a rigid base fabricated from steel
sections made out of hot rolled Steel.
Sr.
Voltage class
Size
145kV
Composite frame made up of 125x65mm channel
No
1
connected back-to-back.
Weight shall be as per latest IS
The base shall be suitable for mounting on the MSETCLs standard support
structures. Fabrication, welding, etc. shall be done by suitable jig, power press,
templates to avoid deviations during production.
7.17
Assembly:
The disconnector shall be fully assembled at the works of the manufacturer.

Typical operations shall be carried out on each type of fully assembled
disconnect to ascertain that all parts fit correctly and function satisfactorily.
7.18
Painting, galvanizing and climate proofing::
7.18.1 Interiors and exteriors of enclosures, cabinets and other metal parts shall be
thoroughly cleaned to remove all rust, scales, corrosion, grease and other
adhering foreign matter and the surfaces treated by seven tank phosphating
process. After such preparation of surfaces, two coats of zinc oxide primer shall
be applied and air dried before final painting. Colour of the final paint shall be
light grey as per shade no.631 of IS: 5. The final painted/powder coated cubicle
shall present an aesthetically pleasing appearance free from any dent or
uneven surface.
7.18.2 Paint inside the metallic housing shall be anti-condensation type and the
paint/powder coating
on outside surfaces shall be suitable for outdoor
installation. Epoxy Powder coating will be preferable over the conventional

enamel painting.
1320 of 2461
PAGE 104 of 358
MMRDA
7.18.3 All ferrous parts not suitable for painting, such as structural steel, pipes, rods,
levers, linkages, nuts and bolts used in other than current carrying path, etc.
shall be hot dip galvanized. Galvanization shall be done after completion of
fabrication. Thickness of zinc coating shall not be less than 610gm of zinc per
sq. meter of surface. Zinc coating shall be smooth, clean and of uniform
thickness and free from any defect. Preparation for galvanizing and the
galvanizing itself shall not adversely affect the mechanical properties of the
coated material. The quality shall be established by tests as per IS 2633.
Galvanizing of nuts and bolts shall be carried out by centrifugal or suitable other
process so that the bolts will easily fit into the tapped holes/nuts.
7.18.2 All components shall be given adequate treatment of climate proofing as per
IS: 3202 so as to withstand corrosion and severe adverse service conditions.
7.18.3 Complete details of painting, galvanizing and climate proofing of the

equipments shall be furnished in the tender/GTP.
7.18.4 Some Important features to be incorporated in the isolator are listed in

Annexure-D.
7.19
Proto assembly:
The manufacturer is required to offer a proto assembly of equipment
with its
support structure for inspection by the owners engineers, before taking up mass
production, for each type of isolator design. If the proto assembly confirming to
design/drawings is inspected in past by owners engineers and approved, then
bidder can take up mass production after obtaining necessary exemption from
the owner.
8.0 TESTS:
8.1 Type Tests:
i)
(Dry/Wet) Power frequency voltage withstand test
1321 of 2461
PAGE 105 of 358
8.1.1
MMRDA
ii)
Lightning impulse test
iii)
iv)
Short time current test for main switch
v)
Short time current test for earth switch
vi)
Mechanical endurance test
vii)
IP- 67 test
viii)
High voltage test on solid core post insulator
ix)
Additional/Special Tests Applicable/as specified.
The equipment/material offered in the Tender should have been successfully

type tested in any NABL (National Accreditation Board for Testing and
Calibration Laboratories) accredited test laboratory
in line with relevant
standards amended up to date and the Technical Specification, within the last
5(five)years as on the date of opening of the Tender. The bidder shall be
required to submit copies of the Type Test Reports alongwith the
offer/drawings. In case these type tests are conducted earlier than five years,
all the type tests shall be carried out by the successful bidders/manufacturer, in
the presence of purchasers representative, free of cost to the purchaser.
8.1.2
If there is any change in the components or design in the equipment since

after earlier passing of the Type Test, the bidder shall bring out in his offer all
such changes made in the components, materials, designs, etc. In such case
the bidder/manufacturer shall carryout the Type Tests at his cost and in the
presence of Purchaser's representative.
8.1.3
Even if the equipment/material has been Type Tested earlier, the Purchaser
reserves the right to demand repetition of one or more tests included in the list
of Type Tests, in the presence of Purchaser's representative without any cost
implication to MSETCL.
8.1.4
During the type test, the disconnector shall be mounted on own support
structure or on equivalent support structure and installed alongwith its own
operating mechanism to make the type test representative. Drawing of
equivalent support structure if any and mounting arrangements made for type
test shall be furnished for purchasers approval before conducting the type
1322 of 2461
PAGE 106 of 358
MMRDA
tests.
8.1.5
The type tests shall be conducted on the disconnector alongwith approved

insulators and terminal connectors.
8.1.6
Mechanical endurance test shall be conducted on the main switch as well as

earth switch on one disconnector of each type.
8.1.7
The purchaser/MSETCL reserves the right to conduct Type Tests included in

the list of Type Tests on requisite number of samples/ items from any of the lots
in the presence of purchasers representatives. If the equipment/material
doesnt withstand the Type Test then the equipment / material supplied till then
will be liable for rejection. These Type Tests shall however be conducted by the
supplier/manufacturer within a reasonable time. After successful passing of the
Type Tests, all the equipments/material supplied earlier shall be modified in line
with the equipment/materials which has successfully passed the Type Test.
Incase supplier fails to carryout the Type Tests within reasonable time or
doesn't agree to carryout the Type Tests at his cost, his equipment/material
supplied earlier shall be rejected and order placed shall be cancelled and
payments made earlier for these supplies shall be recovered by the
Purchaser/MSETCL.
8.2
Routine Tests /Acceptance Tests
i)
Visual and dimensions check
ii)
Voltage test on control & Auxiliary circuit

a) Operational test on motor operated mechanism box @85% of rated
operating voltage
b) Operational test on motor operated mechanism box @100% of rated
operating voltage
c) Operational test on motor operated mechanism box @110% of rated
operating voltage
d) Measurement of insulation resistance before dielectric test on control
and auxiliary circuits
e) Power frequency voltage(2kV) withstand test on control and auxiliary
1323 of 2461
PAGE 107 of 358
MMRDA
circuits
f) Measurement of insulation resistance after dielectric test on control
and auxiliary circuits
iii)
iv)
v)
Measurement of resistance of the main circuit (RYB Pole)

Mechanical operation test (Main & Earth Switch)
Uniformity of zinc coating by 4succesive dips of 1 minute in copper
sulphate solution (Prepared as per IS 2633)

vi)
Measurement of mass of zinc coating(90 microns minimum)
vii)
Additional/Special Tests Applicable/specified.

a) RIV test
8.2.1 All acceptance and routine tests as stipulated in the relevant standards shall be
carried out by the supplier in presence of purchaser's representative during predispatch inspection.
8.2.2 Mechanical operation test (routine test) shall be conducted on the complete
disconnector (Main switch and Earth switch) at manufacturer works in presence
of MSETCLs representative.
8.2.3 The test report of power frequency voltage withstand test conducted on the
insulator shall be furnished for purchasers acceptance in lieu of conducting the
power frequency (dry) test on main circuit (routine test).
8.3
Immediately after finalization of the programme of type/acceptance/routine

testing, the supplier/manufacturer shall give three weeks' advance intimation to
the MSETCL, to depute their representative for witnessing the tests.
8.4
Special Tests:
Special tests listed in Annexure IV shall be carried out in presence of

purchasers representative, free of cost to the purchaser.
1) RIV Test
8.5
Test certificates and documents of the following items shall be submitted for
1324 of 2461
PAGE 108 of 358
MMRDA
verification at the time of routine tests/acceptance tests.

a.
Chemical analysis of copper, alongwith a copy of central excise

certificate/gate pass indicating genuine source or procurement of
electrolytic grade copper.
b.
Bearings
c.
Fasteners
d.
Universal / Swivel joint coupling
e.
Insulators
f.
Gears
g.
Auxiliary Switch
h.
Interlocking Devices
i.
Terminal block
The purchaser/MSETCL may, at his discretion, request additional test certificates for
other items as reasonably required to substantiate the Quality of the same.
9.0
INSPECTION:
The inspection may be carried out by MSETCL at any stage of manufacture.

The successful Tenderer shall grant free access to the purchaser's
representative at a reasonable time when the work is in progress. Inspection
and acceptance of any equipment under this specification by the purchaser
shall not relieve the supplier of his obligation of furnishing equipment in
accordance with the specification and shall not prevent subsequent rejection if
the equipment is found to be defective. The supplier shall keep the purchaser
informed in advance about the manufacturing programme so that arrangement
can be made for inspection. The purchaser/MSETCL reserves the right to insist
for witnessing acceptance/routine testing of the bought out items.
10.0
QUALITY ASSURANCE PLAN:
10.1 The tenderer shall invariably furnish the following information alongwith his offer,
failing which, his offer shall be liable for rejection. Information shall be
separately given for each type of disconnector.
1325 of 2461
PAGE 109 of 358
i.
MMRDA
Statement giving list of important raw materials, including but not limited
to:
a)
Copper
b)
Steel
c)
Springs
d)
Bearings
e)
Nuts & Bolts
f)
Grease
g)
Operating mechanism and its components such gear, aux. switch,

terminal block, interlocks, etc.
ii.
Names of sub suppliers for the raw materials, list of standards according
to which the raw materials are tested, list of tests normally carried out on
raw
materials
in
the
presence
of
tenderer's/manufacturers
representative, copies of test certificates, etc.

iii.
Information and copies of test certificates as in (i) above in respect of

bought out accessories.
iv.
List of manufacturing facilities available.
v.
Level of automation achieved and list of areas where manual processing

still exists.
vi.
List of areas in manufacturing process, where stage in inspections are

normally carried out for quality control and details of such tests and
inspections.
vii.
Special features provided in the equipment to make it maintenance free.
viii.
List of testing equipments available with the tenderer/manufacturer for

final testing of equipment and test plant limitation, if any, vis-a-vis the
type, special, acceptance and routine tests specified in the relevant
standards.
10.2
The successful tenderer/ manufacturer shall, within 30 days of placement order,

submit following information to the purchaser/MSETCL:
i. List of raw materials as well as bought out accessories and the name of subsuppliers selected from the list furnished along with offer.
ii. Type test certificates of the raw material and bought out accessories.
1326 of 2461
PAGE 110 of 358
MMRDA
iii. Quality assurance plan (QAP) with hold points for purchaser's/MSETCLs
inspection. The Quality assurance plan and purchaser's hold points shall be
discussed between the purchaser and supplier before the QAP is finalized.
10.3
The successful tenderer shall submit the routine test certificates of
bought
out accessories at the time of routine/acceptance testing of the fully assembled

disconnector. The Indian bidder shall also submit copies of central excise gate
passes for the raw materials.
12.0
PERFORMANCE GUARNATEE:
The equipment offered shall be guaranteed for satisfactory performance for a

period of 60 months from the date of receipt of complete equipment at
destination store /site in good condition or 54 months from the date of
satisfactory commissioning of equipment, whichever is earlier. The equipments
found defective/failed within the above guarantee period shall be replaced
/repaired by the supplier free of cost within one month of receipt of intimation.
If the defective /failed equipments are not replaced/ repaired as per the above
guarantee clause, the Purchaser/MSETCL shall recover an equivalent amount
plus 15% supervision charges from any of the bills of the supplier.
12
DOCUMENTATION:
12.1
All drawings shall conform to International Standards Organization (ISO) 'A'

series of drawing sheet / Indian Standards specification IS: 656. All drawings
shall be in AUTOCAD and all dimensions and data shall be in Metric System of
units.
12.2
List of drawings and documents:

The tenderer shall furnish four sets of the following drawings alongwith his offer:
a.
General outline and assembly drawings of the disconnector, operating

mechanism & insulator.
b.
Sectional views and descriptive details of items such as moving

blades,contacts, arms, contact pressure, contact support, turn and twist
1327 of 2461
PAGE 111 of 358
MMRDA
mechanism, bearing, housing of bearings, bushes, balancing of heights,

phase coupling pipes, base plate, operating shaft, guides, swivel joint,
Operating mechanism and its components, etc.
c.
Loading diagram
d.
Drawings with structure for the purpose of type tests.
e.
Name plate.
f.
Schematic drawing
g.
Type test reports in case the equipment has already been type tested.
h.
Test reports, literature, pamphlets of the bought out items, and raw
material.
12.3
The successful tenderer/ manufacturer shall, within four weeks of placement of

order, submit three sets of final versions of all the above said drawings for
purchaser's/MSETCLs approval. The purchaser shall communicate his
comments/approval on the drawings to the supplier within two weeks of receipt
of the documents. The supplier shall, if necessary, modify the drawings and
resubmit three copies of the modified drawings for purchaser's approval within
two weeks from the date of purchaser's comments. After receipt of purchaser's
approval, the supplier shall, within three weeks, submit required prints of all
relevant and final drawings and a soft copy of the same for purchaser's use.
12.4
One set of the type test reports, duly accepted by MSETCL, shall be submitted
by the supplier for distribution, before commencement of supply. Adequate
copies of acceptance and routine test certificates, duly approved by the
purchaser/MSETCL, shall accompany the dispatched consignment.
12.5
The manufacturing of the equipment shall be strictly in accordance with the

approved drawings and no deviation shall be permitted without the written
approval of the Purchaser. All manufacturing and fabrication work in connection
with the equipments prior to the approval of the drawing shall be at the
suppliers/manufacturer risk.
12.6
Approval of drawings/work by the purchaser shall not relieve the supplier of his
responsibility and liability for ensuring correctness & completeness of the
drawings and inferring the correct interpretation of the latest revision of
1328 of 2461
PAGE 112 of 358
MMRDA
applicable standards, rules and code of practice.
12.7
INSTRUCTION MANUAL
Ten copies of the instruction manual describing method of erection, operation

and maintenance procedures in English shall be supplied for each type of the
disconnector prior to dispatch of the equipment. The manuals shall be duly
bound and shall contain all drawings and information required for erection,
operation and maintenance of the disconnector, including but not limited to the
following particulars:
a.
Overall GA drawing identifying the components/ parts of the

disconnector as shipped, along with assembly drawings.
b.
Detailed dimensions and description of all auxiliaries.
c.
Detailed views of the insulator stacks, metallics, operating

mechanism, structure, interlocks, spare parts, etc.
13
13.0
PACKING AND FORWARDING:
The equipment shall be packed in crates suitable for vertical/horizontal

transport, as the case may be, and suitable to withstand handling during
transport and outdoor storage during transit. The supplier shall be responsible
for any damage to the equipment during transit, due to improper and
inadequate packing. The easily damageable material shall be carefully packed
and marked with the appropriate caution symbols. Wherever necessary, proper
arrangement for lifting, such as lifting hooks etc. shall be provided. Any material
found short inside the packing cases shall be supplied by supplier without any
extra cost to the purchaser/MSETCL.
13.1
Each consignment shall be accompanied by a detailed packing list containing

the following information:
a)
Name of the consignee.
b)
Details of consignment.
1329 of 2461
PAGE 113 of 358
13.2
MMRDA
c)
Destination.
d)
Total weight of consignment.
e)
Sign showing upper/lower side of the crate.
f)
Handling and unpacking instructions.
g)
Bill of Quantity indicating contents of each package.
The supplier shall ensure that the packing list and Bill of Quantity are approved
by the purchaser before dispatch.
14
SUPERVISORY ERECTION AND COMMISSIONING
14.1 The purchaser/ MSETCL may call for the services of one foreman (erector) of the
supplier, who is trained in the suppliers/manufacturers works for supervision
of erection and commissioning of the disconnectors. The erector shall direct the
sequence of erection. The erector shall correct in the field, any errors or
omissions on the part of the tenderer/supplier, in order to make the equipment
and material properly perform in accordance with the intent of this specification.
The erector shall also instruct/advise the plant operators on the operation and
maintenance of the commissioned equipment. The erector shall be responsible
for any damage to the equipment, on commissioning the same, if such damage
results from faulty or improper erection. Apart from the above, the
purchaser/MSETCL shall not be responsible for any other expenses such as
Erector's salary, insurance against personal injuries to the Erector etc. Special
tools, if required for erection and commissioning, shall be arranged by the
manufacturer at his cost.
15.0
DISQUALIFICATION CRITERION
15.1
The bidder/manufacturer is liable for disqualification on account of any of the

following reasons:
a)
Poor quality and workmanship of the products previously supplied and

frequent failures during warranty period as experienced by the
purchaser.
1330 of 2461
PAGE 114 of 358
MMRDA
b)
Bidder against whom litigation is in progress.
c)
Bidder, who in the opinion of the purchaser, has mala fide intentions in
the conduct of business with the company (MSETCL).
d)
Bidder who is declared to be defaulter as per the terms and conditions

laid by the company.
Not withstanding anything stated above, the purchasers decision in this regard
15.9
will be final.
16
Support structure:
16.1
The support structure for the isolators shall be as per MSETCL standard
drawings.
16.2
The structure should have suitable mounting arrangement for base
channel
and provision of foundation bolts of the structure should be in-line with relevant
indicative structural drawings enclosed for isolators of different voltage class.
PRINCIPAL TECHNICAL PARTICULARS OF 145KV CLASS ISOLATORS
S.No
Technical Parameter
Requirement
1.
Rated voltage (kV rms)
145 KV
2.
Rated Freq. (Hz)
--------- 50 ----------
3.
System Neutral Earthing
---- Effectively earthed ----
4.
No. of phases (Poles)
------------ 3 ------------
5.
Temperature rise
-- As per relevant IS / IEC Publication ---
6.
Safe duration of overload

a. 150% of rated
current
---- 5 minutes ------- 30 minutes ----
b. 120% of rated
current
7.
Type of disconnect (AB)
Double Break Centre post Rotating (DBCR)
1331 of 2461
PAGE 115 of 358
S.No
8.
9.
MMRDA
Technical Parameter
Requirement
Rated normal current (Amps)

WEB
a) 1250
WOEB
a) 1250
b) 2000
40 (kA rms)
withstand capacity of MB and

EB for 3 seconds.
10.
Rated Peak current (kA peak)
100
of MB and EB
11.
Rated short circuit (kA peak)
100
making current of E.B.

12.
Special requirements
a) Earthing
blades
shall
be
capable
to
discharge the trapped charge of the line.

b) Isolator Main switch shall be required to
make or break line charging current when no
significant change in voltage occurs across
the isolating distance on account of make or
break.
13.
Basic insulation level

A) Lightning impulse
withstand voltage: (kV
peak)
650
a)To earth
700
b)Across isolating distance
B) Rated power frequency

withstand voltage (kV
rms)
275
315
a) To earth
b) Across isolating
distance
14.
15.
Minimum Creepage distance
3625 (mm)
Rated Mech. Term load
1332 of 2461
PAGE 116 of 358
S.No
16.
MMRDA
Technical Parameter
Requirement
i) Straight load
(kg.)
51
ii) Across load
(kg.)
17.33
Rated Magnetizing current
0.7
(Amp.) / capacitive current

make and break
17.
Phase to phase spacing (mm)
3000
for installation
18.
19.
Minimum Clearances (mm)

a) Phase to earth
1270
b) Phase to phase
1430
Height of lowest live point

above ground level (mm)
20.
4600
Derating factor for specified
site condition
21.
OPERATING MECHANISM
Motor Operated
Motor details:
Make
22.
Operating voltage, type &
415V AC, 50Hz, Squirrel cage Induction Motor,
rated power & Starter
0.5HP, DOL starter
Class of insulation
Class F
Temperature rise
Restricted to class B
OPERATING MECHANISM
BOX (Main Switch)
Cubicle sheet/gauge thickness
1) Stainless steel sheet of 2 mm thickness

2) Aluminum plate/casting of 3mm thickness
Rain hood Material details
(Same material as that of operating

mechanism box)
Ingress Protection class

23.
IP 67
Auxiliary switch details

Make
No. of contacts
8 NO + 8 NC + 2 MBB contacts
1333 of 2461
PAGE 117 of 358
S.No
MMRDA
Technical Parameter
Requirement
Capacity
10A cont.
DC breaking capacity & time
2A, 20 milliseconds
constant
24.
OPERATING MECHANISM
Manual operated
BOX (Earth Switch)

Cubicle sheet/gauge thickness

Rain hood Material details
(Same material as that of operating mechanism

box)
25.
Ingress Protection class
IP 67
Metal & Cross section Area of
For 2000Amp >1000 sq. mm of copper tube
moving Blade/contacts(Main
For 1250Amp > 625 sq. mm of copper tube
Switch)
26.
27.
Metal & cross section Area of
Copper tube minimum 50% of cross sectional
moving Blade (Earth Switch)
area of moving blade of main switch
Minimum no of operations the
1000
isolator should make without

deterioration of contact
28.
Insulator base plate material
HDG MS plate 10 mm thick
details
NOTES:
DBCR Double Break Centre pole Rotating isolator

AB
Air Break
MS Mild Steel
MB
EB
Main Blade
Earth Blade
HDG Hot Dip Galvanized

MBB Make Before Break
1334 of 2461
PAGE 118 of 358
MMRDA
1335 of 2461
PAGE 119 of 358
MMRDA
IMPORTANT POINTS TO BE INCORPORATED IN ALL ISOLATORS
1.
The Turn & Twist assembly of moving contact should be provided with
sealed double ball - bearing.
2.
The moving contact pipe should be supported with self - greased, Teflon / Brass
bushes, at the rotating points, for smooth operation.
3.
The gear box enclosure should be made of Malleable cast iron (MCI) or
Ductile cast iron (DCI); and not of sheet steel so that misalignment of gears
does not take place.
4.
Design and Weight of supporting structure should be as per MSETCLs

standardized drawings attached and shall be procured from approved vendor
for structures only.
5.
All functional / moving parts should be provided with brass bushes.
6.
Bearing assembly should be provided / designed with same separation

between the bearings; the assembly should be totally packed/sealed.
7.
The operating mechanism box should be of Stainless steel sheet of thickness

not less than 2 mm or aluminum sheet /casting not less than 3 mm thick with
ingress protection of IP-67.
TECHNICAL SPECIFICATION FOR INSTRUMENT TRANSFORMERS
1.0
SCOPE:
1.1
This specification covers design, manufacture, assembly, testing at

manufacturers works, packing and delivery of outdoor instrument transformers
for protection services in 132kV Sub-stations in Maharashtra State (India)
1336 of 2461
PAGE 120 of 358
MMRDA
1.2 It is not the intent to specify completely herein all details of the design and
construction of equipments.However, the equipment shall conform in all
respects to high standards of engineering, design and workmanship mentioned
in clause 4.0 and shall be capable of
performing continuous commercial
operation up to the intended life of 25 years in a manner acceptable to the

MSETCL, who will interpret the meanings of drawings and specification and
shall have the power to reject any work or material which, in his judgment, is
not in accordance therewith.
1.3
The equipments offered shall be complete with all components necessary for
their effective and trouble free operation. Such components shall be deemed to
be within the scope of Manufacturer's supply irrespective of whether those are
specifically brought out in this specification and/or the commercial order or not.
2.0
SCHEDULE OF REQUIREMENT:
2.1
The requirement of instrument transformers to be supplied against this

specification shall be as per tender /specified hereunder.
3.0
SERVICE CONDITIONS:
3.1

satisfactory continuous operation under the following tropical conditions.
3.1.1
Maximum ambient temperature in open air 50.00

(C):
3.1.2
Maximum ambient temperature in shade (C)
45.00
3.1.3
Minimum temperature in shade(C):
3.50
3.1.4
Relative humidity (%)
10 to 100
3.1.5
Maximum annual rainfall (mm)
1450
3.1.6
3.1.7
Maximum altitude above mean sea level 1000
(Kg/m2) 150
(Meter)
1337 of 2461
PAGE 121 of 358
MMRDA
3.1.8
Isokeraunic level
(days/year) 50
3.1.9
3.1.10 General nature of climate :
0.3 g.
Moderately hot
and humid
tropical climate, conducive to

rust and fungus growth.
4.0
STANDARDS:
4.1
Unless otherwise specified elsewhere in this specification, the
rating, performance and
testing of the instrument transformers and accessories shall conform to the latest revisions
of relevant IEC,IS available at the time of placement of order/LOA.
4.2
Equipments meeting with the stipulations of equivalent IEC, ANSI, CSA which ensure
equal or better quality than the standards listed below shall also be acceptable. In such
case the manufacturer should submit two copies of such standards, in authentic English
translation, if the language of the standard is other than English. In case of dispute, the
stipulations in the English translation, submitted by the bidder, shall prevail. Further, in the
event of conflict between the stipulations of the standard adopted by the bidder and the
corresponding Indian Standard specification, the stipulation of Indian Standard
specification shall prevail, however the MSETCL decision will be final and shall be binding
on bidder/manufacturer.
CURRENT TRANSFORMERS
LIST OF STANDARDS
Sr.No.
1
Standard No.
IS-2165
Title
Insulation
co-ordination
of
highest
voltages
for
equipments .
2
IS-2705(I-IV)
Current Transformers
IS-2099
High voltage porcelain bushing.
IS-3347
Dimensions of porcelain transformer bushing.
IS-2071
Method of high voltage testing.
IS-335
Insulation oil for transformers and switchgears.
IS-2147
Degree of protection provided by enclosures for low
1338 of 2461
PAGE 122 of 358
Sr.No.
MMRDA
Standard No.
Title
voltages, switchgear and control.
IEC-185
Current transformers.
IEC-270
Partial discharge measurement.
10
IEC-44(4)
Instrument transformer measurement of PDs.
11
IEC-171
Insulation co-ordination.
12
IEC-60
High voltage test techniques.
13
IEC-8263
Method of RIV tests on high voltage insulators.
14
IEC-60044-1-2003
International standard for instrument transformers
IEC-60044-2
15
IEC-61869-1,2
International standard for instrument transformers
16
IS-11322
Partial Discharge Test
17
18
Indian Electricity Rules, 1956.

IEC-815
Porcelain housing for instrument transformers.
POTENTIAL TRANSFORMERS LIST OF STANDARDS
Sr.No. Standard
Reference
Title
No.
1
IS 3156
Voltage transformers
IS-2099
High voltage porcelain bushings.
IS-3347
Dimensions of porcelain transformer bushing.
IS-335
Insulating oil for transformers and switchgears.
IS-3202
Code
of
practice
for
climate
proofing
of
elect.equipments.
6
IS-2147
Degree of protection provided by enclosures for low

voltage switchgears and controls.
5.0
IEC-186
Voltage transformers.
IEC-815
Porcelain housing for instrument transformers.
IEC-60044-2
International standard for Potential Transformers
PRINCIPAL TECHNICAL PARAMETERS:
The Current transformers and voltage transformers covered in this specification shall meet
1339 of 2461
PAGE 123 of 358
MMRDA
the technical requirements specified in Guaranteed Technical Particulars. (GTP)
6.0
GENERAL TECHNICAL REQUIREMENTS:(COMMON FOR ALL INSTRUMENT

TRANSFORMERS)
6.1.1
The Instrument Transformers shall be of outdoor type, single phase, 50 Hz, self cooled and
suitable for the services indicated and for operation in the climatic conditions specified
without protection from sun, rain and dust. The Instrument Transformer shall be complete
in all respects and shall conform to the modern practice of design and manufacture. The
insulation of the instrument transformers shall be so designed that the internal insulation
shall have higher electrical withstand capability than the external insulation. The designed
dielectric withstand values of external and internal insulations shall be clearly brought out
in the Guaranteed technical particulars (GTP) for instrument transformers. The dielectric
withstand values specified in this specification are meant for fully assembled instrument
transformer.
6.1.2
BUSHING INSULATOR (PORCELAIN/SILICON COMPOSIT INSULATOR):
6.1.2.1. The Instrument Transformers shall be porcelain-clad and oil filled units suitable for outdoor
Installation. The porcelain housing shall be of a single-piece construction for 145 kV .The
housing shall be made of vitreous porcelain of high mechanical and dielectric strength.
Glazing of the porcelain shall be of uniform brown or dark brown color with smooth surface
6.1.2.2 The porcelain hollow insulator used for the instrument transformer shall be homogenous,
free from lamination cavities and other flaws or imperfection that might affect the
mechanical or dielectric qualities. The hollow insulator shall conform to the latest edition
of IS: 5621. The puncture strengths of the hollow insulator shall be entirely free from
external and internal corona. Unless specified, the total creepage distance of the hollow
insulator shall be suitable for heavily polluted atmosphere (25mm/kV).The hollow insulator
shall have ample insulation, mechanical strength and rigidity for the conditions under with
they will be used and shall be designed to prevent accumulation of explosive gases and
provide adequate oil circulation to remove internal heat. There shall be no undue stressing
of any part of the bushings due to temperature changes and adequate means shall be
provided to accommodate conductor expansion.
1340 of 2461
PAGE 124 of 358
MMRDA
The hollow insulator shall be so designed that when operating at highest system voltage
6.1.2.3 specified, there will be no electric discharge between the conductors and hollow insulator.
No corrosion or injury shall be causing to conductor insulation or supports by the formation
of substances produced by chemical action. The insulation of hollow insulator shall be
coordinated with that of the instrument transformer such that the flashover, if any, will
occur only externally to the Instrument Transformer. The hollow insulator shall not cause
radio interference when operated at rated voltage. The specification of the bushing shall
be stated in the drawings.
6.1.2.4
Bidders may also offer Silicon Composite Insulators of proven design as against the
porcelain insulator. Instead of the porcelain-clad oil filled design, SF6 gas filled instrument
transformers are acceptable provided the same meets the other technical requirements
of the specification.
6.1.2.5
Details of attachment of metallic flanges to the porcelain for pressure release valve,
primary / secondary terminals shall be clearly indicated in the drawing
6.1.3
6.1.3.1
METAL TANKS:
The metal tanks shall have only the bare minimum number of welded joints so as to
minimize the possible locations of oil leakage. The metal tank shall be made out of Mild
steel. Thickness of metal tank shall be more than 3.00mm. The tanks shall be coated with
at least two coats of zinc rich epoxy painting/ hot dipped and galvanized tanks. All the
ferrous hardware exposed to atmosphere shall be hot-dip galvanized. All the fixing nuts,
bolts, washers, etc. used in the live parts shall be of
6.1.4
6.1.4.1
stainless steel.
PREVENTION OF OIL LEAKAGES & ENTRY OF MOISTURE
As specified elsewhere in this specification, the instrument transformer shall be

guaranteed for a trouble free and maintenance - free performance for a period as
specified. Therefore, the bidder/manufacturer shall ensure that the sealing of instrument
transformer is properly achieved. In this connection the arrangement provided by the
bidder/manufacturer at various locations including the following ones shall be described,
1341 of 2461
PAGE 125 of 358
MMRDA
supported by sectional drawings.
i) Locations of emergence of primary and secondary terminals

ii) Interface between porcelain housing and metal tanks
iii) Cover of the secondary terminal box.
6.1.4.2
Nuts and bolts or screws used for fixation of the interfacing porcelain bushings for taking
out terminals shall be provided on flanges cemented to the bushings and not on the
porcelain.
6.1.4.3
For gasket joints, wherever used nitrite butyl rubber or better gaskets shall be used. The
gasket shall be fitted in properly machined groove with adequate space for
accommodating the gasket under compression.
6.1.5
INSULATING OIL:
Insulating oil required for first filling of the instrument transformer shall be covered in
bidder's/manufacturers scope of supply. The oil shall meet the requirements of latest
edition of IS 335/IEC Publication No. 296
6.1.6
OIL LEVEL COMPENSATION:

Instrument transformer shall be hermetically sealed to prevent climatic breathing
and entering air & moisture in the tank. For compensation of variation in volume of the
oil due to temperature variation, nitrogen cushion or Stainless Steel bellows shall be used.
Rubber diaphragms are not permitted for this purpose. All parts of bellows shall be of
stainless steel only.
6.1.6.1
OIL LEVEL INDICATOR:
Instrument transformer provided with nitrogen cushion for Compensation of oil volume
variation shall be provided with prismatic type oil sight window at suitable location so
that the oil level is clearly visible with naked eye to an observer standing at ground level.
6.1.6.2
EARTHING:
1342 of 2461
PAGE 126 of 358
MMRDA
Metal tank of the instrument transformer shall be provided with two separate earthing
terminals for bolted connection to 50 x 8 mm GI flat to be provided by the MSETCL, for
connection to station earth-mat. The size of two numbers of earthing terminals shall be
16mm dia x 30mm length, HDG, with one plain washer and one nut. The connection points
shall be marked with the "earth" symbol no.86 of IEC publications 117-1 part I.
6.1.6.3
LIFTING ARRENGEMENT:
Instrument transformers shall be provided with suitable lifting arrangement, to lift the
entire unit. The lifting arrangement (lifting eye) shall be positioned in such a way as to
avoid any damage to the porcelain housing, primary terminals or the tanks during the
process of lifting for installation/transport. The general arrangement drawing shall show
clearly the lifting arrangements provided such as lifting eye, lug, guides etc.
6.1.6.4
NAME PLATE:
The instrument transformer shall be provided with non-corrosive, legible nameplates,

with the information specified in relevant standards (IS 2705, IEC 60044-1, IS3156 Part
I to IV, IEC 60044-2, IEC 60044-4) duly engraved/punched on it. Minimum thickness
1.5mm.
6.1.6.5
MOUNTING:
Mounting details for fixing the instrument transformer on MSETCLs supporting
structure shall be strictly in accordance with the mounting details shown in enclosed
sketch Nos. 252.137.01, 252.136.01 for Current Transformers and 252.147.01,
252.146.01 for Potential Transformers.
6.1.6.6
TERMINAL CONNECTORS:
The terminal connectors required for connection of the instrument transformer to

MSETCLs bus bar shall be arranged by the MSETCL.
1343 of 2461
PAGE 127 of 358
6.1.6.7
MMRDA
TEST TAP FOR MEASUREMENT OF CAPACITANCE AND TAN DELTA:
The current and voltage transformers of rating 145kV class and above shall be provided
with suitable test tap for measurement of capacitance, tan delta as well as partial
discharges, in factory as well as at site. Provision shall be made of a screw on cap for
solid and secure earthing of the test tap connection, when not in use. A suitable caution
plate shall be provided, duly fixed on the cover of the secondary terminal box, indicating
the purpose of the test tap and necessity of its solid earthing as per prescribed method
before energizing the CT/PT
7.0.0
INSPECTION :
7.0.1
The inspection may be carried out by the MSETCLs representative at any stage of
manufacture. The successful bidder/manufacturer shall arrange and grant free access
to the MSETCL's representative at any reasonable time when the work is in progress.
All facilities must be made available by bidder/ manufactures for unrestricted inspection
of the works, raw material, and manufacture of all the accessories and for conducting
necessary tests as declared herein.
7.0.2
The Manufacturer shall keep the MSETCL informed, in advance, of the time of starting
and of the progress of manufacture of equipment in its various stages and the
arrangement should be made for inspection.
7.0.3
The inspection will be carried out at the manufacturers works by MSETCL

representative and shall be as per the details given in inspection format.(Annexure C)
6.1.6.7
TEST TAP FOR MEASUREMENT OF CAPACITANCE AND TAN DELTA:
The current and voltage transformers of rating 145kV class and above shall be provided
with suitable test tap for measurement of capacitance, tan delta as well as partial
discharges, in factory as well as at site. Provision shall be made of a screw on cap for
solid and secure earthing of the test tap connection, when not in use. A suitable caution
plate shall be provided, duly fixed on the cover of the secondary terminal box, indicating
the purpose of the test tap and necessity of its solid earthing as per prescribed method
1344 of 2461
PAGE 128 of 358
MMRDA
before energizing the CT/PT
7.1.0
RAW MATERIAL INSPECTION
7.1.1
Inspection of raw material shall be done by MSETCL inspector and raw material test
reports shall be made available at the time of inspection and shall be attached with
routine/acceptance tests cum dispatch clearance.
7.1.2
Provision shall be made by the manufacturer for some of the essential tests for bought
out items at its works
7.2.0
STAGE INSPECTION
7.2.1
Stage inspection shall be carried out by MSETCL representative for

i)
Verification of winding process
ii)
Ovening and tanking process random sample
iii)
Verification of primary and secondary winding details
iv)
7.2.2
FINAL TESTING
Final tests (Routine/Acceptance) as per Annexure A / (c) & Annexure B / (c) shall be
conducted by the manufacturer and witnessed by MSETCL representative.
7.3.0
ROUTINE/ACCEPTANCE TESTS (REF. ANNEXURE_A)
7.3.1
Routine/Acceptance tests shall be conducted at manufacturers works. The

manufacturers testing lab shall have NABL accreditation. All the equipments used for
testing should have valid calibration on the date of testing.
7.3.2
All acceptance and routine tests as stipulated in the relevant standards shall be carried
out by the Manufacturer in presence of MSETCL's representative.
7.3.3
Tan delta value of instrument transformers at factory/works should be less than 0.5%
at rated voltage which
would be taken as reference value. If tan delta value of
1345 of 2461
PAGE 129 of 358
MMRDA
instrument transformers while in service exceeds the prescribed limit of 0.7% within
guarantee period, it will be considered as failure within guarantee period( Tan delta &
capacitance test of instrument transformers shall be measured at 10KV at site) and
shall be replaced free of cost by bidder/manufacturer
7.4.0
DISPATCH OF MATERIAL
7.4.1
No material shall be dispatched from its point of manufacture unless the material has
been satisfactorily inspected and tested.
7.4.2
Inspection and acceptance of any equipments under this specification by the

MSETCL shall not relieve the Manufacturer of his obligation of furnishing equipment in
accordance with the specification and shall not prevent subsequent rejection, if the
8.0.0
QUALITY ASSURANCE PLAN
8.0.1
The manufacturer/bidder shall invariably furnish the following information along with his
offer, failing which his offer shall be liable for rejection. Information shall be separately
given for each type of instrument transformer.
Statement giving list of important raw materials, including but not limited to :
S.N.
Item
Name of
List of
List of tests on
Details of test
Manufacturer
tests and
the raw materials
certificates as per
standards
which are
relevant IS/IEC,
according witnessed/verified
to which
by manufacturer
test report and

date
the raw
materials
are
tested
a.
Conductor
1346 of 2461
PAGE 130 of 358
b.
Insulation
c.
Core
d.
Porcelain
MMRDA
housing
e.
Insulating Oil
f.
Sealing
material
g.
Insulated
wire
ii
List of manufacturing facilities available. In this list the bidder shall specifically mention
whether lapping machine, vacuum drying plant, air conditioned dust free room with
positive air pressure for provision of insulation, oil leakage testing facility, facility for testing
tan delta of insulation at rated voltage etc. are available.
iii
Level of automation achieved and list of areas where manual processing still exists.
iv
List of areas in manufacturing process, where stage inspections are normally carried out
for quality control and details of such tests and inspections.
List of testing equipments available with the manufacturer for final testing of instrument
transformer and test plant limitation, if any, vis-a-vis type test and the routine tests
specified in the relevant standards.
vi
Manufacturer shall submit:

a)The routine test certificates of bought out accessories & Raw material at the time of final
acceptance testing of the fully assembled instrument transformer.
b)Details of vacuum drying & oil impregnation to the offered lot of instrument transformers
shall be submitted at the time of final acceptance testing.
c)The manufacturer shall also submit copies of central excise gate passes for raw material
viz.Oil, Copper, Aluminum, Insulating material, Core material etc.
9.0.0
PERFORMANCE GUARANTEE
The equipment offered shall be guaranteed for satisfactory performance for a period of
60 months from the date of receipt of complete equipment at site in good condition or 54
months from the date of satisfactory commissioning whichever is earlier. The equipments
1347 of 2461
PAGE 131 of 358
MMRDA
found defective/failed within the above guarantee period shall be replaced/re-paired by

the Manufacturer free of cost within one month of receipt of intimation. Transportation of
failed /defective instrument transformer to the manufacturers works shall be arranged by
bidder/manufacturer & the cost for the same shall be borne by bidder/manufacturer. If
the defective/failed equipments are not replaced/ repaired as per the above guarantee
clause, MSETCL shall recover an equivalent amount plus 15% supervision charges from
any bill of the Manufacturer.
10.0.0
DOCUMMENTATION
10.0.1
Drawings (Auto Cad, all dimensions in mm)
10.0.2
General constructional features of the instrument transformer and dimensions of

conductor, depth of insulation, clearance between paper insulation and the inside of
porcelain, grading stages used for primary insulation, whether and how a semi
conducting tape is used to cover metal foils etc
10.0.3
The Sectional view shall show the materials /gaskets/ sealing used for perfect hermetic
sealing and arrangement for compensation of oil volume variation.
10.0.4
The
insulation,
the
winding
arrangements,
method
of
connection
of
the
primary/secondary winding to the primary /secondary terminals etc.
10.0.5
Bushing used its make and dimensions alongwith the mechanical and electrical
characteristics.
10.0.6
List of drawings & documents
GA diagram
ii
Sectional view with winding details.
iii
Combined Rating plate & diagram plate drawing.
iv
Secondary terminal box & secondary terminals.
Primary terminal assembly
vi
Pressure release device/SS below.

1348 of 2461
PAGE 132 of 358
MMRDA
vii
Oil level indicator
ix
Drain plug/Oil filling plug/N2 Valve
Bushing drawing.
xi
Bill of Quantity
xii
Packing scheme.
xiii
Guaranteed Technical Particulars. (GTP)
xiv
Quality Assurance Plan (QAP)
xv
Type test reports as listed in Annexure A (a)
10.0.7
The manufacturing of the equipments shall be strictly in accordance with the approved
drawings and no deviation shall be permitted without the written approval of the MSETCL.
All manufacturing and fabrication work in connection with the equipment prior to the
approval of the drawing shall be at the Manufacturer's risk.
7.4.0
11.0.0
Packing & Forwarding

The equipment shall be packed as per approved packing scheme and shall be suitable
for
horizontal/vertical transportation, as the case may be, and suitable to withstand
handling during transport and outdoor storage in stores before erecting.
The
Manufacturer shall be responsible for any damage to the equipment during transit, due
to improper and inadequate packing. The easily damageable material shall be carefully
packed and marked with the appropriate caution symbols. Wherever necessary, proper
arrangement for lifting, such as lifting hooks etc. shall be provided. Any material found
short inside the packing cases shall be supplied by Manufacturer without any extra cost.
12.0.0
Disqualification norms:
12.0.1
The Manufacturer/Bidder is liable for disqualification on account of any of the following

reasons:
d) Poor quality and workmanship of the products previously supplied and frequent
failures as experienced by the MSETCL.
e) Manufacturer/Bidder against whom litigation is in progress.
f) Manufacturer/Bidder, who in the opinion of the MSETCL has malafied intentions in
1349 of 2461
PAGE 133 of 358
MMRDA
the conduct of business with the company (MSETCL),

g) Manufacturer/Bidder who is declared to be defaulter as per the terms and conditions
laid by the company.
12.0.2
Notwithstanding anything stated above, the MSETCLs decision in this regard will be final.
CURRENT TRANSFORMERS (Protection)
13.0.0
TYPE AND STANDARD RATIOS
S. No.
Voltage level
Type
Standard ratio
132kV
1600-800/1A, 5C
132kV
II
800-400/1A, 5C
CURRENT TRANSFORMERS USE-TYPE & STANDARD RATIOS
Voltag
New projects
Replacement
e level
Design
Type
Ratio
Design
Type
Ratio
132kV/
Live tank
1600-800/1A, 5C
Live
1600-800/1A, 5C
110kV/
only
II
800-400/1A, 5C
tank/Dead
II
800-400/1A, 5C
100kV
tank
13.1.0
CURRENT TRANSFORMERS (LIVE TANK/DEAD TANK)
13.1.1
The C.T. shall be hermetically sealed and method of such sealing shall be detailed
in the drawing and shall be subject to the approval of the MSETCL.
13.1.2
PRIMARY WINDING
CTs of Dead tank design shall be hermetically sealed to eliminate breathing and
also to prevent air and moisture from entering the oil in the tank. Primary winding
shall be hair pin type, bar type or wound type, made out of high conductivity
1350 of 2461
PAGE 134 of 358
MMRDA
copper/Aluminum. Conductors used for primary winding shall be rigid, or else

housed in rigid metallic shell. The current density of conductor shall not exceed the
following values:
a) Copper
b) Aluminum
- 1.65 A/sq. mm (@ rated cont. thermal current)

- 1.00 A/sq. mm (@ rated cont. thermal current)
However, CTs of 33 kV/22kV class shall be dead tank only & Primary windings shall
be of Copper only.
No. of primary turns, Cross sectional area of primary winding conductor/ Cross
sectional
area of secondary winding conductor, and current density shall be
indicated in sectional view drawing. No. of primary turns of type tested CT are to be
indicated alongwith type test report No. and date. Offered CTs of higher dynamic
force (Id X Tp)* than that of type tested CT shall not be accepted. The design value
of current density for short circuit current as well as conductivity of the metal used
for primary winding shall meet the requirement of IEC 60044-1. The
bidder/manufacturer shall, in his offer furnish detailed calculations for selection of
winding cross sections. In regard to primary winding it may be noted that the rated
extended primary current shall be 120% of the rated primary current.
*Id- Dynamic current, Tp- No. of primary turns
13.2.0
PRIMARY TERMINALS
The primary terminals shall be made of heavily tinned electrolytic grade copper when
the primary winding is of copper. The primary terminals shall be of 30mm diameter x
80mm length for the CTs up to rated primary current of 800A, above 800A two such
studs in parallel shall be provided for each terminal with spacing of 200mm between
the studs.
Palm type Aluminum primary terminals shall be provided when primary winding is of
Aluminum. The current density of the terminal pad shall not be greater than that of
primary winding current density. Polarity shall be marked on each terminal.
1351 of 2461
PAGE 135 of 358
13.3.0
MMRDA
SECONDARY WINDING
Suitably insulated copper wire of electrolytic grade shall be used for secondary windings.
For multi ratio design, suitable tappings shall be provided on the secondary winding.The
bidder/manufacturer shall furnish the magnetization curve/s for the protection core/s.
13.3.1
In order to ensure low leakage reactance to PS cores of CT following design factors shall
be considered and indicated in drawings:
the core of current transformer shall be joint less ring type,
the secondary winding turns shall be substantially evenly distributed along the whole
length of the magnetic circuit;
the primary conductor shall pass through the approximate centre of the core aperture;
the influences
of conductors of the adjacent phase outside of the current
transformer housing and of the neighboring phases shall be negligible.
13.4.0
SECONDARY TERMINALS:
Secondary terminal studs shall be provided with at least 3 nuts and adequate plain and
spring washer for fixing the leads. The studs, nuts and washer shall be made of brass duly
nickel-plated. The minimum outside diameter of stud shall be 6mm. The length of at least
15mm shall be available on the studs for inserting the leads. Horizontal spacing between
centers of adjacent studs shall be at least 1.5 times the circum dia. of the nuts.
Polarity shall be invariably marked for each secondary terminal. Facility shall be provided
for short circuiting and grounding of the CT secondary terminals inside the terminal box.
13.5.0
SECONDARY TERMINAL BOX:
The C.T. secondary terminals shall be brought out in a weatherproof terminal box. The
terminal box shall be provided with removable gland plate and glands. The cable glands
shall be suitable for 1100 volts grade PVC insulated, PVC sheathed multicore stranded 6
sq.mm copper or 10 sq.mm. Aluminum conductor cable. This terminal box shall be dust
and vermin proof. The terminal box shall be provided with sealing arrangement and shall
1352 of 2461
PAGE 136 of 358
MMRDA
meet the requirements of IP 55 of IS 13947. Suitable quantity of silica gel shall also be
provided in a porous container. The dimensions of the terminal box and its opening shall be
adequate to enable easy access and working space with the use of normal tools.
13.6.0
HERMITIC SEALING:
The Current Transformer shall be vacuum filled with oil after processing and thereafter
hermitically sealed to eliminate breathing and to prevent air and moisture entering into the
tank. Oil filling and/or oil sampling cocks to be provided. It is to be ensured that due to
opening/closing of cock hermetic sealing shall not be disturbed, further extra oil shall be
available in C.T. to take out sample for DGA test throughout the working life of CT.
13.7.0
INSTRUMENT SECURITY FACTOR(ISF)

The instrument security factor of metering core of CTs shall be low enough, but not greater
than 5. This shall be demonstrated on all the ratios of metering core in accordance with
procedure specified in IEC185 or IS2705. In case the instrument security factor of 5 or less
is not possible to be achieved on higher ratio, auxiliary CTs of ratio 1/1 and 0.2S accuracy
class shall be deemed to be included in the manufacturers scope of supply.
15.0.0 TYPE TESTS for CTs (REF. ANNEXURE A )
15.0.1 The equipment/material should have been successfully type tested in line with the
relevant IEC/IS and technical specification, within the last five years from the date
of opening of the tender. The bidder/manufacturer shall submit copies of the type
test reports alongwith the drawings submitted for MSETCL approval. In case these
type tests are conducted earlier than 5 years, all the type tests shall be carried out
by the successful bidder/manufacturer in the presence of MSETCLs representative,
free of cost, before submission of equipment drawings for approval.
15.0.2 If there is any change in the components or design in the equipment since its earlier
passing of the type test, the bidder/manufacturer shall bring out in his offer all such
change made in the component, materials, design etc.
In such cases,
bidder/manufacturer shall carry out the type tests at his cost and in presence of
MSETCLs representative
1353 of 2461
PAGE 137 of 358
MMRDA
15.0.3 The type test shall be carried out at Laboratories accredited by National
Accreditation Board for testing and calibration Laboratories (NABL).
15.0.4 If, the equipment/material has been type tested earlier, the MSETCL reserves the
right to demand repetition of one or more tests included in the list of type test in
presence of MSETCLs representative.
15.0.5 The MSETCL reserves the right to conduct tests included in the list of type tests as
per IS on requisite number of samples/items from any of the lots during the tenure
of the supply at MSETCLs cost in the presence of MSETCLs representative. If the
equipment/material does not withstand the type test, then the equipment/material
supplied till then will be liable for rejection. The Manufacturer, in such an eventuality
shall be allowed to modify the equipment and type test the same again at his own
cost in the presence of the MSETCL's representative. These type tests shall
however be conducted by the Manufacturer within a reasonable time. After
successful passing of the type tests, all the equipments/material supplied earlier
shall be modified/replaced in line with equipment /materials which has successfully
passed the type test. In case Manufacturer fails to carry out the type test within
reasonable time or does not agree to carry out the type test at his cost, his
equipment/materials supplied earlier shall be rejected and order placed shall be
cancelled and payments made earlier for these Manufacturers shall be recovered
by the MSETCL.
The details of the type tests to be carried out by manufacturer are as per Annexure
A
15.0.6 In-house test facility at Manufacturers unit:
Manufactures shall have routine test facilities (As per IS 27015 and IS.IEC: 600441) and test facility for Temperature rise test, Lightning Impulse test and Composite
error test ( for ensuring low reluctance of PS core)
ANNEXURE_A
S.No. Particulars
As per IEC
1354 of 2461
PAGE 138 of 358
MMRDA
Type Tests
1)
Temperature-rise test
IS 2705, Part I to IV
IEC 61869
2)
3)
Lightning Impulse
voltage
withstand
test
on primary IS 2705, Part I to IV
terminals
IEC 61869
Switching Impulse test (Wet) for CTs of 400kV class
IEC 61869
4)
Wet test for outdoor type current transformers
IEC 61869
5)
Electromagnetic Compatibility tests/RIV Test
IEC 61869
6)
Tests for accuracy
IEC 61869
7)
Verification of the degree of protection by enclosures
IEC 61869
8)
Enclosure tightness test at ambient temperature
IEC 61869
9)
Pressure test for the enclosure
IEC 61869
10) Short-time current tests
IEC 61869
Note:In case type tests are conducted earlier than 5 years, the tests shall be carried
out by manufacturer in the presence of MSETCL representative, free of cost, before
submission of equipment drawing for approval.
c)
Routine /Acceptance Tests
1)
Visual and dimensional check
2)
Power-frequency
voltage
withstand
tests
on
primary
terminals
3)
IEC 61869
Partial discharge measurement
IEC 61869
4)
Power-frequency voltage withstand tests between -sections

1355 of 2461
PAGE 139 of 358
MMRDA
IEC 61869
5)
Power-frequency voltage withstand tests on secondary
IEC 61869
6)
Tests for accuracy according to accuracy class (Ratio error,
Phase angle error, Turns ratio for PS Class, Composite error
IEC 61869
test for ensuring for low reactance)

7)
Verification of terminal markings and polarity
IEC 61869
8)
Lightning impulse test to be conducted on random sample of

the batch & to be witnessed by MSETCL inspector.
9)
IEC 61869
Composite error test by direct method as per IS 2705-3,
Annexure A A-5 & A-6 Composite error test by indirect
IEC 61869
method
10) Enclosure tightness test at ambient temperature
IEC 61869
11) Pressure test for the enclosure
IEC 61869
12) Determination of the secondary winding resistance
IEC 61869
13) Test for rated knee point voltage
Measurement of exciting current at rated knee point voltage

14) Inter-turn overvoltage test
IEC 61869
IEC 61869
15) Verification of ISF
IEC 61869
16) Dielectric test on random sample before Heat run test
-----do---
17) Heat run test on random sample
-----do---
18) Dielectric test on random sample after Heat run test
-----do---
19) Measurement of Capacitance and tan delta for each CT of
-----do---
the lot
Special Tests:
1356 of 2461
PAGE 140 of 358
MMRDA
S.No Particulars
As per IEC
.
b)
Special tests
1) Chopped lightning impulse voltage withstand test on primary IS 2705, Part I to IV

terminals
IEC 61869
2) Multiple chopped impulse test on primary terminals
IEC 61869
3) Measurement of capacitance
and dielectric
dissipation IS 2705, Part I to IV
factor
IEC 61869
4) Transmitted overvoltage test
IEC 61869
5) Mechanical tests
IEC 61869
6) Gas dew point test(In case of SF6 CTs)
IEC 61869
7) Determination of the instrument
security factor (FS) of IS 2705, Part I to IV
measuring
IEC 61869
Note: In addition to type tests specified in Annexure-A manufacturer shall have

successfully conducted above special tests on current transformers and reports
thereof shall be within 5 years from the date of opening of tender. In case special tests
are conducted earlier than 5 years, the tests shall be carried out by manufacturer in
the presence of MSETCL representative, free of cost, before submission of equipment
drawing for approval.
Routine/Acceptance tests:
Note: Temperature rise test and lightning impulse test shall be carried out on random
sample of the batch.
16.0.00
POTENTIAL TRANSFORMERS PTs (IVTs) UPTO 220KV

VOLTAGE CLASS
16.0.01
The PT shall be vacuum filled with oil after processing and hermetically
1357 of 2461
PAGE 141 of 358
MMRDA
sealed to eliminate breathing and to prevent air and moisture entering

the tanks. Method adopted for hermetic sealing shall be described in the
drawing and shall be subject to approval of the MSETCL.
16.0.02
The PT shall be so constructed that it can be easily transported in

Horizontal / vertical position.
16.1.00
PRIMARY WINDING:
16.1.01
Primary winding shall be made of suitably insulated electrolytic copper

wire. Type of insulation used shall be described in the offer/drawings.
16.1.02
In case of dual primary voltage PT shall be provided with suitable taps

on the secondary windings and the same shall be brought out at the
terminals to enable the connections to be made at site for operation at
either of the voltages specified. The change-over shall be suitable for
locking after the reconnections. The arrangement provided for change
over as well as locking shall be clearly brought out in the drawings.
16.1.03
The rating and the diagram plates specified elsewhere in this

specification should also indicate the above reconnection arrangement.
16.2.00
16.2.01
SECONDARY WINDING:
Suitably insulated copper wire of electrolytic grade shall be used
for secondary windings. Type of insulation used shall be described in
the offer/drawings. The secondary windings of the PT shall be protected
by 2 Nos. of HRC fuses in parallel for each core.
16.3.00
SECONDARY TEMINAL BOX
16.3.01
The PT secondary terminal shall be brought out to a weatherproof

terminal box. The HRC fuses meant for protection of secondary winding
shall also be located in the terminal box. The terminal box shall be
provided with removable gland plate and glands suitable for 1100 volts
grade PVC insulated, PVC sheathed multi-core 2.5sq.mm. to 10 sq.mm.
stranded copper or aluminum conductor cable. The terminal box shall
be dust and vermin proof. (IP-55 class). Suitable arrangement space
heater shall be provided for drying the air inside the terminal box. The
dimensions of the opening of terminal box shall be adequate to enable
easy access and working space with the use of normal tools.
16.3.02
Polarity shall be invariably marked at the secondary terminals in the

terminal box.
16.3.03
Capacitance & Tan Delta measuring terminal should be provided with its
1358 of 2461
PAGE 142 of 358
MMRDA
earthing arrangement in secondary terminal box and Caution to earth

the same before energizing PT shall be indicated in the name/rating
plate.
16.3.04
The PT shall be provided with a rating plate with dimensions and

markings as per IS 3156. The markings shall be punched and not
painted.
16.4.00
PRIMARY TERMINALS:
16.4.01
The primary terminal shall be of size 30mm dia x 80mm length for all
PTs. The primary terminal shall be of heavily tinned electrolytic copper
of 99.9% conductivity. The minimum thickness of tinning shall be 15
micron
16.5.00
SECONDARY TERMINALS:
16.5.01
For external connection of secondary windings, terminal studs shall be

provided with at least 3 nuts and adequate plain and spring washers.
The studs, nuts and washers shall be of brass properly nickel-plated.
The size of stud shall be 6mm outside dia. A length of at least 15mm
shall be available on the studs for inserting the leads. Horizontal spacing
between the centers of adjacent stud shall be at least 1.5 times the
circum dia of the nuts.
16.6.00
NAME PLATE/RATING PLATE:

The PTs shall be provided with a rating plate with dimensions and
markings as per IS 3156 Parts-I to III & IEC 60044-2. In addition to this,
Project/Substation name shall also be indicated on name plate.
Sr.No.
1.
Particulars
132kV
Type
Single phase/Outdoor type of oil filled and hermetically

sealed.
2.
Type of mounting
3.
Ratio
Pedestal type
taps(wherever On secondary side by reconnection of link.
applicable)
4.
Rated voltage factor
5.
Highest
1.2 Continuous and 1.5 for 30 seconds
system 145kV/123kV
Voltage
6.
Core
details
and Core: I & II for protection
1359 of 2461
PAGE 143 of 358
Sr.No.
7.
MMRDA
Particulars
132kV
purpose
Core III for metering
Class of accuracy
Core I & II:3P Class

Core III: 0.2 Class
8.
Burden (VA)
132KV
Core I 200 VA
Core II 50 VA
Core III 50 VA
Voltage ratio
Voltage ratio (primary/Secondary)

132KV/ 3 /110V/3 -110V/ 3 -110V/3
Three
Windings
110KV/ 3 /110V/3 -110V/ 3 -110V/3
Three
Windings
100KV/ 3 /110V/3 -110V/ 3 -110V/3
Windings
9.
Basic
insulation 650
level(KVP)
10.
One
minute
frequency
power 275
withstand
voltage dry/wet
(KV rms.)
primary/secondary
voltage (KV)
11.
Minimum
creepage 3625
distance (mm).
12.
Primary
Terminal 30 x 80
(mm)
13.
Mounting Frame size 600x600 30

(mm) and Holes
1360 of 2461
PAGE 144 of 358
Three
Sr.No.
14.
MMRDA
Particulars
132kV
Acceptable limits of As per IS 3156 Parts-I to III & IEC 60044-2

temperature rise.
15.
Type
of
oil S.S. Bellow or Nitrogen cushion
compensation
15.0.0
15.0.1
TYPE TESTS for PTs (REF. ANNEXURE B )
The equipment/material should have been successfully type tested in

line with the relevant IEC/IS and technical specification, within the last
five years from the date of opening of the tender.
The
bidder/manufacturer shall submit copies of the type test reports

alongwith the drawings submitted for MSETCL approval. In case these
type tests are conducted earlier than 5 years, all the type tests shall be
carried out by the successful bidder/manufacturer in the presence of
MSETCLs representative, free of cost, before submission of equipment
drawings for approval.
ANNEXURE B
S.No. Particulars
a
1.
As per IEC
Type Tests
Temperature Rise
IS 3156 Parts-I to III & IEC

60044-2
2.
3.
Short Circuit Withstand Capability IS 3156 Parts-I to III & IEC

Test
60044-2
Lightning Impulse test

60044-2
4.
High voltage Power Frequency IS 3156 Parts-I to III & IEC

Wet
Test
for
Outdoor
Type 60044-2
Transformer
5.
Determination Of Errors

60044-2
6.
RIV Test
1361 of 2461
PAGE 145 of 358
MMRDA
60044-2
Note:In case type tests are conducted earlier than 5 years, the tests
shall be carried out by manufacturer in the presence of MSETCL
representative, free of cost, before submission of equipment drawing for
approval.
Special Tests:
S.No
Particulars
As per IEC
.
b
Special tests, Optional tests and

Additional tests
1) Chopped Impulse on Primary IS 3156 Parts-I to III & IEC
Winding
60044-2
2) Measurement of Capacitance & IS 3156 Parts-I to III & IEC

Dielectric Dissipation Factor
3) Mechanical Test
60044-2
60044-2
Note: In addition to type tests specified in Annexure-A manufacturer

shall have successfully conducted above special tests on current
transformers and reports thereof shall be within 5 years from the date of
opening of tender. In case special tests are conducted earlier than 5
years, the tests shall be carried out by manufacturer in the presence of
MSETCL representative, free of cost, before submission of equipment
drawing for approval.
Routine Tests:
c
Routine Tests for each potential

transformer
1.
Verification of Terminal Markings

60044-2
2.
Power Frequency withstand test IS 3156 Parts-I to III & IEC
1362 of 2461
PAGE 146 of 358
MMRDA
on primary windings
3.
4.
60044-2
Measurement of Capacitance & IS 3156 Parts-I to III & IEC

Dielectric Dissipation Factor
60044-2
Partial Discharge Measurement

60044-2
5.

on Secondary windings
6.
7.
60044-2

between sections
60044-2
Determination of errors

60044-2
8.
Lightning Impulse Test

60044-2
9.
Dielectric
Test
before IS 3156 Parts-I to III & IEC

10. Temperature Rise Test
60044-2
60044-2
11. Dielectric Test after Temperature IS 3156 Parts-I to III & IEC
rise test
60044-2
1363 of 2461
PAGE 147 of 358
BLANK PAGE
1364 of 2461
MMRDA
Annexure-C
Inspection Format for CTs & PTs
S.
Component
N.
s&
Characteristics
CLAS
Type
operation
Quantum of check
Ref.
Acceptance
of
Docu
norms
check
ment
M
100
1sample
Visual
sample
Measu
Bought out items

1.1
Insulation
Visual
paper
--
Free from
damage
Major
Dimension
DO
thickness
As
As per mfg.
rement Samp
per
std/ IS 9335
le / lot
mfg.
(3)
std/
IS
9335(
3)
Grammage
DO
DO
DO
Tensile
PAGE 149 of 358
1365 of 2461
DO
DO
S.
Component
N.
s&
Characteristics
MMRDA
CLAS
Type
operation
strength
DO
Ref.
Acceptance
of
Docu
norms
check
ment
Test
Quantum of check
DO
IS
IS 9335 (3)
9335
(3)
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
Elongation at
break %
Conductivity of
aq. Extract
Ph of aq. Extract
Ash content
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
Measu
1sam
IS
IS 13730
rement
ple
Moisture content
1.2
Supper
Dimension
enameled
Major
copper wire
13730
/ lot
Elongation at
DO
Test
DO
1sampl
PAGE 150 of 358
1366 of 2461
1sample
DO
DO
S.
Component
N.
s&
Characteristics
MMRDA
CLAS
Type
operation
Quantum of check
Ref.
Acceptance
of
Docu
norms
check
ment
M
break%
/ lot
/ lot
Springiness
DO
DO
DO
DO
DO
Flexibility
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
Test
DO
IS
&Adherence
Resistance to
abrasion
Resistance
measurement
Heat Shock Test
Cut through test
DO
IS 13730
13730
Breakdown
DO
DO
DO
DO
DO
voltage
Porcelain
1.3
insulator
Visual
Major
Visual
100%
1sampl
PAGE 151 of 358
1367 of 2461
1sample
Free from
damage
S.
Component
N.
s&
Characteristics
MMRDA
CLAS
Type
operation
Quantum of check
Ref.
Acceptance
of
Docu
norms
check
ment
M
examination
Dimension
DO
1sam
As
As per drg.
Measu
ple/
per
/mfg std
rement
lot
drg.
IS 5621
/mfg
std IS
5621
Electrical routine
test
IS
DO
Test
IS5621
5621
DO
DO
DO
DO
Free from
DO
Porosity test
DO
DO
DO
Temperature
Cycle test
DO
DO
DO
Visual
Major
Visual
100%
PAGE 152 of 358
1368 of 2461
damage
S.
Component
N.
s&
Characteristics
MMRDA
CLAS
Type
operation
Quantum of check
Ref.
Acceptance
of
Docu
norms
check
ment
M
DO
Dimension
1.4
1sam
As
As per
Measu
ple/
per
approved drg.
rement
lot
appro
Tank &
ved
tank
drg.
Cover
100%
Leakage
DO
Leakage test
Leaka
Test
ge
Check at 30
P.S.I.
Check
at 30
P.S.I.
1sampl
1.5
Nitrile
Visual
Major
Visual
100
butyle
Rubber O
1sam
PAGE 153 of 358
1369 of 2461
1sample
Free from
-
damage
As
As per drg. /
S.
Component
N.
s&
Characteristics
MMRDA
CLAS
Type
operation
Quantum of check
Ref.
Acceptance
of
Docu
norms
check
ment
M
Ring
ple/
Dimension
DO
Measu
per
lot
rement
mfg std
drg. /
mfg
std
Hardness
DO
Test
DO
IS
IS 3400
3400
Tensile
strength
DO
DO
DO
DO
DO
DO
DO
DO
DO
Elongation at
break%
DO
DO
DO
Compression Set
at 70 C
DO
DO
DO
S.R.B.C.
1.6
Gasket
1
Visual
Major
Visual
100%
sample
1sam
1sample
PAGE 154 of 358
1370 of 2461
Free from
damage
As
As per drg. /
S.
Component
N.
s&
Characteristics
MMRDA
CLAS
Type
operation
Quantum of check
Ref.
Acceptance
of
Docu
norms
check
ment
M
DO
Dimension
Measu
ple/
rement
lot
N
per
Mfg. Std.
drg. /
Mfg.
Std.
Hardness
DO
Test
IS
IS 4253
DO
4253
DO
DO
DO
Tensile
strength
DO
DO
Compression set
at
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
As
As per drg. /
per
P.O.
110C for 24 hrs

Compressibility
1sam
ple/
PAGE 155 of 358
1371 of 2461
S.
Component
N.
s&
Characteristics
MMRDA
CLAS
Type
operation
Quantum of check
Ref.
Acceptance
of
Docu
norms
check
ment
M
Dimension
Major
lot
drg. /
Measu
P.O.
rement
1.7
Core
Surface defects
Visual
DO
Magnetizing
Characteristics
DO
Test
damage
DO
DO
Free from
1sample
sample
As
As per drg. /
per
P.O.
drg. /
P.O.
1.8
Insulating
Appearance
Major
Visual
Oil
100%
Density at
DO
Test
29.5 C
1Sam
IS
Oil shall be
355:1
clear &
993
transparent
DO
IS 335:1993
DO
DO
ple/ch
ambe
r
Kinematic
DO
DO
DO
PAGE 156 of 358
1372 of 2461
S.
Component
N.
s&
Characteristics
MMRDA
CLAS
Type
operation
Quantum of check
Ref.
Acceptance
of
Docu
norms
check
ment
M
viscosity
Interfacial tension
at
DO
DO
DO
DO
DO
Flash point
DO
DO
DO
DO
DO
Pour point
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
1Sam
1Sampl
1Sample/c
ple/ch
e/cham
hamber
DO
DO
ambe
ber
27C
Neutralization
value
Water Content .
Ppm
Corrosive sulpher
Electrical
Strength (BDV)
KV (rms)
DO
DO
PAGE 157 of 358
1373 of 2461
S.
Component
N.
s&
Characteristics
MMRDA
CLAS
Type
operation
Quantum of check
Ref.
Acceptance
of
Docu
norms
check
ment
M
1sampl
1 sample
Dielectric
dissipation factor
(tan delta)
DO
DO
DO
DO
DO
DO
DO
Specific
Resistivity
(a)at 90C
1
DO
DO
DO
1 sample
sample
(b) at 27C
2. In process inspection/check
2.1
Accuracy test
Secondary
Major
Test
100 %
IS 2705
IS
Winding
2705
Over voltage
Interturn test
Resistance
Measurement
DO
DO
DO
DO
DO
DO
PAGE 158 of 358
1374 of 2461
DO
DO
DO
DO
S.
Component
N.
s&
Characteristics
MMRDA
CLAS
Type
operation
Quantum of check
Ref.
Acceptance
of
Docu
norms
check
ment
M
Turn ratio for PS

core
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
Exciting current
measurement
Measurement of
ISF
DO
Knee point
DO
voltage test
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
Power frequency
withstand test for
DO
DO
DO
1 min @
3KV rms
2.2
Base &
Pressure test
PAGE 159 of 358
1375 of 2461
S.
Component
N.
s&
Characteristics
MMRDA
CLAS
Type
operation
Quantum of check
Ref.
Acceptance
of
Docu
norms
check
ment
M
Major
Tank
on complete
100 %
Leak
Assembly
assembly at10
Measur
age
p.s.i for 8Hrs.
ement
chec
No leakage
k at
10
p.s.i.
Visual
Visual Inspection
DO
DO
& fitment of
secondary
As
As per app.
per
Drg
app.
Drg.
terminals
Fitment of
DO
Primary terminals
Physica
l
DO
Fitment of
Insulator
DO
DO
DO
PAGE 160 of 358
1376 of 2461
DO
DO
DO
DO
S.
Component
N.
s&
Characteristics
MMRDA
CLAS
Type
operation
Quantum of check
Ref.
Acceptance
of
Docu
norms
check
ment
M
2.3
Vaccum
Temperature of
drying & oil
oven
Major
Measur
Hourly
ement
readin
/VA
C/
Impregnatio
WI
90-100C
7.5.1
/ 02
DO
Test
Vacuum leakage
No leakage
hourly
Measurement of
DO
DO
DO
DO
DO
No water for
water in vapor
6 hours in
condenser
vapour
Oil Tests
IS33
IS335:1993
5:19
93
a) Tan delta
Major
Test
For
DO
No water for
every
6 hours in
charge
vapour
PAGE 161 of 358
1377 of 2461
S.
Component
N.
s&
Characteristics
MMRDA
CLAS
Type
operation
Quantum of check
Ref.
Acceptance
of
Docu
norms
check
ment
M
b) B.D.V
DO
N
-
Test
5:19
c) PPM
DO
DO
d) specific
DO
DO
resistivity
IS33
PAGE 162 of 358
1378 of 2461
93
IS335:1993
MMRDA
Routine/Acceptance Tests for CTs

Sr.
Components
No
3
& operation
Final testing
Characteristics
Type of
CLASS
Visual & Dimension check Critical
check
Test
Quantum of check
Ref. Document
M
C
N
1
1sample/ 1 sample/
App. Drg.
(ROUTINE &
sample/
ACCEPTAN CE
lot
lot
Verification of terminal
DO
Measure 100%
App.Drg.
lot
TEST)
marking polarity
Acceptance norms
100%
100%
IS 2705 and
IS 2705 and
IS.IEC: 60044-1
IS.IEC:
60044-1
ment
Accuracy
Test a) Ratio & Phase angle
DO
Test
DO
DO
DO
DO
DO
DO
Test
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
error
b) Turn ratio for PS core
c)Composite error test for

ensuring low reactance
Knee point voltage

measurement
PAGE 163 of 358
1379 of 2461
MMRDA
Exciting current
measurement
Secondary winding
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
resistance measurement
PF test on secondary
winding for
1 min.
PF Test on Primary winding
for
1 min
Overvoltage interturn test
Partial discharge test
Measurement of C & Tan

Delta
PAGE 164 of 358
1380 of 2461
MMRDA
Dielectric test before

DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO

Dielectric test after
Impulse test
Components &
Sr. No
operation
Quantum of check
Characteristics
CLAS S
Type of
M
check
Check
for proper
packing
Physical
Major
100
%
Packing &
4
Dispatch
Ref. Document
Acceptance norms
As per approved
As per approved
packing list/scheme
packing
plant
list/scheme
STD
Preparation of
invoice
DO
DO
DO
PAGE 165 of 358
1381 of 2461
BLANK PAGE
1382 of 2461
MMRDA
Test facilities at Manufacturers unit:
Manufactures shall have in-house routine test facilities (As per IS 27015 and
IS.IEC: 60044-1) and test Facility. For Temperature rise test, Lightning Impulse
test and Composite error test by direct method (for ensuring low reluctance of
PS core)Routine/Acceptance Tests for PTs
Sr. Component Characterist CLAS

No
s&
ics
Type
Quantum of check
of check
operation
3
Final
Ref.
Acceptance
Docume
norms
nt
Visual &
Critical
Test
1sampl
App.
sample/
Drg.
testing
Dimension
sample/
e/
(ROUTINE
check
lot
lot
App. Drg.
lot
&
ACCEPTAN Verification
CE TEST)
DO
of terminal
Measure 100%
100% 100% IS 3156
IS 3156
ment
marking
polarity
Determinatio
n of errors
according to
the
requirements
of
DO
DO
Test
DO
DO
DO
appropriate
accuracy
class
(100%rated
voltage)
Power
1383 of 2461
PAGE 167 of 358
DO
frequency
MMRDA
DO
DO
DO
DO
DO
DO
DO
dry withstand DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
dry withstand
test on
primary
winding
Power
frequency
test on
secondary
winding
Induced
overvoltage
test
Measuremen
t of Partial
discharge
test
Dielectric
test before
Temperature
rise test
Temperature
rise test
Dielectric
test after
Temperature
rise test
Lightning
Impulse Test
Note: Temperature rise test, Lightning Impulse test and Composite error test by direct
method on random
1384 of 2461
PAGE 168 of 358
Sr. Components Characteris CLASS Type of

No
& operation
tics
MMRDA
Quantum of check
check
M
Packing &
Check for
Dispatch
proper
Preparatio
packing
n
Major Physical 100%

DO
DO
DO
Ref.
Acceptance
Document
norms
As per plant As per plant

STD
-
of invoice
1385 of 2461
PAGE 169 of 358
STD
-
MMRDA
1386 of 2461
PAGE 170 of 358
MMRDA
1387 of 2461
PAGE 171 of 358
MMRDA
1388 of 2461
PAGE 172 of 358
MMRDA
1389 of 2461
PAGE 173 of 358
MMRDA
1390 of 2461
PAGE 174 of 358
MMRDA
1391 of 2461
PAGE 175 of 358
MMRDA
1392 of 2461
PAGE 176 of 358
MMRDA
PRINCIPLE TECHNICAL PARAMETERS FOR LIGHTENING ARRESTORS

(SURGE ARRESTERS)
PRINCIPLE TECHNICAL PARAMETERS FOR LIGHTENING ARRESTORS

(SURGE ARRESTERS)
1.0
1.1
SCOPE:
This
specification
covers
the
design,
manufacture,
assembly
testing
atmanufacturers works, packing and delivery of Metal Oxide (Gapless) Surge

Arresters for 132 system complete with Discharge Counters, Insulating Base
and Other Accessories for use invarious sub-stations in the state of
Maharashtra in India.
1.2 It is not the intent to specify completely herein all the details of design
andconstruction of surge arresters. However, surge arresters shall conform in
all respect to the high standards of design and workmanships mentioned in
Clause 4.0 and be capable of performing in continuous commercial operation.
The arresters and discharge counters offered shall be complete with all parts,
necessary for their effective and troublefree operation.
2.0
SERVICE CONDITIONS:
The surge arresters and accessories shall be suitable for continuous, satisfactory
operation under climatic conditions listed below:
1393 of 2461
PAGE 177 of 358
3.0
MMRDA
SYSTEM PARTICULARS:
The equipments offered under this specification shall be suitable for the system
conditions and parameters as below:
1394 of 2461
PAGE 178 of 358
MMRDA
Note: 1) * indicate values of LAs to be provided for tertiary protection of 400KV Single
phase transformer.
2)
V *_/2
1 p.u. = ----------------- kVp
_/3
where, V= Highest system voltage
3) E. E.- Effectively Earthed
4.0 STANDARDS:
The surge arresters shall conform to the latest editions available at the time of
placement of order/s of the standards listed below. Copies of Indian Standard
1395 of 2461
PAGE 179 of 358
MMRDA
Specifications can be obtained, on payment of requisite charges, from The

Bureau of Indian Standards, Manak Bhawan, 9, Bahadurshah Zafar Marg,
New Delhi - 110 002 (India).
SR.
NO.
1)
2)
STANDARD REF. NO.
IEC 60099-4
TITLE
International Standard for Metal Oxide Surge
Arresters Without Gap ofAC System
IS:3070
Specification
(Part-III)
Alternating Current Systems (Part-III)
3)
IS:4759
4)
IS:2633
5)
IS:5621
6)
IS:2147
7)
---
for
Lightning
Arresters
for
Hot Dip Zinc-Coating on Structural Steel and

Other Allied Products.
Method for Testing Uniformity of Coating on
Zinc Coated Particles.
Specification for Large Hollow Porcelain for
use in Electrical Installation
Degree of Protection Provided by Enclosures
for Low Voltage Switch Gear and Control.
Indian Electricity Rules, 1956
Note: i) For the purpose of this specification all technical terms used shall have the
meaning as per IEC 60099-4 specification.
ii) For the parameters of the arrester which are not specified in IEC specification for
surge arresters, the provisions of IS:3070 (Part-III) shall be applicable.
iii) Equipments meeting with the requirements of other authoritative standards, which
ensure equal or better quality than the specified standards shall also be acceptable.
Salient points of difference between the standards adopted and the specified
standards shall be clearly brought out in the bid. Four copies of the authoritative
English translation of reference standards shall be furnished alongwith the offer.
5.0 SPECIFIC TECHNICAL REQUIREMENTS:
5.1 The Metal Oxide (Gapless) Surge arresters shall conform to the technical
1396 of 2461
PAGE 180 of 358
MMRDA
requirements as below:
SR.
SYSTEM VOLTAGE WISE
PARTICULARS
NO.
REQUIREMENT OF PARAMETERS
132kV/
1)
System Voltage
2)
Voltage Rating of Surge Arrestor(kVrms)
3)
110kV
Maximum Continuous Operating Voltage

(M.C.O.V.) in kVrms
4)
Type of Mounting
5)
Connection
102/81
Pedestal
P-E
a) Long Duration Discharge Class

6)
120/96
b) Minimum Energy Handling Capability

(kJ/kV)
8
Compression Type Palm Terminal Connector
I) Suitable for ACSR Moose/AAAC

Morculla
II)
7)
Suitable for ACSR Zebra/ACSR
Panther
III) Sub Conductor Spacing (mm), if
Bundled
IV) Take Off
8)
9)
---
Twin/ Single Zebra/ Panther
225
Vertical
Whether Insulating Base and Discharge

Counter with milliammeter are Required
Yes
Min. Creepage Distance of Arrester 3625/

Housing (mm)
3075
10)
Installation
Outdoor
11)
Class
Station Class
12)
13)
Typeof Construction for 10kA Rated

Arrester
Nominal
Discharge
Current
Corresponding to 8/20 microSec Wave
Single Column, Single Phase
10
1397 of 2461
PAGE 181 of 358
MMRDA
Shape (kArms)
14)
15)
16)
17)
Ratio of Switching Impulse Residual

Voltage to Rated Voltage of Arrester
Minimum Prospective Symmetrical Fault
Current For Pressure Relief Test (kArms)
Corona Extinction Voltage (kVrms)
40
Rated Voltage of the Arrester
Max. Partial Discharge when Energized

at 1.05 Times of M.C.O.V.(picoCoulomb)
Not exceed 10
Note: The details of conductor mentioned against item 7(I) and (II) are as below:
SR.
NO.
NAME OF ACSR/AAAC
TOTAL CROSS
OVERALL
SECTIONAL AREA
DIAMETER OF THE
(sq.mm.)
CONDUCTOR (mm)
1)
ACSR PANTHER
261.50
21.00
2)
ACSR ZEBRA
484.50
28.62
3)
ACSR MOOSE
597.20
31.77
4)
AAAC MORCULLA
33.12
5.2 The energy handing capability of each rating of arrester offered supported by
calculations shall be furnished.
5.3 The surge arresters shall be fitted with pressure relief devices and arc diverting
parts and shall be tested as per the requirement of IEC 60099-4 specification for
minimum prospective symmetrical fault current of 40kA(rms) for 250mSec.
5.4 A grading ring shall be provided, if necessary, on each complete arrester for proper
stress distribution.
5.5 The arrester shall have single column construction for each phase.
1398 of 2461
PAGE 182 of 358
MMRDA
5.6 PROTECTIVE LEVELS:
The basic insulation levels and switching impulse withstand levels of the lines and
equipments to be protected, have been specified in System Particulars. The required
protective levels of the surge arrester are specified in technical requirements. The
protective characteristics of the arresters offered shall be clearly brought out in the
schedule of Guaranteed Technical Particulars enclosed.
6.0 GENERAL REQUIREMENTS:
6.1 Each individual unit of surge arrester shall be hermetically sealed and fully
protected against ingress of moisture. The hermetic seal shall be effective for the entire
life time of the arrester and under the specified service conditions. The bidder shall
furnish in the bid, a sectional view of the arrester, showing details of sealing and
pressure relief device employed.
6.2 The surge arrester shall be suitable for hot line washing.
6.3 The surge arrester shall be suitable for pedestal/gantry mounted type mounting.
6.4 All the necessary flanges, bolts, nuts, clamps etc. required for assembly of
complete arrester with accessories shall be included in scope of supply.
6.5 The drilling details for mounting the arrester on purchasers support shall be strictly
as per the details given in Drawing No. 015.1269 Rev-1.
6.7 HOUSING OF SURGE ARRESTORS:
6.7.1 PORCELAIN HOUSING SURGE ARRESTER
6.7.1.1 The housing of surge arrestor for line shall be preferable porcelain type.
6.7.1.2 Porcelain housing shall be free from lamination cavities or other flaws affecting
the mechanical and electrical strengths.
1399 of 2461
PAGE 183 of 358
MMRDA
6.7.1.3 The porcelain housing shall be thoroughly vitrified and non-porous.
6.7.1.4 The creepage distance of the arrester housing shall be as indicated in the
technical requirements.
6.7.1.5 The housing petticoats shall be preferably of self-cleaning type (aerofoil

design). The details of the porcelain housing such as height, angle of inclination, shape
of petticoats, gap between the petticoats, diameter (ID &OD) etc. shall be furnished by
the bidder with the offer, in the form of detailed drawings.
6.7.1.6 The arrester housing shall conform to the requirements of IEC 60099-4
specification for metal oxide surge arresters.
6.7.2 POLYMERIC HOUSING SURGE ARRESTER
6.7.2.1 The housing of surge arrestor for Power Transformer/ICTs shall be of polymer
type.
6.7.2.2 A metal oxide surge arrester with a Housing Made of Polymeric Material
preferably of Silicon Rubber, without air voids neither between the housing and the
metal oxide resistors nor the housing itself.
6.7.2.3 Arresters must have directly moulded housings. The surge arresters shall
strictly conform to IEC 60099-4/IS:3070 (Part-III) with latest amendment if any in all
respects. Maximum residual voltage shall comply with the requirement given
hereunder.
6.7.2.4 The surge arresters meeting any other authoritative standards, which ensure
equal or better performance than mentioned above, shall be acceptable.
6.7.2.5 The polymer material which is used for the arrester housing must be tracking
and erosion resistant, stabilized against UV radiation and preferably of Silicon Rubber.
6.7.2.6 The cantilever strength of the surge arrester with polymer housing shall not be
1400 of 2461
PAGE 184 of 358
MMRDA
less than 150kgs. Polymer housing shall be tested in accordance to IEC 61462.
6.8 GALVANISATION, NICKEL PLATING:
6.8.1 All ferrous parts exposed to atmosphere shall be hot dip galvanized as per
IS:2629. Tinned Copper/Brass Lugs shall be used for internal wiring of discharge
counter. Screws used for electrical connections shall be either of brass or nickel plated.
6.8.2 Line terminal pads, ground terminal pads and name plate bracket shall be hot
dip galvanized.
6.8.3 The material shall be galvanized only after completing shop operations.
7.0 ACCESSORIES & FITTING:
7.1 The surge arresters shall be provided with the Compression Type Palm Terminal
Connector as per the details given in Drawing No. MSETCL/DES.&ENG./SA
TERMINAL CONNECTOR/03-2012
7.2 A discharge counter shall be provided for the arrester meant for 132 kV system
and tertiary protection. The discharge counter shall be offered with milliammeter for
measuring the leakage current and shall not require any DC or AC Auxiliary supply. It
shall be suitable for outdoor use. The installation of discharge counter shall not
adversely affect the arrester performance.
7.3 The discharge counter shall register operation when a surge strikes the surge
arrester.
7.4 All necessary accessories and earthing connection leads between the bottom of
the arrester and the discharge counter shall be included scope of supply. The
discharge counter shall be so designed that the readings of discharges recorded by
the counter and the readings of milliammeter shall be clearly visible through an
inspection window to a person standing on ground. The maximum height of installation
of discharge counter on purchasers support shall be 1.5 meters from ground level.
1401 of 2461
PAGE 185 of 358
MMRDA
7.5 Each surge counter shall have terminals of robust construction for connection to
earthing lead and these shall be suitably arranged so as to enable the incoming and
outgoing connection to be made with minimum bends.
7.6 Degree of protection of surge monitor shall be IP-67. Type test report for IP-67
shall be submitted.
7.7 The grounding terminals shall be suitable for accommodating grounding

connection to steel earthmat. Proper functioning of the surge counter with surge
arrester shall be guaranteed by the bidder.
7.8 NAME PLATE
The arrester shall be provided with non-corrosive legible name plate.
i) Name plate material should be 0.5mm thick metal photo anodized aluminium plate
of satin finish printed photographically using the metal photo process, with image
sealed below the anodized layer colors other than black may be embedded by resist
for screen process.
ii) Any other better form of name plate if proposed to be used the same shall be got
approved alongwith the sample.
iii) Following information shall be engraved on Name Plate:
1) Maharashtra State Electricity Transmission Company Ltd.

2) Order No.
3) Manufacturers Name or Trade Mark and Identification of the Surge Arrester
4) Rated Voltage
5) Maximum Continuous Operating Voltage
6) Type
7) Rated Frequency
8) Nominal Discharge Current
9) Long Duration Discharge Class
1402 of 2461
PAGE 186 of 358
MMRDA
10) Pressure Relief Current in kArms

11) Identification of Assembly Position of the Unit
12) Year of Manufacture
8.0 TESTS:
8.1 No surge arrester shall be dispatched without inspection and testing. The
inspection may be carried out by the MSETCLs representative at any stage of
manufacture. The bidder shall grant free access to the MSETCLs representative at a
reasonable time when the work is in progress.
8.2 Inspection and acceptance of any equipment under this specification by the
MSETCL shall not relieve the supplier of his obligation of furnishing equipment in
accordance with the specification and shall not prevent subsequent rejection if the
8.3 TYPE TEST:
The surge arresters offered, shall be fully type tested as per relevant standards at
laboratories which are accredited by National Accreditation Board of Testing and
Calibration Laboratories (NABL), Government of India to prove that the equipment
offered meets the requirements of the specification. In case equipment of the type and
design offered has already been type tested in NABL accredited laboratory, the bidder
shall furnish two sets of type test reports along with his bid.
All the type tests should have been successfully carried out within 5 (five) years from
the date of first bid submission. In case these type tests are conducted earlier than
preceding five years all the type tests as per the relevant standards will have to be
carried out by the manufacturer in the NABL Accredited Laboratories at his own cost
before commencement of supply. For any change in the design/type which is already
type tested and the design/type offered against this specification, the purchaser
reserves the right to demand testing without any extra cost.
8.4 All routine and acceptance tests as stipulated in the specified standards shall be
carried out by the supplier in presence of MSETCLs representative at bidders cost.
1403 of 2461
PAGE 187 of 358
MMRDA
The acceptance tests, wherever possible, shall be performed on the completed

arresters. The number of samples to be subjected to acceptance tests shall be decided
by the purchaser at the time of actual testing.
8.5 The special thermal stability test as per IEC 60099-4 for metal oxide surge
arresters shall be carried out as acceptance test.
8.6 The acceptance tests shall include the galvanization test on metal parts.
8.7 The functional (operation) acceptance tests shall be carried out on the surge
counter by way of checking its operation at following nominal discharge currents:
a) 100Amps with 8/20 microSec waveshape.

b) 10kA with 8/20 microSec waveshape.
9.0 QUALITY ASSURANCE PLAN:
9.1 The Manufacturer shall furnish Quality Assurance Plan (QAP) adopted by him/his
sub-supplier in the process of manufacturing all major equipment/components.
9.2 Precautions taken for ensuring the usage of quality raw materials and subcomponents shall be stated in the Quality Assurance Plan.
10.0 DOCUMENTATION:
10.1 The bidder/manufacturer shall submit 2 sets of complete drawings along with
detailed Bill of Quantity for approval to concerned SE, EHV Constrcution Circle,
MSETCL. In normal practice, the documents submitted for approval will be
commented upon or approved if in order, within 20 days from the date of receipt of the
same SE, EHV Constrcution Circle, MSETCL.
10.2 The manufacturing of the equipments shall be strictly in accordance with the
approved drawings and no deviation shall be permitted without the written approval of
the Design, Contarcst & Monitoring Department, MSETCL, Mumbai. All manufacturing
and fabrication work in connection with the equipments prior to the approval of the
1404 of 2461
PAGE 188 of 358
MMRDA
drawing shall be at the supplier's risk.
11.0 SCHEDULES:
11.1
11.1 The bidder shall fill in the following schedules, which form part of the bid
specification and offer. If the schedules are not submitted duly filled in with the offer,
the offer shall be rejected.
Schedule - A Guaranteed Technical Particulars for the Surge Arresters

Schedule - B List of Type Tests to be Carried Out and Submitted for Approval
Schedule - C List of Documents to be submitted for Approval
GUARANTEED TECHNICAL PARTICULARS FOR METAL OXIDE SURGE
ARRESTERS
1405 of 2461
PAGE 189 of 358
MMRDA
1406 of 2461
PAGE 190 of 358
MMRDA
1407 of 2461
PAGE 191 of 358
MMRDA
SCHEDULE - B
LIST OF TYPE TESTS TO BE CARRIED OUT AND SUBMITTED FOR APPROVAL
Manufacturer has to carry out following type test on all voltage ratings of surge
arresters and furnish the same for approval:
1) Insulation Withstand Test

2) Residual Voltage Test
3) Long Duration Current Impulse Withstand Test
4) Switching Surge Operating Duty Test
5) Power Frequency Voltage vs. Time Characteristic
6) Accelerated Aging Test
7) High Current Short Circuit Test
8) Low Current Short Circuit Test
9) Artificial Pollution Test
10) Partial Discharge Test
11) Bending Moment Test
12) Temperature Cycle and Porosity Test
13) Seal Leakage Test
14) IP-67 Test on Surge Counter
15) Environmental Test
16) STC on Terminal Connector (40kA for 3 Secs)
17) Seismic Test
18) Radio Interference Voltage (RIV) Test
1408 of 2461
PAGE 192 of 358
MMRDA
19) Galvanising Test
Special Tests for Polymer Housed Surge Arrester (Silicone Rubber Housing):
20) Weather Ageing Test for 1000Hrs

(i) Salt Fog Test
(ii) UV Light Test
21) Tracking & Erosion Resistance Test as per ASTM D-2303
22) Flammability Test as per UL-94
23) Silicon Content Test
Please note that, manufacturer has to submit the above stated type test reports for
respective surge arresters. In case he fails to submit the same, the drawing approval
of surge arrester will not be processed.
SCHEDULE - C
LIST OF DOCUMENTS TO BE SUBMITTED FOR APPROVAL
Following documents has to be furnished while submitting for approval:
1) General Arrangement Drawing

2) Palm Type Terminal Connector
3) Top Terminal Pad
4) Recommended Minimum Clearance
5) Porcelain/Polymer Insulator
6) Pressure Release Arrangement
7) Cross Section of Arrester Unit
8) Grading Ring
9) Surge Monitor
10) Method of Connecting Surge Counter with Surge Arrester
11) Insulating Base Fixing Details
12) Metal Oxide Varistor/ZnO Block
13) V-I Characteristics
1409 of 2461
PAGE 193 of 358
MMRDA
14) V-T Characteristics

15) Name Plate
16 Bill of Quantity
17) GTP in MSTECLs Standard Format
18) Quality Assurance Plan
1410 of 2461
PAGE 194 of 358
MMRDA
1411 of 2461
PAGE 195 of 358
MMRDA
1412 of 2461
PAGE 196 of 358
MMRDA
Principle technical parameters for Marshalling Boxes
1.0 GENERAL TECHNICAL REQUIREMENTS:
1.1 The marshalling box shall have the arrangement of terminal block Columns as
follows:
a) 200 Way marshalling box shall have four columns of terminal blocks, each with 50
terminals.
b) 120 Way marshalling box shall have three columns of terminal blocks, each with
40 terminals.
c) 60 Way marshalling box shall have three columns of terminal blocks, each with 20
terminals.
d) The installation of Terminal block shall commence from top of the column and
bottom side of the column shall be kept without terminal blocks so as to enable
installation of additional terminal blocks in future whenever required.
1.2 The marshalling box shall be dust, rain, vermin and weather proof suitable for
1.3 The box shall be standing on base & angle frame and having a single door with
three hinges for 200Way/120Way boxes whereas a single door with two hinges for
60Way boxes. Switch board type handle and locking arrangement and hooks for
padlocking shall be provided for the door. Holes of 23 mm diameter shall be provided
at the foundation pad for fixing to the foundation. Supply of foundation bolts of
adequate size and number shall be in the scope of the supplier.
1.4 Cable entries shall be from bottom. Removable gland plate of at least 10 SWG
thickness shall be provided for this purpose.
1.5 A switch, HRC fuse, socket and holder suitable for 230 V AC lamp shall be
provided.
1413 of 2461
PAGE 197 of 358
MMRDA
1.6 The dimensions of the marshalling box shall be adequate to ensure all clearances.
Details are indicated in the PTP.
1.7 The marshalling box shall be made out of cold rolled sheet steel.
1.8 A sloping rain hood shall be provided to cover all sides. All doors/covers shall be
designed with special shape sections and provided with adequate size of neoprene
gaskets to prevent ingress of moisture. The complete enclosure shall provide a degree
of protection not less than IP55.
1.9 Two nos. of earthing terminals shall be provided on two sides of the marshalling
box for connection to the earth mat.
1.10. Gaskets shall be provided all round the perimeter of doors & gland-plates.
Neoprene antivibration gasket of size 18mm x 5mm thickness, on door and
15mmx2mm thickness on gland plates shall be provided.
2.0 Nuts and Bolts: All nuts and bolts including foundation bolts shall be Electro
galvanized.
3.0 Terminal blocks:
3.1 TBs shall be M5 clip-on-type, one piece molded complete with insulated barriers,
stud type brass terminals, washers, brass nuts, brass lock nuts and identification
strips. Studs, Screws and Washers etc. shall be made out of brass bars or sheets and
shall be nickel plated. The springs shall be made of non-magnetic stainless steel. The
washers shall be of brass having minimum 0.5 mm thickness and nickel plated. The
connectors shall be rated for 1100 volts at 30A continuous current. The terminations
will be carried out with tinned electrolytic copper lugs of crimping type. The body of the
terminals shall be suitable to withstand 3500V for 1 minute under fault conditions.
3.2 Adequate Nos. of tinned electrolytic copper lugs suitable for 2.5sqmm/10sqmm
conductor as stated below shall be provided.
Type
Conductor Size
2.5 Sq.mm.
1414 of 2461
10 Sq.mm.
PAGE 198 of 358
MMRDA
A) 200 terminal M.K.
380 No. Lugs
20 No. Lugs
B) 120 terminal M.K.
230 No. Lugs
10 No. Lugs
C) 60 terminal M.K.
120 No. Lugs
---
4.0 Painting:
4.1. All sheet steel work shall be phosphated by seven tank method with the following
procedure and in accordance with IS: 6005 "Code of practice for Phosphating Iron and
Steel".
4.2 After application of the primer, two coats of finishing epoxy paint shall be applied,
each coat followed by stoving. The second finishing coat shall be applied after
completion of tests. The panel shall have color conforming to shade 631 of IS-5 for
outside and inside of the panel and black colour for base frame.
5.0 Tests:
5.1 The equipment offered shall be fully type tested as per list given below and as per
the relevant standards.
1) IP-55 Degree of Protection. 2) High Voltage Test. 3) Heat Run Test. 4) Voltage
drop across terminals before & after heat run.
5.2 Acceptance Test :
Following acceptance tests shall be carried out at the time of inspection
1) Insulation Resistance test

a) Between adjacent terminals.
b) Between terminals & metallic body.
2) High Voltage test
a) Between adjacent terminals.
b) Between terminals & earth.
6.0
The Marshalling Kiosks shall meet with the below listed basic technical
1415 of 2461
PAGE 199 of 358
MMRDA
requirements:
Requirements
Particulars
200 Ways
6.1
120 Ways
60 Ways
General requirements:
6.1.1
Installation
Outdoor Type
6.1.2
Type
Pedestal Mounting
Inside min.
clearance
6.1.3
(dimension in
1200
1200
750
mm)
H
6.1.4
900
750
750
6.1.5
350
350
350
6.1.6
Electrical
Clearance
As per IE Rules 1956
Min. thickness of
6.1.7
sheet steel SWG
12 SWG (2.50 mm)
(mm)
Degree of
6.1.8
Protection as per
IP 55 or better
IS 2147
6.2
Terminal Block:
Suitable to connect 10 Sq.mm. aluminum and 2.5
6.2.1
Size
Sq.mm. copper conductor as per standard drawing

available on MSETCLs website.
6.2.2
Type
Stud type with transparent cover
6.2.3
Normal Current
30A
6.2.4
Rated voltage
1100 Volts
6.2.5
Insulation Level
3 kV 1 Minute
6.2.6
Minimum
clearance
between terminal
250 mm
block and cable

gland
1416 of 2461
PAGE 200 of 358
6.2.7
MMRDA
Minimum
clearance
between two
180 mm
rows of terminal
block
6.3
Fuse base, fuse link, Fuses & Neutral Links:
6.3.1
Type
HRC
6.3.2
Normal Current
15 A
6.3.3
Rated voltage
1100 V
6.3.4
Insulation level
3 kV 1 Minute
Surface
Epoxy powder coating to Colour Shade No. 631 as
coating/painting
per IS-5, both inside & outside.
6.3.5
NOTE: -
* - Provision for arrangement of the addition of extra Terminal Block shall be made,
if required.
Principle technical parameters for Street lighting poles and fixtures
Street light poles and fixtures

1. The pole shall be tubular type steel structure.The tubular pole shall have
stepped construction, having 150mm diameter at the bottom and 100mm and
75mm dia respectively at the middle and top. Cable entry shall be through
mounting pipe and shall be terminated on a 2 way connector inside the control
box.
2. The control gear shall consist of all the necessary components pre-wired up to
terminal block, and shall be suitable for mounting on the tubular pole at a height
of 7.7M above ground. The poles shall be as per Drawing no. DES. & ENG.III/252.536 enclosed.
3. The lighting fixtures shall be dust and weather proof, suitable for outdoor
installation having a degree of protection not less than IP43. The fixture shall
comprise of a deep drawn aluminum lamp housing and a die-cast aluminum
alloy weather proof box for housing control gear. Alternatively, one piece, deep
1417 of 2461
PAGE 201 of 358
MMRDA
drawn sheet aluminum enclosure with partition for lamp housing and control
gear may be offered. The fixture shall have external finishing of stoved enamel
of grey hammer stone shade.
4. Interior of lamp housing shall have stoved white enamel finish.
Electro
brightened and anodized side reflector shall ensure high light output from the
1x150W high pressure sodium vapor lamp to be provided for each fixture. The
fixture shall have clear acrylic bowl of high transparency fitted with tropicalised
and ozone resistant gasket. The bowl shall be of hinged design, and shall be
secured to the lamp housing by means of stainless steel toggles. It should be
possible to replace the bulb by releasing the toggles and opening the acrylic
lamp cover.
5. Loops of approximately 1 meter length shall be provided at each pole bottom

for the cables used.
6. Pipe type earthing is to be provided to Main DB and for each pole and to be
connected at suitable location on pole to have effective earthing.
7. Two separate pipes are to be used for incoming and outgoing cables at each
pole.
Specifications for Control and LT Power Cable
1.0 STANDARDS:
1100 V grade standard FRLS type C2 category control cable and LT XLPE
FRLS type C2 category power cables shall conform to latest revisions available
at the time of placement of order of all relevant IS standard as listed in Table I
& II.
2.0
GENERAL TECHNICAL REQUIREMENTS FOR FRLS TYPE C2 CATEGORY

CONTROL AND POWER CABLE:
2.1
2.1.1
CONDUCTOR:
Copper conductor used shall be made from high conductivity copper rods
1418 of 2461
PAGE 202 of 358
MMRDA
complying with IS: 613/1964 (amended upto date). The copper conductor shall
consist of untinned annealed High
conductivity copper.
2.1.2 2.5 Sq.mm copper conductor where specified shall have three strands and
Class-2 flexibility as per IS: 8130/1984 (amended upto date).
2.1.3 Aluminium conductor shall be made from E.C. grade aluminium and shall
conform to class-2 as per IS: 8130/1084 (amended upto date). The material of
the aluminium conductor shall be of H2/H4 grade.
2.1.4 Number of strands shall not be more than the minimum numbers stated in IS:
8130/1984 (amended upto date).
2.2
INSULATION:
2.2.1 The insulation shall be of Type-A PVC compound conforming to requirement

of IS: 5831/1984 (amended upto date) & shall be applied by extrusion.
2.2.2 The average thickness of insulation and tolerance on thickness of insulation

shall be as per IS: 1554 (Part-I)/1988 (amended upto date).
2.2.3
The insulation shall be so applied that it fits closely on the conductor and it
shall be possible to remove it without damage to the conductor.
2.3
CORE IDENTIFICATION:
2.3.1 For cable with up-to five cores, the cores shall be identified by colour as per
Clause No.10.1 of IS: 1554 (Part-I)-1988 (amended upto date).
2.3.2 For reduced neutral conductor, the insulation colour shall be black.
2.3.3 For 6 core and above, cores shall be identified by numbering as per Clause No.
10.3 of IS: 1554 (Part-I)/1988 with a grey base colour.
2.4
LAYING UP OF CORES:
1419 of 2461
PAGE 203 of 358
MMRDA
2.4.1 In two, three and other multi-core cables, the cable shall be laid up together
with a suitable lay; the outermost layer shall have right-hand lay and the
successive layers shall be laid with opposite lay, where necessary, the
interstices shall be filled with non-hygroscopic material.
2.4.2 The recommended plan for lay-up of cores shall be as per IS: 1554 (Part-I)1988 (amended upto date).
2.5
INNER SHEATH:
2.5.1 Filler and inner sheath shall be of non hygroscopic fire retardant material, shall
be softer than insulation and outer sheath, Inner sheath shall be of type ST-1.
It shall be ensured that the shape is as circular as possible. The inner sheath
shall be so applied that it fits closely on the laid up cores and it shall be possible
to remove it without damage to the insulation.
2.5.2 The thickness of the inner sheath shall be as per IS: 1554 (Part-I)/1988
amended upto date.
2.6
ARMOURING:
2.6.1 The armouring shall be of single Galvanized steel wire/formed wire/strips as

per provision of IS: 1554(Part-I) amended upto date and the same shall comply
with the requirements of IS: 3975/1988 amended upto date.
2.6.2 When armouring is specified for single core cable, the same shall consist of
aluminium wire/strips.
2.6.3 Armouring shall be applied over the insulation in case of Single core cable and
over the inner sheath in case of two, three and multi-core cables.
2.6.4 The armour wires/formed wire/strips shall be applied as closely as practicable

with minimum coverage of 90%.
1420 of 2461
PAGE 204 of 358
MMRDA
2.6.5 The direction of lay, a binder tape, type of armour, joints in armour and
resistance of armour shall be as per Clause No.13.0 of IS:1554 (Part-I)/1988
amended upto date.
2.7
OUTER SHEATH:
2.7.1 The outer sheath shall be of ST-1 Type FRLS PVC compound conforming to
the requirements of IS: 5831/1984 amended upto date. It shall be applied by
extrusion.
2.7.2 The application, colour and thickness of outer sheath shall be as per Clause
No.14.0 of IS: 1554 (Part-I)-1988.
2.7.3 The following particulars shall be embossed on the outer sheath at intervals of
not exceeding one meter throughout the length of the cable.
(a) Manufacturer's Name

(b) Voltage Grade
(c) Year of Manufacture
(d) M.S.E.T.C.L.
(e) Type (FRLS)
3.0
GENERAL TECHNICAL REQUIREMENTS FOR LT XLPE FRLS TYPE C2

CATEGORY POWER CABLES:
3.1
Armoured Cable:
1100 volts Grade L.T. FRLS type C2 category cable with standard H2/H4 grade
of E.C. grade Aluminium Conductor, XLPE insulated, colour coded, laid up, with
fillers and/or binder tape (where necessary), provided with extruded PVC inner
sheath, single galvanized steel strip armoured & provided with PVC outer
sheath. Both inner and outer sheath shall be of Type ST-2 conforming to IS7098 (Part-I) 1988 (amended upto date) and bearing FRLS & ISI mark.
3.2
Insulation, Inner sheath & outer sheath: Insulation, inner sheath and outer
1421 of 2461
PAGE 205 of 358
MMRDA
sheath shall be applied by separate extrusion. Inner sheath shall be applied by

extrusion only. Bedding of PVC tape for inner sheath is not acceptable. Colour
of outer sheath shall be Black.
4.0
TESTS:
4.1
Type Test:
4.1.1 All the cables should have been successfully type tested as per IS: 1554(PartI)/1988 amended up to date for control cables and IS: 7098 (Part-I) 1988,
amended upto date for power cables.
Following tests shall constitute as optional tests to be carried out on cable on

both types of cables:
a) Oxygen Index: Min. 29 (As per ASTM D 2863)

b) Temperature Index: 250 Deg. C (As per ASTM D 2863)
c) Flammability Test:
i) Swedish Chimney method (As per SS.424-14-75 Class F3
ii) Grouped vertical cable under fire condition (As per IEEE - 383 )
iii) Bunched vertical cables in enclosure under line condition (As per IEC-332-3
category-B)
d) Halogen acid gas (HCL) estimation Max. 20% (As per IEC 754 Part-I)
e) Smoke Density test Max. 60% (As per ASTM D 843)
4.2
Routine Tests:
All the Routine tests as per IS: 1554 (Part-I)-1988 amended up to date for
control cables and IS-7098 (Part-I)/1988, amended upto date for power cables
shall be carried out on each and every delivery length of cable.
4.3
Acceptance Tests:
All acceptance tests as per IS: 1554 (Part-I)-1988 amended up to date for
control cables and IS-7098 (Part-I) 1988, amended upto date for power cables
shall be carried out on the sample taken from the delivery lot including the
1422 of 2461
PAGE 206 of 358
MMRDA
optional test as per Clause No 4.1.1.
LIST OF STANDARDS FOR L.T. PVC TYPE C2 CATEGORY CONTOL & POWER
CABLE
SR. NO.
STANDARD NO.
TITLE
1.
IS:1554 (Part-I) 1988
2.
IS:8130/1984
3.
IS:5831/1984
4.
IS:3961/1967
Recommended current rating for cables
5.
IS:3975/1988
Armouring of cables.
6.
IS:613/1964
7.
ASTM D2863
PVC insulated (Heavy Duty) electric

cables.
Conductors for insulated electric cables
and flexible cords.
PVC insulation and sheath of electric
cables
Specification for copper rods for electrical

purposes.
Standard test method for measuring the
minimum oxygen concentration to
8.
ASTM D2843
support caldle like combustion of plastics

(oxygen Index).
9.
IEC 60332-3
10.
SS-424-14-75 (Class-F3)
Tests on electric cables under fire

condition.
Svensk standard for flammability testing.
IEEE standard for type test of class I.E.
11.
IEEE-383
electronic cables, Field splices and

connections for nuclear power generating
stations.
12.
IEC-754 Part-I
---
LIST OF STANDARDS FOR L.T. XLPE FRLS TYPE C2 CATEGORY POWER

CABLES
1423 of 2461
PAGE 207 of 358
SR. NO.
MMRDA
STANDARD NO.
TITLE
Specification for XLPE Insulate PVC
sheathed
1.
IS 7098 (Part-I)/88
cables for working voltages upto and

including
1100 volts.
2.
IS 5831/84
3.
IS 8130/84
4.
IS 3975/88
5.
IS 10482 (Part-I)-1983
6.
ASTM D2863
Specification for PVC Insulation and

sheath of electric cable.
Specification for conductors for Insulated
Electric Cables as flexible cords.
Specification for Mild Steel wires formed
wires and tapes for Armouring of cables.
Fictious calculation method.
Standard Test Method for Measuring the
minimum Oxygen concentration to support
Candle like Combustion of Plastics
7.
ASTM D2843
(Oxygen
Index)
8.
IEC-60332-3
9.
SS-424-14-75
Tests on Electric Cables under fire

condition
Svensk standard for flammability testing.
IEEE standard for Type Test of class IE
10.
IEEE-383
Electronic Cables ,Field Splices, and

connections for Nuclear Power Generating
Stations.
Specifications for centrifugally cast C. I. Pipe Earthing set (Station Type A) for EHV
Substation
1.0
The earthing electrode, station type A, shall be CENTRIFUGALLY CAST , cast

iron pipe of 150 mm nominal diameter with standard length of 3 meters
(Tolerance +/-5%) and 10mm thickness, without spigot.
1.1
The C.I. pipe shall be provided with perforations of 16mm on opposite sides of
1424 of 2461
PAGE 208 of 358
MMRDA
wall, at an alternate distance of 75mm along the length, as shown in the

enclosed diagram (D&E-S2/419).
1.2
The earthing set shall be provided with cast iron funnel with wire mesh as
shown in the diagram.
1.3
The drawing (No. D&E-S2/420) indicating typical earth pit arrangement is

enclosed.
2.0
The cast iron pipe shall have clamping arrangement for connecting to the
Earth Grid as per the enclosed drawing No.(D&E-S2/419, the description
of which shall be as follows
2.1 Two strips of M.S. Flats (hot dip galvanized) of size 75 x 10mm shall form twohalf
rings around the socket position of the C.I. Pipe for fixing to the pipe, and
extend on both sides for clamping and fixing the earth grid as shown in the
drawing.
2.2
The half rings of M.S. Flats shall be bolted rigidly to the C.I.Pipe at four
points 90 deg. apart with 16mm bolts and nuts and shall be punched for rigid
fixing as shown in the drawing.
2.3
The two strips of M.S. Flats shall be bolted together on both sides with 16mm
bolts and nuts as shown in the drawing.
2.4
Two pairs of holes on each side of the M.S.Flat shall be provided at 40mm
centre to centre for fixing the earth grid to the Electrode with 12mm dia bolts.
1.8
All bolts nuts and washers shall be hot dip galvanized, of GKW or equivalent
approved make, and the spring washer shall be of spring steel, duly electro
galvanized.
1.9
M S Flat of size 75x10 mm shall be used to form Main & Grid conductors of
the earth mat
& 50x8mm G.I. Flats for risers meant for structures and
equipments earthing. Joints between GI flats shall be welded and painted. Earth
1425 of 2461
PAGE 209 of 358
MMRDA
terminal connection with equipments shall be bolted tightly for firm contact.
Technical specifications Conductor (ACSR & AAA), 4 IPS tube (Aluminum bus
bars) and earth wire.
Technical specifications Conductor (ACSR & AAA) and earth wire
1.0
Technical specifications for conductor(ACSR) and earth wire
1.1
ACSR type zebra, shall be used for the 132 KV switchyard portion. twin
conductor shall be used for 132 KV main buses.
1.2
Aluminum strands of ACSR shall be manufactured from electrolytic

grade aluminum rods suitably hard-drawn on wire drawing machines.
1.3
Re-enforcing steel wire (galvanized) of ACSR shall be drawn from high

carbon steel rods produced by any of the following processes.
a) Acidic or open heat process.
b) Electric furnace process or basic oxygen process.
1.4
No joints shall be permitted in the Aluminum wires in the outermost layer

of ACSR. Similarly, no joints shall be permitted in the galvanized steel
wire except those in the base rod or wire before final drawings.
2.0
The conductor shall meet with the following technical parameters
No.
Parameter
Specification
ACSR Z
ACSR M
Number of strands / wire diameter

Aluminum
54/ 3.18 mm
54/3.53 mm
Steel
7 / 3.18 mm
7/3.53 mm
Sectional area (overall)
484.5 mm
597 mm2
Sectional area (aluminum only)
428.9 mm
528.5 mm2
Overall diameter
28.62 mm
Approximate weight
1621 Kg/Km 1998 Kg/Km
Calculated DC resistance at 20C
31.77 mm
0.06915 /Km
0.05596
/Km
3.0
The earth wire shall meet the following technical parameters
1426 of 2461
PAGE 210 of 358
MMRDA
7/3.15 mm
7/3.66 mm
Size of strand
3.15 mm
Number of strands
7 Nos
7 Nos
Type of Galvanizing
Heavily hot
heavily hot
dip galvanized
3.66 mm
dip
galvanized
4.0
Overall diameter of earth wire
9.45 mm
10.98 mm
Ultimate tensile strength
54 KN
68.4 KN
TYPE TESTS
The following type tests shall be conducted on the samples of conductor in

presence of Purchasers representative. The sample for type tests shall be
selected by Purchasers representative. The type test shall be conducted once
on sample/samples of conductor for every 1500 Kms or part thereof of
production from each manufacturing facility.
7.1
Ultimate Tensile Strength.
7.2
Corona Extinction Voltage on twin or quadruple conductor as the case

may be.
7.3
Radio Interference Voltage on twin or quadruple conductor as the case

may be.
7.4
DC Resistance at 20 Deg C and at various temperatures.
7.5
Stress-Strain Test and design stress-strain curves shall be submitted to

the purchaser.
7.6
Ampacity Test (current carrying capacity test) at various temperatures.
5.0
ROUTINE/ACCEPTANCE TESTS
5.1
Visual and Dimensional Check on Drum

8.2 Visual Check for Joints, Scratches etc.
8.3 Dimensional Check on Aluminum Alloy/Aluminium Strands
8.4 Lay- Ratio Test of Various Layers
8.5 Elongation and Torsion Tests
8.6 Breaking Load Test on Aluminium/Aluminum Alloy Strands
1427 of 2461
PAGE 211 of 358
MMRDA
8.7 Breaking Load Test on welded Aluminium/Aluminium alloy strands.

8.8 Breaking Load Test on Steel Strands.
8.9 Resistance Test
5.2 Length/Weight verification of conductor/earthwire by rewinding method.
8.11
Wrapping test on Aluminum & Steel strands for ACSR conductor.
8.12
Dip test & mass of zinc test for steel strands.
LIST OF STANDARDS
The 560 Sq.mm. AAA conductor shall conform to the following Indian Standard which
shall mean latest revision/amendments/changes adopted and published:
(i) IS 398(IV)-1994
Specification for Aluminum/Alloy
Part I to V as relevant
Conductors for overhead transmission purposes.
(iii) IS: 1778:1980
Reel and Drums for bare conductors.
(iii) IS: 8263: 1976
Method of Radio Interference tests on High

Voltage insulators
(iv) IS: 1841
EC grade Aluminum rod produced by rolling

(2nd revision)
(v) IS: 7623
Specification for Lithium soap grease.
(vi) IS: 9997 1988
Aluminum Alloy redraws rods.
(vii) IS 12776-2002
Specification for G.S. earthwire.
7.
Technical specifications for GI perforated cable trays
Specifications for G.I. Perforated Trays (HOT DIP Galvanised)
1.0
1.1
SCOPE
This specification covers design, manufacturing, predispatch instructions

and supply of Hot dip Galvanised perforated cable trays of various sizes
required for laying of control and power cables at our various 400KV S/S.
1428 of 2461
PAGE 212 of 358
2.0
2.1
REQUIREMENT
The various sizes of cable trays required are as below:

Size of tray
3.0
MMRDA
Thickness of Sheet/Tray
80 x 20 mm
1.6mm (16 SWG)
200 x 40mm
2.0mm (14 SWG)
400 x 40mm
2.0mm(14 SWG)
STANDARDS
3.1 The recommended practice for hot dip galvanizing of iron and steel and method
for testing and inspection shall conform to the requirements of the latest Indian
or American or British standards and in particular to the latest edition of the
following Indian Standards.
i)
IS 2629 Recommended practice for hot dip galvanizing of iron and
steel.
ii)
IS 2633 Method for testing uniformity of casting on zinc coated
articles.
iii)
IS 4759 Method for determining of mass of zinc coating on zinc coated
iron and steel.
4.0
SPECIFIC TECHNICAL REQUIREMENTS
4.1
The trays shall be perforated as per our drawing No. PTCC/34 enclosed
with this specification.
4.2
The trays shall be hot dip galvanized after punching the perforation with
a coating of zinc not less than 340 g/m2.
4.3
Each tray shall be of standard length of 2.5 meters.
4.4
Trays shall be supported by cross arm at interval of 1500 mm and shall be

clamped to
cross arm with the help of 2 nos. of 8 mm dia bolts. (This
clause is only for guidance of bidder to design the strength of the cable trays
1429 of 2461
PAGE 213 of 358
MMRDA
and to make provision for fixing 8 mm dia bolts).
4.5
The offered tray shall not have sharp edges, cuts, abrasions, etc. & the zinc
coating shall be adherent, smooth, reasonably bright, continuous and free
from such imperfections like flux, ash and dross inclusions, bare and black
spots pimples, lumpiness and runs, rust stains, bulky white deposits and
blisters.
5.0
INSPECTION AND TESTING:
5.1
The cable trays shall be subjected to galvanizing
test as per relevant
standard specified above, in presence of MSETCLs, representative at the time

of inspection..
Technical Specifications for Power Line Carrier Equipments:
A)
For 220KV & below schemes
1.1.0
LINE TRAPS:
1.1.1. The line traps offered shall conform to the technical requirement as per
Annexure III-T-A. Line traps shall block the entry of carrier signal into
switchyard, but at the same time shall prevent undue loss of carrier signal for
all power system conditions, thus making functioning of the Power Line Carrier
Systems independent of switching conditions inside the sub-station. Its
impedance shall be negligible at power frequency (50 Hz) so as not to affect
the power transmission but must be relatively high for the entire carrier
frequency band.
1.1.2. Line trap shall consist of a main coil designed to carry continuously the rated
current at the maximum ambient temperature. It shall be provided with a
suitable protective device and a tuning device.
1.1.3. Line trap shall be provided with a protective device which shall be so designed
1430 of 2461
PAGE 214 of 358
MMRDA
and arranged that neither significant alteration in its protective functions nor
physical damage shall result from either temperature rise or the magnetic field
of the main coil at continuous rated current or rated short time current. The
protective device shall neither enter into operation nor remain in operation
following transient actuation of the power frequency voltage across the line trap
by the rated short time current. For proper co-ordination with the lightning
arrestors installed in the sub-stations, the line traps shall be provided with
protective device. The lightning arrestor shall conform to the technical
requirement as per item 11 of Annexure III-T-A.
1.1.4. For 220KV line traps, no visual corona discharge at 156KV r.m.s. power
frequency voltage should take place. Depending on the design, it may be
necessary to provide bird barriers, which shall be included by the bidder in his
offer.
1.1.5. Line traps are to be tuned for a broad carrier frequency band (90 KHz to 500
KHz) which will include the carrier frequency pairs chosen for transmission line
section. The resistive component of impedance of the trap, within its bandwidth,
shall not be less than 600 ohms.
1.1.6. The line traps should be suitable for outdoor pedastal mounting and the
hardware for pedastal mounting including the Lattice type support structure with
three post insulators as approved by MSETCL shall be provided. Mounting
Pedestal should match with lattice type structure with three post insulators as
approved by MSETCL vide Letter No. MSETCL/CE (Tr. Proj.)/D&E IV/WT
Structure/14514 Dtd. 27.10.08. Magnetic separators if required shall also be
provided. (The drawings are attached in Annexure I)
1.1.7. The bidder shall quote line traps (of series 2) for following rated continuous
current and rated short-time current capacities, as per IS-8792-1978.
Rated
continuous Rated short-time current (series
current
2)
1) 1600 A
40KA
1431 of 2461
PAGE 215 of 358
MMRDA
1.2.0 COUPLING CAPACITORS:
1.2.1. The coupling capacitors shall conform to the technical requirement as per
Annexure III-T-B.
1.2.2. The coupling capacitor shall have the capacitance of 6600pf (+10%) and shall
be mounted directly on pedestal suitable for MSETCLs standard structure as
per the drawings available on MSETCLs website.
1.3.0. COUPLING DEVICES:
1.3.1 The coupling devices shall be designed to perform the following functions:
i)
Coupling filter:- Coupling filter in conjunction with the capacitance of the

coupling capacitor shall constitute an electric filter of band-pass type. It
shall match the characteristic impedance of the high tension line with
impedance of the connection line for PLC transmitter/ receiver.
ii)
Drainage of charging current::- The primary of the coupling unit shall

have a low impedance for the operating frequency of the power line (50
Hz) so that the charging current of the coupling capacitor is grounded.
iii)
Isolation:- The coupling device shall provide the isolation between input
and output circuits and should be able to withstand a test voltage of at
least 5KV r.m.s. for 1 minute. The coupling device may form a single
assembly or be divided into several separate components. The same
component may take over more than one function.
1.3.2. The coupling device shall conform to the technical requirement as per Annexure
III-T-C.
1.3.3. The composite loss:- It is the power loss occurring in the carrier signal after
passing through the coupling device along with the coupling capacitor. Coupling
device is supposed to be loaded with its primary and secondary impedances
while capacitor is assumed to have no loss.
1432 of 2461
PAGE 216 of 358
MMRDA
1.3.4. The bidders shall specify the minimum capacitance of the coupling capacitors
with which the coupling devices may be used for the 90 KHz to 500 KHz
transmission band.
1.3.5. The coupling devices shall be provided with the three element protective
devices, as detailed below, which shall protect the carrier equipment against
excess voltage which may occur when the coupling capacitor becomes
defective or the ground lead connected to the coupling device is interrupted.
i) Drainage coil: To ground the charging current of the coupling capacitor.
ii) Protective device: To protect the carrier equipment against excessive

voltage.
iii) Earth switch: For grounding low voltage terminals for carrying out
maintenance or any other work on coupling device. Proper locking
arrangement shall also be provided for the Earthing switches.
1.3.6. Two nos. phase-earth coupling devices should be capable of being used to form
phase-phase or inter-circuit coupling in such a manner that even if one coupling
device fails the system continues to work on phase to earth coupling basis
without any mismatch problems. The cost of the matching transformer shall be
included in the cost of coupling devices offered.
1.3.7. The coupling devices offered shall be suitable for 75 ohm unbalanced HF output
impedance and shall be of 200W capacity
No lightning arrestor shall be
provided at the carrier side of the coupling device.
1.3.8. The coupling device shall be suitable for line impedance as indicated in
Annexure III-T-C. Adequate number of taps shall also be provided on the line
side of the coupling device so as to make it possible to achieve matching with
actual line side impedance during commissioning.
1.3.9. The coupling filters (LMU) should be housed in a weather proof galvanized steel
1433 of 2461
PAGE 217 of 358
MMRDA
casing suitable for installation on the steel pedestal which shall also be used
for mounting capacitors.
1.3.10.
All the elements of the coupling device and protective device will be
mounted on a single galvanized steel frame to be mounted on the steel support

of the coupling capacitor. The bidders shall include the interconnecting copper
leads of 4 mm sq. cross-section. All connectors shall be provided with crimped
lugs and stainless steel nuts and bolts for connection.GI bolts for fixing the steel
frame to the coupling capacitor support shall be included in the scope of
supply.
1.4.0 HIGH FREQUENCY CO-AXIAL CABLE (UNBALANCED) I.S. 5802 Part-II 1975
1.4.1. High frequency co-axial cable shall be offered to connect coupling unit installed
In the switchyard to the PLC terminals installed indoor. The high frequency
cable to be offered by the bidders shall be suitable for being laid directly to the
ground or in trenches or in ducts. The cable shall be braided tinned copper
screened and steel armored. The capacitance of the cable shall be low so as
to minimize attenuation at the carrier frequency range. The impedance of the
HF cable shall match with the output impedance of the PLC terminals and
secondary impedance of the coupling units. The cable shall be insulated to
withstand a test voltage of 4KV. The H.F. cable offered shall conform to the
technical requirements as per Annexure III-T-D.
1.5.0. POWER LINE CARRIER TERMINAL:
1.5.1. The Bidders shall offer (2x4) KHz Twin channel, multipurpose, Field tunable
PLC terminals of latest IC virsion Technology for 132KV Lines.
1.5.2. PLC terminals of latest IC version are required for speech Tele-protection and
other superimposed channels. The PLC terminal shall be suitable for adjacent
band working and shall have necessary frequency stability.
The entire
signaling band shall be available for transmission of data from one station to
end station with back to back connection of signaling band at the in between
stations. Filters or any other equipments required for this purpose shall be builtSECTION 6B4_B: ELECTRICAL WORKS UNDER MSETCL SUPERVISION
1434 of 2461
PAGE 218 of 358
MMRDA
in feature of the PLC terminal offered for all 220 KV, 132KV transmission lines.
The carrier terminals offered for lines of different voltages shall conform to the
technical requirements as per Annexure III-T-E.
1.5.3. Provision shall be made in the carrier terminals offered to compensate for rising
and falling trend of frequency response due to change of line characteristics.
The measures adopted to incorporate this feature with its limitations shall be
clearly brought out in the offer.
1.5.4. The Bidders shall offer fully field tunable (suitable for tuning at site) PLC
terminals including
a) programmable transit band-pass filters, data cards, from 300 to 3760 Hz in

incremental steps of 60 Hz.
b) Programmable "Pilot" frequency
c) Programmable "speech cut off" suitable for 2 KHz and 2.4 kHz.
The tuning of frequencies shall be possible both in IF and H.F. sections. The
tuning of frequencies shall be easily possible without any cumbersome
procedure. Any equipment required for this purpose shall be clearly brought
out and shall be offered as an optional item. The procedure for tuning of
frequencies shall be given in detail in the offer, with the support of drawings etc.
1.5.5. Suitable facility shall be incorporated in the PLC terminals to compensate the
mismatch introduced due to paralleling of a number of PLC terminals at a
station. Measures adopted for this purpose shall be clearly brought out and
explained in detail in the offer.
1.5.6. Suitable connectors for termination of H. F. cable of 75 ohms unbalanced

and150 Ohms balanced impedance shall be provided in the PLC terminal. The
connectors shall be of universal type suitable to adopt 75 ohms unbalanced and
150 Ohms balanced H.F. cable, and also suitable for connection to adjacent
PLC terminals. The connectors shall be installed in the PLC cabinet at such a
height as to facilitate working with ease. Screw clamp type terminals shall be
provided for interconnection wiring.
1435 of 2461
PAGE 219 of 358
MMRDA
1.5.7. The PLC terminals shall be equipped with companders through selectable
switches so as to enable to introduce as and when necessary. Further, the PLC
terminals shall also be provided with the following minimum built-in features:
i) H.F. hybrid to facilitate adjacent band working.
ii) Matching transformer to facilitate working for 75 ohms unbalanced and 150
Ohms balanced impedance.
iii) Dummy impedance 75 ohms unbalanced and 150 Ohms balanced, for
testing, with a selector switch as applicable.
iv) Transit band pass filter to facilitate data transmission.
v) Universal type H.F. connector suitable for 75ohms unbalanced and 150
Ohms balanced H.F. cable as applicable. The H.F. connectors shall be T-type
and mounted at such a height so as to facilitate working with ease.
vi) Exhaust fan working on 230 V, 1 phase, A. C. supply.
vii) Loop test facility.
viii) Each PLCC terminal for speech as well as for protection purpose shall be
provided with plug in type telephone hand set, four wire express telephone &
buzzer
ix) a) Normal band width of each PLCC channel shall be 300-3600 HZ and
shall be suitable for transmission of Facsimile messages preferably at
2400 baud.
b)
One speech channel 300-2000 HZ plus a band of 2000-4000 HZ for the

transmission of data. Data signaling rates 50, 200, 600, 1200 baud shall
be possible.
1436 of 2461
PAGE 220 of 358
c)
MMRDA
Three 600 baud channels or one 2400 baud channel for full band of 3003600 HZ
d)
Transmission for speech and protection channels. Protection channels

shall be suitable for coded as well as un coded transmission and should
have in-band signaling i.e trip signal frequencies shall be transmitted
within the speech band without any necessity for separate band for
protection.
1.5.8. The PLC Terminal shall be provided with the required alarm facilities such as
pilot fail, carrier fail etc. The indication on panel shall be by display LED's
together with an acoustic (audiable) alarm. Three spare potential free contacts
shall be provided and wired unto terminal strip for remote indication.
1.5.9. The PLC terminals shall be provided with emergency call facility from the carrier
set for point to point contact with the next station complete with telephone hand
set suitable for hanging inside the PLC cabinet and with termination to enable
to connect an external telephone set for point to point communication.
1.5.10. In the PLC terminals offered suitable features shall be incorporated to ensure
that in the
event of any short circuit of the output terminals of the power
supply unit. The unit is switched off the supply without causing any damage to
the power supply unit itself. This is necessary to provide protection against any
accidental short circuits or short circuits due to failure of some components in
the circuits.
1.5.11.
The power consumption of the PLC terminals shall be minimum and shall
be commensurate with the output power of the PLC terminals as specified to

keep the size of the battery optimum.
1.5.12.
PLC terminal shall be mounted in floor mounting, vermin proof sheet
metal cabinet. The construction will incorporate a swing frame on which all the
equipments are mounted. The cubicle shall be provided with an exhaust fan on
the top working on 230 V, A.C.,1-phase. Louvers for inlet of air in the cubicle
shall be provided at the bottom of the cubicle to avoid dust entering from below.
1437 of 2461
PAGE 221 of 358
MMRDA
The individual parts of the carrier set should be accessible from the front,
making it possible to place the carrier cabinets side by side, back to back and
against the wall. All component parts of the carrier sets shall be suitably
tropicalised and protected against bad effects of humidity, fungus etc. Building
block principle should be employed in the construction of carrier sets. The
cabinet shall be suitable for top or bottom cable entry.
1.5.13.
The PLC Terminal described above is of anologue design / type.
Bidder may Offer partly or fully digital PLC Terminals of equivalent or

Better performance / features. These shall, however, meet the basic
requirements
specified
above
and
shall
not
have
any
price
difference.
1.6.0. EQUIPMENTS FOR TELEPROTECTION:
1.6.1. The F.M. voice frequency transmission equipment for protection signaling is
required for transfer of trip commands from one end of the line to the other for
remote tripping of breaker.
1.6.2.0. TELEPROTECTION EQUIPMENT FOR 220KV/132KV/100KV LINES:
1.6.2.1.
i) The built in protection coupler shall be suitable for transmission / reception
of two commands with a possibility to extend up to four commands in future by
just inserting additional modules. Further when the protection coupler is
equipped for four commands, it shall be possible to programmer them as two
coded and two un-coded commands. Trip commands from protection coupler
should have a coded signal.
1.6.2.2 The speed of transfer trip channels shall be such that the time interval
measured from the point of initiation of the transmitter (including the time
taken for transmission of the signal over carrier link) and closing of the output
contact at the receiver end shall not exceed 25 ms
1438 of 2461
PAGE 222 of 358
MMRDA
1.6.2.3.The Tele-protection equipment shall be provided with interconnection unit

suitable for connection to the protective relays. The output contact provided in
the receiver shall be capable of making the trip coil circuit of the 132KV breaker
whose rating is 220 V D.C., 200 W per trip coil per phase. In case, however, an
additional relay is required to be included for providing the contact of desired
rating, the trip transfer time of 25 ms shall be inclusive of the operating time of
this auxiliary relay.
1.6.2.4.The carrier protection equipment offered shall be suitable for transmission of

double protection commands.
1.6.2.5.The bidders shall offer only inband type tele-protection equipment such that
speech channels and the tele-protection signals are arranged in such a manner
that the superimposed signaling band is kept free for tele-metering, etc. In other
words, the transmission of Tele-protection signals should take place within
speech band. No trip signaling frequency should be beyond 2000 HZ.
1.6.3.0. COMMON FEATURES FOR TELEPROTECTION EQUIPMENT:
1.6.3.1.The voice frequency transmission equipment shall be insensitive to corona

noise and shall remain unaffected by impulse type noises generated by
operation of switchgear equipments or by short circuits. The bidder shall clearly
explain the measures adopted to make the equipment insensitive to corona
noise, white noise and impulse type noise of amplitude greater than the level of
trip signal.
1.6.3.2.The protection equipment offered by the bidder shall include 2 Nos. of

changeover contacts as spares for use by the protection relaying scheme. In
addition to these, 4 Nos. of spare changeover contacts shall be provided for
each of the supervision contacts provided in his protection equipment. The
bidder shall prepare a coordinated interconnection drawing to connect his Teleprotection equipment with the protection relays.
1.6.3.3. Test facility should exist for end to end and loop test with equipment remaining
fully operational without transmission of genuine trip command during testing.
1439 of 2461
PAGE 223 of 358
MMRDA
1.6.3.4. The total number of VFT channel for protection signaling shall be as indicated
in the schedule of requirements.
1.7.0. ELECTRONIC AUTOMATIC EXCHANGE FOR PLCC:
1.7.1. The Electronic Private Automatic Exchange (EPAX) for PLCC shall be used at
all the sub stations in M. S. E. T.C.L s Power Grid, where several local
subscribers shall be able to inter-communicate selectively with one another as
well as place or receive trunk calls. The EPAX offered shall be of latest
technology and of modular design. Any line (outlet) of the EPAX shall be
reached by any other line of the same EPAX by dialing the corresponding local
number. The latter shall consist of one or two digits according to the number of
lines. No four wire group selectors are being provided for the PLC terminals. As
such the EPAX offered shall incorporate the function of four wire group
selectors also for all the directions. The EPAX offered shall conform to the
technical requirement as per Annexure III-T-F.
1.7.2.
The bidders are required to quote for EPAXs equipped as under.

(i) 20 Trunk lines and 8 subscriber lines.
(ii) 12 Trunk lines and 8 subscriber lines.
1.7.3. It shall be possible to use the lines EPAXs as either subscriber lines or trunk
lines. The EPAXs offered shall be micro processor based fully digital, non
blocking and programmable. The procedure of programming may be clearly
brought out and explained with the help of diagrams etc. in the offer. The EPAX
offered shall be automatic and shall be able to function without the help of
operator.
The EPAX should support single two or three digit numbering scheme. The
software should support both E&M signaling and D.C. loop trunks. The EPAX
shall have universal ports wherein any type of card of EPAX can be inserted
into any slots. If, the purchaser requires more than designated trunks, the same
has to be met with a decrease in the subscriber lines. The number of Trunks
can be either E&M or loop or a combination of both. The EPAX shall support
1440 of 2461
PAGE 224 of 358
MMRDA
duplication of CPU and PSU card, in the event of master CPU or PSU card
failure, the slave cards take over smoothly without any breakdown. The EPAX
shall support digital Telephones with display, on single pair of cable. The EPAX
shall have voice guidance cards with call back facility for proper guidance to the
subscriber. The procedure of programming may be clearly brought out and
explained with the help of diagrams etc. in the offer. The EPAX offered shall be
automatic and shall be able to function without the help of operator.
1.7.4 The EPAX offered shall be provided with the following facilities:a) Call transfer b) Priority interrupt c) Conference d) Call forward e) Call consult
f) Facility to connect data g) Automatic alternate route selection h) follow me i)
Ring when free j) Either party release k) Real time clock l) Audible & visual
alarm on all fault cards.
1.7.5 The EPAX shall be self-contained and shall provide its own ringing current and
tones. The tones shall be from 400 Hz oscillators.
1.7.6 The call processing time should be minimum. While a call is being initiated the
pulses sent shall be visually displayed with the help of LEDs on the line and
trunk card. The pluses sent should be audible to the person initiating call.
1.7.7. The EPAX offered shall be compatible for working in conjunction with PLC
terminals, microwave, UHF, VHF, Optical fibre and DOT lines. The interface
card required for this purpose shall be offered as on optional as an optional
item. However the EPAX shall be wired for this purpose.
1.7.8. Alarm type of fuses shall be provided with both audible and visual alarms and
the bead of the blown fuse shall give instant indication of the blown fuse.
1.7.9. The EPAXs shall be housed in dust proof steel cabinets of suitable design which
shall be such as to facilitated efficient maintenance of the unit.
1.7.10. The EPAX shall work on (-) 48 V D.C. supply. The operating voltage limits shall
be + 15% and -10% and the equipment shall continue to operate satisfactorily
if the supply voltage rises to 20% of the rated value. Loop resistance limits for
1441 of 2461
PAGE 225 of 358
MMRDA
EPAXs: The subscriber loop resistance should be 1000 ohms and for tie lines
1500 ohms maximum
C.C.I.T.T. performance for the telephone of EPAX.
a) for 'O' lines i) Sending reference equivalent + 3.03 dB NOSFER.

ii) Receiving reference equivalent - 5.03 dB NOSFER.
b) for a length of 4.1 Km of 4Lb cable.:

i) Sending reference equivalent + 8.62 dB NOSFER.
ii) Receiving reference equivalent - 1.4 dB NOSFER.
1.8.0. P.B.TELEPHONES
Push button type telephone sets with memory and redial facility shall be offered
and these shall be sturdy and of elegant design and shall conform to
international standards. The telephone instrument shall be provided with line
cords and handset cords of adequate lengths (length to be mentioned in the
offer) preferably of the same colour as that of instruments.
1.9.0. VOICE FREQUENCY TELEGRAPHY EQUIPMENTS:
1.9.1.1. The bidder shall quote unit rates for Voice Frequency Telegraphy (VFT)
Transmitter/Receiver equipments suitable for transmission of data and
facsimile signals over power line carrier in the frequency range of 0.3 to 3.7
KHz.
The VFT should have modular construction and modern design features with
high stability and consistency for the characteristic frequencies under all
conditions of operation. The maximum frequency deviation should not be more
than 0.1 Hz. The VFT shall be suitable for operation on 48 V D.C. power
supplies with positive pole earthed. The VFT shall be able to strap at site to any
required centre frequency of required channel number at a given baud rate up
to 200bauds as per CCITT Standards.
1442 of 2461
PAGE 226 of 358
MMRDA
The VFT shall be provided with necessary modules e.g. galvanic isolator, linematching module with send & receive amplifiers, line transformers for 4 wires
and hybrid for 2 wire operation. The system impedance will be 600 ohms. The
VFT offered shall have monitoring facilities for receive levels, operating voltage
and the automatic indication for any fault and shall be suitable for mounting in
carrier terminal. The quantity of VFTs to be supplied will be finalized after
placement of orders.
1.10.0.
TRANSIT BAND-PASS FILTERS:
The bidder shall quote unit rates for transit band pass filters to filter out the
super imposed channels from the V. F. band. This is in addition to the built-in
transit band pass filter of PLC terminals.
The output and input impedance of transit band-pass filters shall be 600 ohms
and suitable for working with the earlier version of PLC terminals. The Transit
Band Pass Filter offered shall be suitable for installation in the carrier terminals.
The TBF shall be modular and plug in type. The band width for the offered TBF
shall be suitable for group of CCITT channels of different baud rates up to
600Bds, which will be intimated to the successful bidder after finalization of
order.
The quantities of TBFs to be supplied shall be finalized after placement of

orders.
1.12
Remote Extension Interfaces (REI)
The Digital EPAX offered shall be enabling to connect REI with normal P.B.
telephones. The REI units shall work on 48 V DC. The same shall enable to
connect 4 wire E&M trunk and conversion of 4 wires to 2 wire communication.
Surge arrestor and fuses shall be equipped in REI units.
1.13 Terminal Box
1443 of 2461
PAGE 227 of 358
MMRDA
Terminal Box / Marshalling Distribution Frame shall be supplied by the

contractor. The TB/MDF shall be Krone type with surge arrestor and fuses
and shall be equipped with terminals f or I/O connections (Subscribers,
PLCC trunk lines and other exchange lines). The TB/MDF shall be wall
Mountable / panel mountable with adequate terminals matching with the
EPAX capacity.
ANNEXURE III-Q-A
TECHNICAL PARAMETERS OF LINE TRAP
Sr.
PARAMETERS
SPECIFICATION
Purpose
To prevent undue loss of carrier
No.
1
signal for all
power system
conditions
2
Rated System Voltage
145 KV
Inductance (mH.)
0.5 mH.
Rated current(Amps)
630 Amps
1444 of 2461
PAGE 228 of 358
Sr.
MMRDA
PARAMETERS
SPECIFICATION
S-II
for 1 sec. duration (kA
40
No.
5
rms)
6
Assymetric peak value of
102
the Ist Half wave of short

time current (kA peak)
7
Minimum resistive
>600
component of impedance
within the bandwidth (Ohms)
8
Rated tapping loss within
........2.6.....
rated bandwidth in db
9
Radio interference voltage

mV(Maximum value)
10
Protective device:
a) Rated Voltage
...to be decided by the linetrap

mfgr...
b) Nominal discharge
.................10....................
current(1 kA rms)
c) Applicable standard
...........IEC - 99 - 1 PART I........
11
Desired blocking band
..........* 90 to 500 KHz..............
12
Installation
...............Out door................
13
Type of mounting
................pedestal............
14
Type
of
terminal
pads
terminal Suitable for twin Morculla
connections to be provided by tenderer 560 Sq. mm. AAAC

on line side and sub-station side.
15
Take off
.....Horizontal and Vertical....
Notes: *Between 90 KHz and 500 KHz depending upon actual frequencies used.
If it is not possible to achieve blocking band of 90 KHz to 500 KHz in some
cases, the possible blocking bands shall be indicated. If it is possible to achieve
the complete blocking band from 90 KHz to 500 KHz by using more than one
tuning units the same shall also accordingly be indicated.
1445 of 2461
PAGE 229 of 358
MMRDA
ANNEXURE III-Q-B
PRINCIPLE TECHNICAL PARAMETERS OF COUPLING CAPACITORS
Sr.
ITEM
SPECIFICATION
Purpose
To connect high frequency equipment
No.
1.
to high tension power transmission line

2.
Rated voltage
132 kV
3.
Maximum system voltage
145 kV
4.
Rated power frequency (Hz)
50 Hz
5.
Operating frequency range
50 to 500 KHz
KHz
6.
Rated capacitance (pf)
......6600 Pf...... + 10%
7.
One minute power frequency
275
withstand voltage (kV rms)

8.
Impulse withstand test
650
voltage with (1.2/50 Hz) full

wave (kV-Peak)
9.
Minimum length of leakage
3625 mm
or more
path (mm)
10.
Suitable for frequency range
......50 to 500 KHz....
11
Installation
Outdoor on steel pedestals to be

provided by tenderer
12
Type of Mounting
........UPRIGHT.......
13
Type of Pedestal
Galvanised steel lattice type only
14
Centre to centre distance
.....860 mm.....
between the legs of the

lattice structure
15
Type
of
terminal
provided
terminal
pads
connectors
by
and
to
be Twin Morculla
tenderer
for 560 Sq. mm..
connection to the line side. ........Horizontal and Vertical.....

1446 of 2461
PAGE 230 of 358
MMRDA
i)suitable for
ii) Take Off

16
Connection on low voltage
Complete
side
arrangement
connectors,
lead
etc.
with
clamp
for
sturdy
connection to coupling device shall be

provided by Tenderer
17
Type of Sealing
.......Hermatically sealed.....
Note :
1.
The coupling capacitors must withstand the mechanical stresses resulting from
wind pressure of 150 Kg./Sq.meter.
2.
The coupling capacitor stands should have minimum height of 2500 mm. The
height from ground level to the centre of the coupling device shall be 1200 mm.
3.
Should the standard rated capacitance of the manufacture be higher than 6600
pf, the bidders may offer coupling capacitors having capacitance as per their
manufacturers standard practice.
TECHNICAL PARAMETERS OF COUPLING DEVICE
Sr.No. Item
1
Purpose
Specification
a) Transmission of signals from carrier side to
the high voltage line and vice-versa with
minimum loss.
b) Protect the PLC equipment against the
effects of high voltage
Primary Impedance
600 ohms with phase to phase coupling.
Secondary impedance
75 ohms for unbalanced secondary circuit
Maximum composite
2 dB
loss
5
Capacitance of the
> 6600 p.f.
1447 of 2461
PAGE 231 of 358
MMRDA
CVT/C.C. in pf in
conjunction with the
coupling device is to
be used
6
Pass Band
90 KHZ to 500 KHZ
Peak envelope power:
> 200 Watts
for other lines below

400 KV
8
Return loss:
a) Line side
> 12 dB
b) Equipment side
> 12 dB
Constituent elements
a) For phase to
ground coupling
b) For phase to phase
inter circuit coupling
10
Mounting
Three element protective device-1 No.,

Coupling filter -1 No.
Three element protective device-2 Nos.,Coupling
filters -2 Nos., Balancing transformer -1 No.
On a single galvanised steel frame which is to be

provided by the Bidder alongwith the necessary
G.I. Nuts and Bolts
11
Installation
Outdoor on a steel pedestal of Coupling capacitor
12
Interconnection
Suitable interconnecting copper leads of 4 mm sq.

C/S provided with crimped lugs and stainless steel
nuts and bolts for connection
PRINCIPLE TECHNICAL PARAMETERS OF H.F.CABLE
Sr.No. Item
Specification
IS:5802 Part-II) - 1975
Purpose
Interconnection
between
C.D.
&
PLC
terminals
2
Impedance
75 +/- 3 Ohms unbalanced
Withstand voltage
4 KV minimum
1448 of 2461
PAGE 232 of 358
Attenuation
MMRDA
Frequency in KHz- 10
60
300
Attenuation-dB/Km 0.8 1.4 3.3

5
Frequency Range
Length required:
500
4.7
10 KHz to 500 KHz
a) Preferred
500 Meters and 1000 Mtr.
b) Minimum acceptable
200 Meters
Type of Laying
In cable ducts or directly underground
8.
Dielectric
Solid polyethylene dielectric with thickness

2.44 mm minimum.
9.
Rated capacitance
67 pf/m
10.
Rated velocity ratio
0.66
11.
Maximum alternating
5.0 KV (peak)
voltage for continuous use.

12.
Maximum voltage for

unidirectional
10 KV (peak)
pulse
operation
13.
Inner conductor
a) Single dia
Minimum 1.104 mm
Nominal 1.120 mm
Maximum 1.136 mm
b) Material
Plain annealed and high conductivity

electrolytic copper
14.
Cores diameter over
Minimum 7.11 mm
Dielectric
Nominal 7.25 mm
Maximum 7.40 mm
15.
Outer conductor
Single braid of plain annealed copper wire of

diameter 0.20 mm. The braid angle shall be
less than or equal to 450
16.
Protective sheath
Material: Compounded PVC black in colour

Thickness: Minimum 0.85 mm
Maximum 1.05 mm
17.
Overall diameter
Minimum
10.0 mm
Nominal:
10.3 mm
1449 of 2461
PAGE 233 of 358
MMRDA
Maximum: 10.6 mm
18.
Dielectric strength of core
8 KV (r.m.s)
19.
Insulation resistance
23000 Ohms/KM
20.
Attenuation constant
0.1 dB/m maximum. The measuring

frequency shall be 200 MHZ
PRINCIPLE TECHNICAL PARAMETERS OF PLC TERMINALS

Sr.No. Item
Specification
Transmission
Purpose
of
speech
data
and
protection & control signals.

2
Mode of Transmission
Single side-band, amplitude

modulation.
H.F.Range
50 to 500 KHz.
Nominal carrier frequency band 4
KHz,
Multipurpose/Unipurpose
operation.
5
Mode of working
Nominal impedance
Fixed frequency.
i) Carrier frequency side
75 Ohms unbalanced
ii) VF side
600 Ohms.
Return Loss
i) Within the nominal carrier
frequency
band
in
Greater than 10 dB.
the
transmit
Greater than 14 dB.
direction
ii) Within the effectively
transmitted frequency band.
8
Nominal carrier frequency

(Peak envelop power available
at line output of the terminal at
a resistive load equal to the
nominal load impedance for
single Tone keying)
i)
Single channel
20 W to 40 W Programmable
1450 of 2461
PAGE 234 of 358
ii)
Twin channel
MMRDA
40 Watts. (Carrier sets with more

output than those specified above
will not be considered.)
Effectively transmitted speech
a)300 to 2400 Hz for PLC
frequency band selectable
terminals with speech cut off at

2400 Hz.
b)300 to 2000 Hz for PLC
terminals with speech cut off at
2000 Hz
10
11
Effectively transmitted signal
a)300 to 3400 Hz for Unipurpose
frequency band selectable
PLC terminals
depending on speech cut-off
b) 2520 to
for multipurpose
3600 Hz OR
carrier terminals
2640 to 3720
with speech cut
Hz
off at 2400 Hz.
c) 2160 to
for multipurpose
3600 Hz OR
carrier terminals
2280 to 3720
with speech cut
Hz
off at 2000 Hz.
Effectively transmitted speech
300 to 3720 Hz
and data signaling frequency

band.
12
Stability of carrier frequency
+/- 5 Hz.
from its nominal value.

13
Relative levels (VF side)
a) 4 wire-transmit: OdBr to -17 dBr.

b) 4 wire-receive : -3.5 dBr to + 8
dBr.
c) 2 wire-transmit: OdBr.
d) 2 wire-receive : -7 dBr.
14
Level Regulation(Automatic
In the case of a 30 dB change in carrier
gain control)
frequency
signal
level
within
the
regulation range, the change in voicefrequency receive levels of both speech

and signals shall be less than 1 dB.
1451 of 2461
PAGE 235 of 358
15
MMRDA
Telephone signaling channel
By frequency shift keying. The signaling

channel shall be operated by a potential
free open OR close contact at the
transmit side and provide a potential free
change over contact at the receive side.
All relays to be provided in the speech
circuit shall be hermetically sealed.
16
Pulse distortion
The pulse distortion of the signaling

channel, when operated at a signaling of
10 pulses per second and within a markto- space ratio of 40/60, shall not exceed
5 MS for a pair of PLC terminals.
17
Permissible limits for variation
300 - 400 Hz:-0.9 to +3dB)OR+ -
of overall loss (attenuation) of
1.5dB for 400 - 600 Hz:-0.9 to
the speech channel relative to
+1.8dB)the complete 600 1600
800 Hz for back to back
Hz:-0.9 to +0.9dB)band of 300 to
operation of one pair of
1600-2000 Hz:-0.9 to
terminals without compander
+1.8dB)2400 Hz (without 2000

-2400 Hz :-0.9 to + 3dB)
compander).
18
R.F.sensitivity
(-) 43 dBm
19
Transmit/Receive frequency
In a pair of PLC terminals, the frequency
difference.
difference between a voice-frequency

signal applied to the transmit end and
that received at the receive end shall be
"O"
20
Noise performance
The weighted telephone noise level

measured at the speech
i)
Noise generated within the output of a pair of PLC terminals without

terminals
companders
shall
not
60dBmoP,measurements
exceed
shall
be
carried out as per IEC No.495 latest

edition.
1452 of 2461
PAGE 236 of 358
ii)
S/N
Ratio
Committee
(as
MMRDA
per Report 35 dB.
No.14
Tele-
transmission of CIGRE1962)
for
voice
communication
referred to 1 mW at a relative
level of zero.
21
Group delay distortion
Measured at V.F.signal
input
points
shall not be more than 3 ms over the

entire effectively transmitted data signal
frequency band
22
Power supply for PLC
a)48V D.C. (+ve pole earthed), with+

15% and - 10% variation.
b)The terminal shall remain operational
when the supply voltage rises or falls by
20% of its nominal value without any
damage or failure to the equipment.
Voltage withstand requirements Test to be carried out as per IEC

a)Power supply
publication 60 H.V. Test Techniques

1962). When the D.C. power supply
terminals are both isolated from earth,
they shall be capable of withstanding
with out damage a voltage of 500 V D.C.
applied for one minute between both
terminals connected together and earth
When D.C. power supply terminals are
not isolated from earth, they shall be
capable of withstanding without damage
an impulse voltage of 1000V 1.2/50
micro
sec.,
applied
between
each
terminal and earth
1453 of 2461
PAGE 237 of 358
MMRDA
b) Carrier frequency input / When the carrier frequency terminals

output terminals
are isolated from earth they shall be

a voltage of 2000 rms at power
frequency, applied for 1 minute between
both terminals connected together and
earth.
When the carrier frequency terminals

are not isolated from earth they shall be
an impulse voltage of 3000 V, 1.2/50
micro
sec.
applied
between
each
terminal and earth.

c) Voice frequency signaling & Voice frequency, signaling and alarm
alarm circuits.
circuits, when free from earth, shall be

a voltage of 500 V,D.C. applied for 1
minute between the terminals of the
circuit connected together and earth.
PRINCIPLE TECHNICAL PARAMETERS OF ELECTRONIC EXCHANGE

(VERSION-PLCC)
SR
ITEM
SPECIFICATION
Purpose
To establish dialing network
Type
Electronic, Microprocessor based, fully digital.
Capacity
NO.
a)Equipped and Wired 12Trunk Lines and 8 Local subscribers, -12/8
for
20Trunk Lines and 8 Local subscribers, -20/8
Facilities provided
i) ..Call transfer
1454 of 2461
PAGE 238 of 358
MMRDA
ii) ..Priority interrupt

iii) ..Conference
iv) ..Call forward
v) ..Call consult
vi) ..Facility to connect Data channels
vii) ..Automatic alternate route selection
5
Compatibility with
PLCC, MICROWAVE, UHF, VHF, OPTICAL

FIBRE AND DOT LINES.
Power supply
Tolerance for variation +15% - 10% The equipment shall continue to

in power supply
48 V,D.C.
operate satisfactorily if the supply voltage

rises to 20% of the rated value
Subscriber loop ressist 1000 Ohms.

ance.
Exchange Identification Two digit and three digit scheme.
10
Miscellaneous
a.
The
equipment
shall
be
wired
up
completely with main distribution frame using

5 mtrs. length telephone cable.
b. One no. crone tool shall be supplied with

each equipment.
TYPE TESTS TO BE CONDUCTED ON PLCC EQUPMENTS
(FOR
ALL PLCC EQUIPMENTS INCLUDING 400 KV)
1.
Wave traps
a) Impulse voltage test
b) Radio influence voltage test
c) Corona test
d) Short time current test
e) Temperature rise test
2. Coupling capacitor
a) High frequency capacitance & equivalent series resistance
1455 of 2461
PAGE 239 of 358
MMRDA
b) High frequency stray capacitance & stray conductance

c) Radio noise test
d) Temperature rise test
e) Impulse voltage test
f) Servo resonance test
g) Transient response test
h) Power frequency test
3. Coupling Devices
I) Line Matching Unit
a) Short time current test
b) Impulse voltage test
c) Composite loss
d) Return loss
II) Drainage coil

a) Short time current test
b) Continuous current test
III) Earth switch

a) Current carrying capacity
b) Insulation test
IV) Lightening arrestors

a) Power frequency spark over test
b) Impulse voltage test
4) High frequency cable

a) High voltage test
b) Conductor resistance
c) Insulation resistance
d) Capacitance characteristics
e) Attenuation test
f) Impedance test
1456 of 2461
PAGE 240 of 358
MMRDA
5) PLC terminal
a) Ambient temperature & Humidity
b) Supply voltage with battery operation
c) Storage conditions
d) Nominal impedance & return loss
e) Spurious emission
f) Carriers frequency control
g) Frequency accuracy test
h) Loss of speech frequency test
i) Loss of signal test
j) Group delay distortion
k) Automatic grain control
l) Transmit receive freq. Difference
m) Linearity
n) Limiter action
o) Noise generated within terminal
p) Near & Far cross talk
q) Pulse distortion
r) Voltage withstand test on D.C.P.S.Unit
s) Carrier freq. Input/output terminal voltage withstand
t) Radiated susceptibility test
6) Protection couplers
a) Impulse voltage withstand test
b) H.F. disturbance test
c) Power supply interruption test
d) Performance test
e) High voltage withstand test
1457 of 2461
PAGE 241 of 358
MMRDA
1458 of 2461
PAGE 242 of 358
1.0
MMRDA
GENERAL REQUIREMENTS :
Principle technical parameters for Columns, beams, peaks and support structures
1.0
GENERAL REQUIREMENTS
a)
The equipment to be supplied against this specification shall be as per relevant

drawing (will be provided to successful bidder). In case the bidder desires to
supply the material with slightly varying design, the same shall be subject to
purchasers specific approval. The heights of various support structures
indicated in the relevant drawings are typical and indicative. It may be
necessary to carry out slight variations in the height to match the bus height in
relation to the sub-station land contours/ equipment dimensions. Such changes
shall be bidders responsibility.
b)
The quantity of various items to be supplied shall be as per the Bill of Quantity
(Annexure-I) and also as per the scope indicated in the sub station layout plans
furnished. Supply of complete quantity of steel members alongwith accessories
required shall be in the bidders scope.
c)
Unit rates shall be quoted by the bidder for various types of structures and shall
be on tonnage basis.
d)
All columns, beams, and peaks as also the various types of support structures
shall be on tonnage basis.
e)
All the columns, beams, and peaks as also the various types of support
structures and lighting masts/ lighting cum lightning masts shall be of lattice
type design as shown in the relevant drawings.
f)
Shearing, Punching, Bevel cutting and bending of steel members shall be done
accurately so that during assembly there will not be any drifting or reaming of
holes. All bevel cutting shall be accurate, and any variation of more than 1.5
mm may be liable for rejection. Punching shall be done with the use of gauge
1459 of 2461
PAGE 243 of 358
MMRDA
(or by other methods acceptable to the purchaser ) to ensure accuracy. Bending

shall be moderately sharp and true to the details shown on the shop drawing.
Bends may be done either hot or cold.
g)
Identical pieces of structures bearing the same erection mark must be

interchangeable in their relative positions in all structures of which they form a
part. Leg ends, bearing on each other or resting on bases, shall be milled true
to bear and ensure good bearing and perfect alignment. Finished members,
without ends finished for contact bearing, may have tolerance (+) 1.5 mm for a
member upto 3 M long. For longer members, 1 mm per additional 3 M length
will be allowed subject to maximum of 3 mm.
h)
Welding where necessary shall be carried out before galvanising and shall
conform to
relevant
Indian
Standard Specifications.
Caution shall be
exercised to obtain full penetration of the weld when welding light members to
heavy members.
i)
After all shop works are complete, all structural members shall be punched
with Erection Mark and be treated suitably for through cleaning. The duly
treated steel members shall be hot dip galvanized. The galvanization shall be
done as per relevant IS, and shall be capable of withstanding minimum four
one-minute dips in copper sulphate solution. Galvanizing of each member shall
be carried out in one complete immersion.
j)
The equipment support structures for wavetrap, Coupling capacitor, Isolator

with and without earth blade shall be supplied with the equipment. The same
shall be as per foundation plan specified for the structure.
k)
The Gantry and equipment support structures shall be fabricated as per

MSETCLs standard structural drawing/approved drawings for the particular
structure. The equipments should match with the standard structural drawing.
l)
Bolts, Nuts and washers of makes approved by MSETCL shall only be supplied.
All bolts, nuts and washers shall be hot dip galvanised conforming to IS 5358.
Spring washers shall be galvanised
in accordance with IS 1573 service
1460 of 2461
PAGE 244 of 358
MMRDA
condition IV. Excess spelter from bolts, nuts, etc. shall be removed by
centrifugal spinning. Rethreading of bolts after galvanising, shall not be
permitted. Nuts however, may be tapped, but this should not cause appreciable
recking of the nuts on the bolts.
2.0
STEEL SECTIONS:
a) The steel angle sections used for fabrication shall be Mild Steel or High
Tensile steel, as indicated in structural drawing, having yield strength as
specified below conforming to IS-2062 and IS-8500 & EN-10025 JR & JO with
revision thereof.
Designation
Section (Min.)
Yield Strength
(N/mm2)
thickness
Mild Steel
Fe 410 WA/WB
< 20 mm
250
20-40 mm
240
> 40 mm
230
< 16 mm
350
16-40 mm
330
41-63 mm
320
High tensile Steel

Fe 490/B
3.0
PROTOASSEMBLY:
a)
The manufacturer shall fabricate and offer protoassembly of each type of

structure for purchaser's
inspection and approval
(alongwith
relevant
shopfloor drawings at his works) prior to taking up mass fabrication. The

fabrication of protoassembly of particular structure/s shall be exempted if the
manufacturer has in past fabricated and got approved the proto assembly and
supplied the same.
b)
The checking and approval of prototassembly by pruchaser shall not relieve

manufacturer from the responsibility of
workmanship, fitting of
correctness
of engineering,
parts, details, materials supplied and errors or
1461 of 2461
PAGE 245 of 358
MMRDA
omissions if any. Purchaser's approval shall only constitute approval of the

sizes of members, dimensions and fitting arrangement but shall not constitute
approval of the connection between members and other details shown on the
shop drawings which shall be responsibility of supplier. Purchaser's approval
shall not invalidate any claim for damages of any kind for incorrectly fabricated
steel. The cost of assembly and dismantling of each prototype shall be borne
by the supplier.
4.0
DRAWINGS AND BILL OF QUANTITY:
a)
The manufacturer shall furnish to the purchaser 2 sets of final and approved
versions of the
drawings
and bills
of
materials alongwith 1 set of
reproducibles / soft copy to C.E.(Tr. Proj.) within two weeks after final approval.
The drawing shall be preferably in A-3 size paper & B.O.M shall be in A-4 size
paper. The Bills of Material should indicate on each page the type of structure,
its identification mark, the KV rating reference of structural drawing etc. The
supplier shall ensure that the packing list and Bill of Quantity (BOQ) are
approved by the purchaser before
offering the material for pre-despatch
inspection. A copy of approved BOQ and a computer CD shall also be

despatched with the consingement to each consignee.
b)
Structural/Erection drawings of structures shall show each individual member

with its identification mark. Locations and position of the outstanding leg of
angle, length of connecting bolts and their diameter etc.
5.0
a)
MARKING:
Each individual structure member shall be marked with
its respective
identification mark given to it on the erection drawings/BOQ. The marking shall

be stamped with a metal die before galvanising with figure at least 2 cms high
in such a manner and to such optimum depth as to be clearly visible after
galvanising.
The erection mark shall be A-BB-CC-DDD where-
1462 of 2461
PAGE 246 of 358
MMRDA
AA - Manufacturers name code (Alphabet).

BB - Manufacturers order reference (Numerical)
CCC - Type of Structure (Alphabet)
DDD - Mark Number (Alpha-Numeric)
b)
The marking shall be on the outer surface of all angle sections and near one
end but clear of bolt holes. For other members such as channels, flates, gusset
plates etc. the markings shall be so stamped that they are easily discernible
when sorting out members.
c)
Marking on like pieces shall be in identical locations. Members having lengths

3 meters or more shall be stamped with markings at each end.
d)
After galvanising, marks shall be circled or bracketed with black paint.
6.0
GALVANISING:
a)
After all shop work is complete, all structural members shall be punched with
the Erection Mark and be hot dip galvanised in confirmity with IS:2629, IS:4759
and IS:2633. Before
galvanisation, the steel section shall be thoroughly
cleaned of any paint, grease, rust, scale, acid or alkali or such other foreign
matters as are
likely to interfere with the galvanising process or with the quality and durability
of the zinc coating. Pickling shall be very carefully done and shall be proper.
b)
The galvanizing bath shall be of adequate dimensions for facilitating galvanizing

of structural parts in one dip.
c)
The zinc used for galvanising shll be of grade Zn98 as per IS:209. The mass
of zinc coating shall be as follows:
Sr.
Thickness of
Mass of zinc
Thickness of
No. steel article
coating
zinc coating
1)
5 mm and above
610 gm/m2
86 microns
2)
Below 5 mm
460 gm/m2
1463 of 2461
64
PAGE 247 of 358
MMRDA
microns
3)
4)
Fasteners
Spring washers
300 gm/m2
42 microns
272 gm/m2
38 microns
1 gm/m2 = 0.14 Microns
d)
The galvanised surface shall consist of continuous and uniformly thick

coating of zinc, firmly adhering to the surface of steel. The finished surface
shall be clean and smooth and shall be free from defects like discoloured
patches, bare spots, unevenness of coating, spelter which is loosely attached
to the steel, globules, spiky deposits, blistered surface, flaking or peeling off
etc. The presence of any of these defects noticed on visual or microscopic
inspection shall render the material liable to rejection.
e)
There shall be no flaking or loosening when struck squarely with a chisel faced
hammer. The galvanising on steel member shall withstand minimum four one
minute dips in standard copper sulphate solution as per IS:2633.
f)
Galvanising
of
each member shall be carried out
in
one complete
immersion. Double dipping shall not be permitted. When the steel section
is removed from the galvanising kettle, excess spelter shall be removed by
'bumping'. The process known as 'wiping' or 'scraping' shall not be used for this
purpose.
g)
Defects in certain members indicating presence of
impurities
in
the
galvanising bath in quantities larger than that permitted by the specifications,

or lack of quality control in any manner in the galvanising plant, shall render
the entire production in the relevant shift liable to rejection.
7.0
ERRORS:
Any error in shop work which prevents proper assembling and fitting up of
parts in the field by moderate use of drift pins or a moderate amount of reeming
shall be classified as defective workmanship.
All charges required to be
incurred in rectification of defective workmanship, shall be deducted from the

amount due to the contractor against any bill under payment.
1464 of 2461
PAGE 248 of 358
8.0
MMRDA
ACCEPTANCE TESTS:
The following acceptance tests, as per procedure stipulated in IS, shall be

carried out by the supplier in presence of purchaser's representative.
a)
Verification of dimensions : IS:2062/IS:8500/IS:808/IS:1730
b)
Tensile test
: IS:2062/IS:8500
c)
Bend test
: IS:2062/IS:8500
d)
Preece test
: IS:2633/IS:2629
e)
Adhesion test
: IS:2629
f)
Strip test
: IS:6745/IS:4759
TECHNICAL SPECIFICATION FOR VRLA TYPE STORAGE BATTERY SET

TO BE USED AT 132kV SUBSTATIONS
1.0
SCOPE:-
1.1
This specification covers the design, manufacture, assembly, shop testing etc.,
at manufacturers works before dispatch, supply and delivery at site and
erection, testing and commissioning of VRLA storage batteries.
1.2
It is the intention of the purchaser i.e. MSETCL to install the state of the art type
of equipment conforming to modern practices.
1.3
The scope of supply shall include all parts and accessories etc, which are usual
and necessary for erection, operation and maintenance of VRLA batteries as
specified above, though not individually and specifically stated or enumerated.
2.0
2.1
The requirement of VRLA Battery sets to be supplied against this specification

shall be as per tender /specified hereunder.
3.0
SERVICE CONDITIONS:
3.1

3.1.1
Maximum ambient temperature in open air
1465 of 2461
50.00
PAGE 249 of 358
MMRDA
(C):
3.1.2
Maximum ambient temperature in shade
45.00
(C)
3.1.3
3.50
3.1.4
10 to 100
3.1.5
1450
3.1.6
Maximum wind pressure (Kg/m2)
150
3.1.7
Maximum altitude above mean sea level
1000
(Meter)
3.1.8
Isokeraunic level (days/year)
50
3.1.9
0.3 g.
3.1.1
General nature of climate :
Moderately hot and humid tropical
climate, conducive to rust and

fungus
growth.
4.0
STANDARDS:-
4.1
All equipment and their accessories, covered by this specification shall be

designed, manufactured and tested in compliance with the latest relevant
standards, published by the Bureau of Indian Standards including those, listed
below in order that specific aspects under Indian climatic conditions are taken
care of.
4.2
The equipment and accessories for which Indian Standards are not available
shall be designed, manufactured and tested in accordance with the latest
standards, published by any other recognized National Standards Institution
and latest publication of International Electro Technical commission [IEC].
4.3
The equipment manufactured according to any other authoritative national/

international standard, which ensures an equal or better quality than the
provisions of these specifications shall also be acceptable. Where the
equipment, offered conform to any other standard, salient points of differences
between the proposed standard and the provisions of these specification shall
be clearly brought out in the offer. A copy of such standards [in English] shall
1466 of 2461
PAGE 250 of 358
MMRDA
be enclosed with the offer. However, the decision of MSETCL will be final.
4.4
The equipment shall conform to the Indian Electricity Rules, 1956 with latest
amendments as regarding safety earthing and other essential provisions
specified therein for installation and operation of electrical plants.
4.5
All equipment shall also comply with the statutory requirements of the
Government of Maharashtra where the equipment will be installed. Nothing
shall be construed to relieve the supplier of his responsibility.
The VRLA batteries shall conform to the following standards.
Sr.
No.
Standard No.
Title
Specification for stationary cells batteries, leads acid
IS-1651/1991
IS-1885 [Part-8] /1986
IS-266/1977
BS-46290
type.
batteries.
Sulphuric acid
(Part-4) British standard specification for lead acid type valve
/1997
ANSI,
Electro technical vocabulary: Part- 8-Secondary cells &
regulated sealed type batteries.

IEEE
450/1987IEEE
IEC 896-2/1995
IS-1146
IS-15549-2005
STD
Recommended practice for maintenance, testing and

replacement of large lead storage batteries for
generating stations and sub-stations.
Stationary lead-acid batteries, general requirements and
methods of test (part-2, valve regulated types)
Plastic container for lead acid storage batteries.
Specification for Stationary Valve regulated Lead Acid
Batteries
5.0
OTHER REQUIREMENTS:-
5.1
ACCESSIBILITY AND INTER CHANGEABILITY:-
All working parts, as far as possible, shall be arranged for convenience of

operation, inspection, lubrication and case of replacement with minimum down
1467 of 2461
PAGE 251 of 358
MMRDA
time. All like parts of the equipment, furnished shall be inter changeable.
5.2
QUALITY AND WORKMANSHIP:Workmanship and materials shall be of good commercial quality, suitable for
the purpose, intended and in accordance with the highest standards and
practices for equipment of the class, covered by this specification.
5.3
SAFETY
5.3.1 All equipment shall be complete with approved safety devices wherever a
potential hazard to personnel exists and with provision for safe access of
personnel to and around the equipment for operational and maintenance
functions. The design shall include all necessary precautions and provisions for
the safety of operating and maintenance personnel.
5.3.2. Special care shall be taken to make enclosed equipment proof against entry of
rat, lizards and other creeping reptiles, which may create electrical short circuits
inside, live equipment.
5.3.3. Continuity of power supply is the first consideration and the design shall be
such as to provide facilities to simplify inspection, testing maintenance, clearing and
repair at site.
6.0
CONSTRUCTIONAL DETAILS OF VRLA BATTERY.
6.1
PLATES:
Positive plates shall be made of flat pasted type using lead-Cadmium-antimony
alloys for durability, high corrosion resistant, maintenance free, low discharge
rates and long life both in cyclic as well as in the float applications.
Negative plates shall be heavy duty, durable flat plate using lead calcium alloy
pasted box grid. Negative plates shall be designed to match the life of positive
plates and combination of positive and negative plates shall ensure long life,
durability and trouble free operation of the battery. PLC Operated equipment
should be deployed for preparation of paste to ensure consistency in paste
quality. Conventional / manual type of plate preparation is not allowed.
6.2
SEPARATORS:-
1468 of 2461
PAGE 252 of 358
MMRDA
The separator shall be absorptive glass mat type or spun glass micro porous
matrix type and shall be resistant to sulphuric acid.
It shall be capable of keeping the entire electrolyte (Sp. Gr. 1.250) and shall be
electrically insulated.
Sufficient separator overlap and PVC shield protection to top and bottom edges
of the plates is to be provided to prevent short circuit formation between the
edges of adjacent plates.
The uncompressed water absorption of the separator shall be at least 5 gm. of

water / gm of separator material.
6.2.1 REQUIREMENT OF WICKING TEST ON SEPARATORS:The wicking Test shall be performed on Separator which is used in VRLA
Battery. The total wicking height shall not be less than 630 mm in 24 hours.
6.3
VENTING DEVICE - PRESSURE REGULATING VALVE:Safety valve vent plugs shall be provided in each cell. They shall be explosion
resistant, self-resealing and pressure regulating type. They shall not allow gas
(air) to enter into the cell but shall allow gas to escape from the cell above a
certain internal pressure, which does not lead to deformation or other damage
to the cell. The opening and closing pressure shall be within 1 psi
variation and manufacturer shall declare the closing and opening
pressure values.
6.3.1 The vent plug used shall be explosion resistant and self re-sealing pressure
regulating type. Vent plug shall be such that it cannot be opened without proper
tool.
6.3.2 The valve shall be so designed that it operates at a pressure between 0.14 Kg
/ Sq. mm to 0.63 Kg / Sq. mm to release the excess gas and reseal
automatically as soon as the gas pressure within the cell drops to atmospheric
value.
1469 of 2461
PAGE 253 of 358
MMRDA
6.3.3 All the cells shall be subjected to pressure test up to 0.7 Kg / Sq. mm.
6.3.4 Valve regulated venting device of each cell shall be provided with flame
arrestors to prevent any sparking flame from entering the cell.
6.4
CONTAINERS:-
6.4.1 The container shall be made up of a special grade polypropylene copolymer

plastic material, which should be of flame-retardant.
6.4.2 The container shall be sufficiently robust and not liable to deformation under
internal operating pressures and within the temperature range naturally
encountered, leak proof, non-absorbent and resistant to the acid with low water
vapor permeability.
6.4.3 The container shall be enclosed in epoxy coated steel trays. The steel trays
shall be so designed as to make both vertical and horizontal stacking of cells /
batteries possible.
6.5
LIDS / COVERS:Sealed maintenance free batteries shall have polypropylene copolymer covers.
The complete container along-with lid / cover shall be able to withstand without
fracture for 5 hours at 25 degree Celsius at an internal pressure of 5 times the
normal operating pressure as declared by the manufacturer.
6.6
PILLAR SEAL ASSEMBLY:-
6.6.1 The pillar to lid seal shall be designed to remain gas-tight and electrolyte-tight
during the designated life of the unit. The terminal shall conform to Class 3.2 of
BS: 6290, Part - 4 - 1987.
6.6.2
TIG welding shall be done for post sealing.
6.6.3
Additional Epoxy resin sealing shall be provided for double assurance against
leakage.
6.7
ELECTROLYTE:-
1470 of 2461
PAGE 254 of 358
MMRDA
The electrolyte shall be prepared from the battery grade H 2SO4 conforming to
IS: 266. The batteries shall be supplied in factory filled charged condition. The
entire Electrolyte shall be in immobilized condition i.e. The AGM filling process
shall assure that each cell is saturated with the maximum amount of electrolyte
that can be held by the separators, without leaving excess electrolyte that could
spill or leak. Water required for preparation of electrolyte shall conform to IS:
1069.
6.8
CONNECTORS AND FASTENERS:-
Lead or lead coated copper connectors shall be used for connecting up

adjacent cells and rows. The thickness of lead coating of connectors should be
not less than 25 micron. The lead coating thickness shall be measured in
accordance with APPENDIX-F of IS: 6848: 1979. All the terminals and cells
inter connectors shall be fully insulated or have insulation shrouds. End take off
connections from positive and negative poles of batteries shall be made by
single core cable having stranded copper conductors and PVC / XPE insulation.
Necessary supports and lugs for termination of these cables on batteries shall
also be supplied by the supplier. All connectors and lugs shall be capable of
continuously carrying the 30 minute discharge current of the respective
batteries and through fault short circuit current which the battery can produce
and withstand for the period declared. Bidder / Manufacturer shall furnish
necessary sizing calculations to prove compliance to the same.
6.9
PLATE CONNECTIONS:-
Lugs of plates of like polarity shall be connected by lead burning to a horizontal

strap having an upstanding terminal post adopted for connection to external
circuit. Strap and post shall be casted with lead alloy. The positive and negative
terminal posts shall be clearly marked for unmistakable identification.
6.10
NUT & BOLTS:-
Nuts and bolts for connecting the cells shall be made of copper, brass or
1471 of 2461
PAGE 255 of 358
MMRDA
superior grade passivated stainless steel which should be resistant to sulphuric

acid. Copper & brass shall be coated / plated with suitable materials such as
Nickel / Chrominium to prevent sulphation or corrosion.
6.11
TERMINALS:-
Positive and Negative terminal posts shall have built in lead plated copper or
brass inserts. Terminals of cells shall be clearly and unmistakably identifiable
and marking shall be of permanent nature. Terminal posts shall be suitably
sealed at the lid to prevent leakage of any gas. Any gas escape shall be only
through the venting device provided.
6.12
SUPPORTING RACKS:-
Batteries shall be installed on MS racks to be supplied by the supplier to fit in

the battery /battery charger room. Racks / trays shall be powder coated with
anticorrosive and Acid Resistant paint and supplied in unassembled state. Rack
/ tray shall be subjected to 7 tank processes before painting for protection
against fungus growth and other harmful effect due to tropical environment.
The steel trays / containers shall be stackable one over the other horizontally
in multi-tier arrangement. The bottom most tray shall be mounted on I-channels
with 150 mm height. The positive and negative terminals shall be terminated
onto the terminal plate assembly, which is fitted to one of the steel tray
depending on the convenience at site.
6.13
MARKING:The following information shall be legibly laid durably marked on each cell
battery:1. Nominal Voltage.
2. Name of the manufacturer and type reference.
3. Rated or nominal capacity expressed in ampere hour (AH) with an indication
of the rating expressed either as a current or as time together with the relevant
final voltage of each cell.
4. Voltage for float operation 270 C with tolerance of 1%.
1472 of 2461
PAGE 256 of 358
MMRDA
5. Cell number.
6. Type of positive plate.
7. Type of container.
8. Date of manufacture (month and year) or (week and year).
9. Date on which charge given before dispatch
10. Next Due Date for freshening charge.
7.0
MAXIMUM SHORT CIRCUIT CURRENT:-
The Bidder / Manufacturer shall state the maximum short circuit current of each
battery along-with the safe duration in seconds, which it can withstand
Complying with clause 5.5 of IEC 896 2/1995. Method proposed to be
adopted for protecting batteries from the short circuit conditions should also be
stated to avoid damage to the battery and loss to the associated equipment.
8.0
VENTILATION:-
The battery shall operate satisfactory over the entire range of temperature
indicated in this specification without affecting its normal life. Bidder /
Manufacturer shall indicate the percentage reduction in battery capacity at the
lowest temperature of 27 Degree C.
9.0
CAPACITY:-
The standard Ampere-hour capacity at ten hour rate shall be as given in the
table below and as per boq of Material in tender. The Nominal cell Voltage
should be 2Volts/cell and the end voltage of cell should be 1.80 volts /cell.
Sr.
Substation Type
DC Control Battery
No.
Voltage in V Capacity in AH
132/33kV Substation (Turnkey / Wind / Solar Project)
Substation Battery
220V DC
300AH
ii
PLCC Battery
48V DC
200AH
132/33kV Substation (ORC / Co-Generation Project) If Battery required
1473 of 2461
PAGE 257 of 358
MMRDA
in MSETCL Control Room)
9.1
Substation Battery
110V DC
200AH
ii
PLCC Battery
48V DC
200AH
SELF DISCHARGE RATE OF BATTERY:-
The self-discharge rate at room temperature shall be less than 5 % of the

capacity of each battery per month.
10.0
CHARGING:-
The Bidder / Manufacturer shall state whether an equalizing charge is

recommended for the battery. If so, the equalizing charge voltage, current,
duration and the interval between the equalizing charging shall be specified in
the Data Sheet. Bidder / Manufacturer shall also indicate the requirements for
boost charging.
11.0
LIFE:-
The Battery shall be designed for an expected life of 15 years, when operating
under the conditions specified. The Bidder / Manufacturer shall also quote the
change in life of the battery due to change in temperature form 27 degree
centigrade in the event the batteries are required to be operated under higher
temperature environment.
12.0
MAINTENANCE TOOLS & INSTRUCTION:-
12.1
One number cell testing voltmeter with center-zero 3V-0V-3V range and of
accuracy class 0.5 shall have to be supplied along with each of the battery sets.
The resistance of the voltmeter shall not be less than 100 ohms.
12.2
Three sets of instruction manuals for installation, commissioning and initial

charging along with the calculations of charge / discharge under float and boost
charging and maintenance instructions shall have to be furnished.
1474 of 2461
PAGE 258 of 358
13.0
MMRDA
ELECTRICAL CHARACTERISTICS:-
DESIGN SHOULD ENSURE THAT:-
(a) Battery shall be suitable for constant current constant voltage charging.
(b) Nominal float voltage shall not exceed 2.25 V per cell @ 27 degree C.
(c) Recharging shall be done at normal float voltage.
(d) Charging current shall not exceed 0.15 C. Where C is the capacity in AH @
10 hours of discharge to end cell voltage 1.80 V @ 27 deg C.
(e) Except during commissioning, battery shall not demand boost charging at
any point of time during its operation.
(f) Battery shall not demand equalizing charge at any point of time during its
operation.
14.0
PROCESS REQUIREMENT:-
(a) 100% cells shall be tested by Helium leak tester for leak free performance.
Vendor shall attach a copy of the Helium test report along with the dispatch
documents.
(b) Vendor is expected to monitor the voltage and current data of the cells
during initial charge and test discharge by means of automatic data logging for
traceability. Vendor shall maintain the database of the same and provide the
document as and when called for.
15.0
15.1
TESTS
TYPE TESTS for VRLA Batteries (Ref. ANNEXURE A)
15.1.1 The equipment/material should have been successfully type tested in line with
the relevant IEC/IS and technical specification, within the last five years from
the date of opening of the tender. The bidder/manufacturer shall submit copies
of the type test reports along with the drawings submitted for MSETCL for
approval. In case these type tests are conducted earlier than 5 years, all
the type tests shall be carried out by the successful bidder/manufacturer
1475 of 2461
PAGE 259 of 358
MMRDA
in the presence of MSETCLs representative, free of cost, before

submission of equipment drawings for approval.
15.1.2 If there is any change in the components or design in the equipment since its
earlier passing of the type test, the bidder/manufacturer shall bring out in his
offer all such change made in the component, materials, design etc. In such
cases, bidder/manufacturer shall carry out the type tests at his cost and in
15.1.4 If, the equipment/material has been type tested earlier, the MSETCL reserves
the right to demand repetition of one or more tests included in the list of type
test in presence of MSETCLs representative.
15.1.5 The MSETCL reserves the right to conduct tests included in the list of type
tests as per IS on requisite number of samples/items from any of the lots during
the tenure of the supply at MSETCLs cost in the presence of MSETCLs
representative. If the equipment/material does not withstand the type test, then
the equipment/material supplied till then will be liable for rejection. The
Manufacturer, in such an eventuality shall be allowed to modify the equipment
and type test the same again at his own cost in the presence of the MSETCL's
representative. These type tests shall however be conducted by the
Manufacturer within a reasonable time. After successful passing of the type
tests, all the equipments/material supplied earlier shall be modified/replaced
in line with equipment /materials which has successfully passed the type test.
In case Manufacturer fails to carry out the type test within reasonable time or
does not agree to carry out the type test at his cost, his equipment/materials
supplied earlier shall be rejected and order placed shall be cancelled and
payments made earlier for these Manufacturers shall be recovered by the
MSETCL.
The details of the type tests to be carried out by manufacturer are as per Annexure
A given below:
1476 of 2461
PAGE 260 of 358
MMRDA
ANNEXURE A
Sr.
No.
Type Tests Particulars
As per IS/IEC
1) Verification of constructional requirements.

2) Verification of dimensions /weight.
3) Test for capacity
4) Test for charge retention.
5) Endurance test
IS15549 : 2005
6) Ampere-Hour & Watt-Hour Efficiency Test

7) Test for Voltage during Discharge
8) Test for Gas recombination Efficiency
9) Wicking Test on Separators
10)
Test for Short Circuit Current and Internal

Resistance
IEC60896-21 & 22 : 2004
11) Test of Seal Integrity

12) Thermal Runaway
13) Service Life Test
16.0
ANSITI: 330 Specification
ROUTINE TESTS:-
All the routine tests, listed below shall be carried out on all the cells, containers,
hardware being supplied as per latest issue of BS: 6290, Part 4. IE C89-I or
IEEE 1188 (whichever is applicable) at the cost of the supplier.
(a)
Container
(i) Verification of constructional requirements.
(ii) Verification of marking and packing.
(iii) High voltage tests (CI: 7.6 of IS: 1146).
(b)
Cells and batteries:(i) Verification of constructional requirements.

(ii) Verification of markings.
(iii) Verification of dimensions.
(iv) Resistance of Cell / Batteries.
1477 of 2461
PAGE 261 of 358
17.0
MMRDA
ACCEPTANCE TESTS:-
Followings shall constitute the acceptance tests which shall be witnessed by

MSETCLs representative at the works of the manufacturer at the cost of the
supplier/manufacturer.
1. Verification of dimensions.
2. Verification of marking.
3. Tests for capacities for 10 hours discharge rate along with the test for voltage
during
discharge.
4. Ampere-hour and watt-hour efficiency test.

5. Short circuit current test of batteries (arrangement for this shall be provided
during testing).
6. Resistance of cell / batteries.
7. Pressure of vent plug connected with battery (measuring shall be provided
during testing).
8. Measurement of weight / material type and dimension of cell / racks
/batteries and all other accessories as per approval of drawings / technical
data submitted during tender process.
18.0
DRAWINGS / DOCUMENTS:-
The tenderer / Manufacturer shall submit the following drawings documents

along with his offer / at the time of approval.
(a) General battery arrangement including proposed size of individual and

over all dimensions along with sectional views showing all connections
etc.
(b) Layout details of the batteries along with Battery Stand and all
accessories.
(c) Guaranteed Technical Particulars
(d) Graphs, curves etc.
(e) Bill of Quantity
(f) Pamphlets and technical literature giving detailed information of the
1478 of 2461
PAGE 262 of 358
batteries
MMRDA
offered.
(g) Instruction manuals for initial charging and subsequent charging.
19.0
PERFORMANCE GUARANTEE
The Battery Cells offered shall be guaranteed for satisfactory performance for
a period of 72 months from the date of receipt of complete equipment at site
in good condition or 60 months from the date of satisfactory commissioning
whichever is earlier. The Battery Cells found defective/failed within the above
guarantee period shall be replaced/re-paired by the Manufacturer free of cost
within one month of receipt of intimation. Transportation of failed /defective
Material / Batteries to the manufacturers works shall be arranged by
bidder/manufacturer &
the
cost for the
same
shall be borne by
bidder/manufacturer. If the defective/failed Material / Batteries are not replaced/

repaired as per the above guarantee clause, MSETCL shall recover an
equivalent amount plus 15% supervision charges from any bill of the
Manufacturer / bidder.
20.0
TRAINING:-
The Bidder / Manufacturer shall arrange for onsite training of at least five
engineering personnel of MSETCL on operation and maintenance of the VRLA
type of batteries at free of cost. Every detail regarding the intricacies of these
batteries need to be imparted to the trainee engineers.
21.0
No material shall be dispatched from its point of manufacture unless the

material has been satisfactorily inspected and tested.
Inspection and acceptance of any material under this specification by the

MSETCL shall not relieve the Manufacturer of his obligation of furnishing the
same in accordance with the specification and shall not prevent subsequent
rejection, if the material is found to be defective.
1479 of 2461
PAGE 263 of 358
22.0
MMRDA
QUALITY ASSURANCE PLAN
The manufacturer/bidder shall invariably furnish the Quality Assurance Plan for
approval, failing which his material shall be liable for rejection.
23.0
PACKING & FORWARDING
The material shall be packed as per approved packing scheme and shall be
suitable for horizontal/vertical transportation, as the case may be, and suitable
to withstand handling during transport and outdoor storage in stores before
erecting. The Manufacturer shall be responsible for any damage to the material
during transit, due to improper and inadequate packing.
The easily
damageable material shall be carefully packed and marked with the appropriate
caution symbols. Wherever necessary, proper arrangement for lifting, such as
lifting hooks etc. shall be provided. Any material found short inside the packing
cases shall be supplied by Manufacturer without any extra cost.
24.0 DISQUALIFICATION NORMS
The Manufacturer/Bidder is liable for disqualification on account of any of the

following reasons:
a) Poor quality and workmanship of the products previously supplied and

frequent failures as experienced by the MSETCL.
b) Manufacturer/Bidder against whom litigation is in progress.
c) Manufacturer/Bidder, who in the opinion of the MSETCL has malafied
intentions in the conduct of business with the company (MSETCL),
d) Manufacturer/Bidder who is declared to be defaulter as per the terms and
conditions laid by the company.
Notwithstanding anything stated above, the MSETCLs decision in this regard
will be final.
SCHEDULE OF GUARANTEED TECHNCAL PARTICULARS FOR VRLA

LEAD ACID STORAGE BATTERY (TO BE SUBMITTED BY THE BIDDER /
1480 of 2461
PAGE 264 of 358
MMRDA
MANUFACTURER)
Manufacturers name and address :
Conforming to standards.
Type and designation as per IS.
Manufacturers type and designation
Capacity of battery bank at the Cap. Rate of End Cell following discharge
rates at 270C AH Discharge Current voltage
a. 15 minutes.
b. 30 minutes.
c. 45 minutes.
d. 1 hour
e. 2 hours
f. 3 hours.
g. 4 hours.
h. 5 hours.
i. 6 hours.
j. 7 hours.
k. 8 hours.
l. 9 hours.
m. 10 hours.
Number of cells in the battery.
Method of interconnection between cells.
Maximum short circuit current of battery when short circuit is at the end of
terminals
Recommended float-charging voltage across the battery terminals (volts).
10
Recommended boost charging voltage across battery terminals (volts).
11
Time required for boost charging from discharged conditions (in hours).
12
Recommended trickle / float charging rate
13
Recommended boost charging rate.
14
Trickle charging current range / cell.
15
Shelf life of charged battery bank.
16
Open circuit voltage of battery bank when fully charged.
17
AH capacity at 10 hours rate at room temperatures of
1481 of 2461
PAGE 265 of 358
MMRDA
a.150C.
b.270C
c. 500C
18
Cell Particulars:Material of container.

Overall dimensions of each cell.
Weight of cell complete with Electrolyte
19
Voltage:a. Open circuit voltage of cells.

b. Float charging voltage.
c. Boost charging voltage.
21
Type of material / thickness / dimension of positive plates.
22
Type of material / thickness / dimension of negative plates.
23
Separators:a. Type.
b. Materials.
c. Thickness of separator.
23 Type of valve provided.
24
Internal resistance of each cell at
25
Clearance in mm between.
a. Top of plates and top of container.
b. Bottom of plates and bottom of container.
c. Edges of plates and inner surface of container.
26
Maximum ambient temperature that the cells can withstand. Without

injurious effect.
a. Continuously.
b. Short periods (duration to be stated along with temperature).
27
Maximum number of charge / discharge cycles that the cell can withstand.
28
Ampere-hour efficiency at ten-hour discharge rate.
29
Watt-hour efficiency at ten hour discharge rage
30
Estimated life of cell under normal operating conditions (in years) %

change in life of battery for change in ambient temperature 27 degree
centigrade.
31
a. Maximum short circuit current per battery.
1482 of 2461
PAGE 266 of 358
MMRDA
b. Allowable duration of short circuit.

32
Short circuit current for a dead short across the Battery terminals when.
a. Float at 2.1V per cell
b. Boost charge to 2.75 V per cell.
33
Recommended floating voltage per cell and the Minimum variation.
34
Recommended interval at which battery should be Discharged at 10 hour

rate and quick charged.
35
Recommended storage period of a fully charged battery.
36
Inter cell connector.

a. Inter-cell connector furnished? (Yes/No).
b. Type of inter-cell connector (bolted or others)?
c. Materials of inter cell connector.
37
Inter-row, inter tier connectors and end take- off furnished?

Description. Size current rating type and material
38
Battery stack / rack.

a. Outline dimensions.
b. Type and material.
c. Anti-acid coating type.
d. Number of trays.
e. Height of bottom tier from ground level.
f. No. of cells which can be stacked in tray.
g. Dimensions of each tray.
39
Total shipping weight of battery units.
40
A dimensional layout drawing of the battery stock / rack along with battery
attached with the tender (yes /No)
41
The following characteristic curves to be furnished along with the tender

(yes/No).
a. Battery discharge curves at various rates between 1 minute and 10 hour
rate.
b. Curves showing the relation between the cell voltage and charging
current, when
charged at:
(ii) High starting rate.
(iii) Two step charging by starting and finishing rate.
1483 of 2461
PAGE 267 of 358
TECHNICAL
SPECIFICATION
MMRDA
MICROCONTROLLER
BASED
BATTERY
CHARGER TO BE USED AT 132kV SUBSTATIONS
1.0
SCOPE:-
1.1 This specification covers design, manufacture, assembly, inspection and testing
at manufacturer's works, packing and delivery of the Battery Charger Units of
various capacities with accessories for installation in various substations in
Maharashtra State (India) to make uninterrupted power supply.
1.2
The overall scope of work proposed to be assigned to the successful tenderer

according to this specification covering the following aspects.
a) Design and manufacture of Microcontroller based Dual Float cum Boost

Charger along with all accessories as per Technical Specification.
b) Complete testing of the Battery Chargers at manufacturers works.
c) FOR destination supply of Battery Charger.
d) Testing and commissioning of these equipments at site, as required.
1.3
It is not the intent to specify completely herein all the details of the design and
construction of equipment.
However, the equipment shall conform in all
respects to high standards of engineering, design and workmanship as

mentioned and shall be capable of performing in continuous commercial
operation up to the expected life of 25 years, in a manner acceptable to the
purchaser, who will interpret the meanings of drawings and specifications and
shall have the power to reject any work of material which, in his judgment is not
in accordance therewith. The offered equipment shall be complete with all
components necessary for their effective and trouble free operation. Such
components shall be deemed to be within the scope of suppliers supply
irrespective of whether those are specifically brought out in this specification
and/or the commercial order or not.
2.0
2.1
The requirement of Battery Chargers to be supplied against this specification
1484 of 2461
PAGE 268 of 358
MMRDA
shall be as per tender /specified hereunder.
The Battery Charger System shall be an integrated System comprising of

Microcontrollers, Static Rectifiers, Isolating and Protection Devices and all other
Equipment/Accessories required for completeness of the System whether
specifically mentioned herein or not, but necessary for completeness and
satisfactory performance of the System. The Battery Charger Equipment shall
be properly coordinated with the VRLA Battery to ensure complete
compatibility.
All Equipment and Components shall be of excellent quality and reliability for
providing secure DC power required for vital equipment performance,
controlling, monitoring and safeguarding functions in the Substation.
Components shall be capable of withstanding the thermal and dynamic
stresses resulting from internal and external short circuits and circuit switching
operations etc. The design of the equipment shall be such as to minimize the
risk of short circuits and shall ensure personnel and operational safety.
The Battery Charger Manufacturer shall be responsible for design, engineering

and manufacturing of the complete System to fully meet the intent and
requirements of this specification.
3.0
SERVICE CONDITIONS:
3.1
3.1.1
Maximum ambient temperature in open air 50.00

(C):
3.1.2
Maximum ambient temperature in shade 45.00

(C)
3.1.3
3.50
3.1.4
10 to 100
1485 of 2461
PAGE 269 of 358
MMRDA
3.1.5
1450
3.1.6
Maximum wind pressure (Kg/m2)
150
3.1.7
Maximum altitude above mean sea level 1000

(Meter)
3.1.8
Isokeraunic level (days/year)
50
3.1.9
0.3 g.
3.1.1
General nature of climate :
Moderately hot and humid tropical
climate, conducive to rust and fungus

growth.
4.0
STANDARDS:-
4.1
All equipment and their accessories, covered by this specification shall be

designed, manufactured and tested in compliance with the latest relevant
standards, published by the Bureau of Indian Standards including those, listed
below in order that specific aspects under Indian climatic conditions are taken
care of.
4.2
The equipment and accessories for which Indian Standards are not available
shall be designed, manufactured and tested in accordance with the latest
standards, published by any other recognized National Standards Institution
and latest publication of International Electro Technical commission [IEC].
4.3
The equipment manufactured according to any other authoritative national/

international standard, which ensures an equal or better quality than the
provisions of these specifications shall also be acceptable. Where the
equipment, offered conform to any other standard, salient points of differences
between the proposed standard and the provisions of these specification shall
be clearly brought out in the offer. A copy of such standards [in English] shall
be enclosed with the offer. However, the decision of MSETCL will be final.
4.4
The equipment shall conform to the Indian Electricity Rules, 1956 with latest
amendments as regarding safety earthing and other essential provisions
specified therein for installation and operation of electrical plants.
1486 of 2461
PAGE 270 of 358
4.5
MMRDA
All equipment shall also comply with the statutory requirements of the
Government of Maharashtra where the equipment will be installed. Nothing
shall be construed to relieve the supplier / manufacturer of his responsibility.
The Microcontroller based Battery Chargers shall confirm to the following standards:
Sr.
Standard No.
Title
IS: 3895
Specification for Rectified equipment in general.
IS: 2208
Specification for HRC fuses.
IS: 1248
Indicating instruments.
IS: 2147
Degree of protection for cubicle
IS: 375
Specification for wiring.
IS: 4540
IS: 6619
Safety code for semi-conductor rectified equipment
IS: 2026
Transformers.
IS: 2959
A.C. contactors for voltage not exceeding 1000 V.
10
IS: 4237
11
IS: 4064
Air break switches and fuse combination units.
12
IS: 6005
Code of practice for phosphating of iron and steel.
13
IS: 5
Color of ready mix paints.
14
IS: 5921
Printed Circuit Board.
15
IS: 249
Printed Circuit Board.
16
IS : 3231
Electrical relays for power system protection
17
IS : 3842
Electrical relays for A.C. System
18
IEC: 148
Battery Chargers
19
IS : 8836
Miniature ckt. Breakers.
20
IS : 694
21
IS : 1554
PVC insulated (Heavy duty) electric cables
22
IS : 9224
Fuses.
23
IS : 9676
Reference ambient temp. for electrical equipments
No.
Monocrystaline semiconductor rectified assemblies

and equipment.
General requirement for switchgear and control gear for

voltage not exceeding 1000V.
PVC insulated cables for working voltages upto

including 1100 V.
1487 of 2461
PAGE 271 of 358
Sr.
No.
24
Standard No.
IS : 8623
MMRDA
Title
Low voltage switchgear and control gear part (I)
assemblies
5.0
QUALIFYING REQUIREMENTS:-
5.1
The tenderer / manufacturer should have proven experience of not less than 5
years in Design, Manufacture, Supply and Testing at work for equipment / materials
offered for equal or higher voltage class. The equipment/material supplied by
tenderer should be in the successful operation, at least for two years as on the date
of submission of the tender.
5.2 The tenderer / manufacturer should furnish the type test report of the equipment
offered as per ANNEXURE IIA at the time of submission of the document for
approval.
a) The manufacturer should have type tested the equipment offered.
b) The bidder / manufacturer shall have the basic infrastructure for the design,
manufacture and supply of the items offered, like machinery technical knowhow, capacity etc.
c) The purchaser shall be satisfied with the designing, manufacturing,

supplying and financial capacities of the bidder after inspecting the
suppliers work.
5.3 Notwithstanding anything stated above, the MSETCLs decision in this regard will
be final
6.0
OTHER REQUIREMENTS:-
6.1
ACCESSIBILITY AND INTER CHANGEABILITY:-
All working parts, as far as possible, shall be arranged for convenience of

1488 of 2461
PAGE 272 of 358
MMRDA
operation, inspection, lubrication and in case of replacement with minimum

down time. All like parts of the equipment, furnished shall be inter changeable.
6.2
QUALITY AND WORKMANSHIP:-
Workmanship and materials shall be of good commercial quality, suitable for

the purpose, intended and in accordance with the highest standards and
practices for equipment of the class, covered by this specification.
6.3
SAFETY
6.3.1 All equipment shall be complete with approved safety devices wherever a
potential hazard to personnel exists and with provision for safe access of
personnel to and around the equipment for operational and maintenance
functions. The design shall include all necessary precautions and provisions for
the safety of operating and maintenance personnel.
6.3.2. Special care shall be taken to make enclosed equipment proof against entry of
rat, lizards and other creeping reptiles, which may create electrical short circuits
inside, live equipment.
6.3.3. Continuity of power supply is the first consideration and the design shall be
such as to provide facilities to simplify inspection, testing maintenance, clearing
and repair at site.
7.0
CONSTRUCTIONAL DETAILS OF BATTERY CHARGER.
7.1
The Chargers shall be Microcontroller based and shall be indoor, floormounted, self-supporting sheet metal enclosed cubicle type. The Contractor /
Manufacturer shall supply all necessary base frames, anchor bolts and
hardware. The Chargers shall be fabricated from 2.0mm cold rolled sheet steel
and shall have folded type of construction. Removable gland plates for all
cables and lugs for power cables shall be supplied by the Contractor. The lugs
for power cables shall be made of electrolytic copper with tin coat. Provision of
suitable lugs and drilling of Gland Plates shall be matching with the Power cable
1489 of 2461
PAGE 273 of 358
MMRDA
size. The Charger shall be tropicalised and vermin proof. Ventilation louvers, if
provided shall be backed with screens. All doors and covers shall be fitted with
neoprene gaskets. The chargers shall have hinged double leaf doors provided
on front and on backside for adequate access to the Chargers internals. All the
charger cubicle doors shall be properly earthed. The degree of protection of
Charger enclosure shall be at least IP-42 as per IS: 13947 Part I.
7.2
The overall dimensions of the battery charger cubicle shall be 1800 mm (Height
H) x 700 mm (Depth D) x 1000mm (Length L) to suit the requirement to
accommodate the equipment.
7.3
All indicating instruments, control switches and indicating lamps shall be

mounted on the front side of the Charger.
7.4
Each Charger shall be furnished completely wired upto power cable lugs and
terminal blocks and ready for external connections. The control wiring shall be
carried out with PVC insulated, 2.5 sq.mm. stranded copper wires. Control
terminals shall be suitable for connecting two wires, with 2.5 sq.mm stranded
copper conductors. All terminals shall be numbered for ease of connections and
identification. Each wire shall bear a ferrule or tag on each end for identification.
At least 20% spare terminals shall be provided for control circuits.
7.5
The insulation of all circuits, except the low voltage electronic circuits shall
withstand test voltage of 2 KV AC for one minute. An air clearance of at least
ten (10) mm shall be maintained throughout for such circuits, right up to the
terminal lugs. Whenever this clearance is not available, the live parts shall be
insulated or shrouded.
7.6
The perimeter of all doors, removable cover plates shall be having neoprene
gasket all around.
7.7
Bus bars, if required shall be colour coded and live parts shall be shrouded to
ensure complete safety to personnel intending routine inspection by opening
the panel doors.
1490 of 2461
PAGE 274 of 358
7.8
MMRDA
All power and control equipment/components may be installed within the panel
provided that they are operationable after opening the front panel door.
However, LCD Display with Keypad shall be installed on the front door of the
Panel.
7.9
All electrical parameters shall be displayed on LCD provided in the Battery

Charger by operating the Keypad available.
7.10
All fuses shall be link type and shall be located inside the panel. Glass fuses
shall be used for control circuits with suitable fuse bases.
7.11
7.12
Lifting hooks shall be provided for Battery Charger Cubical.
A suitable removable undrilled gland plate of 3mm thickness shall be provided

for cable entry. Cable entry shall be at the front bottom of the cubicle.
7.13
Battery Charger Cubicle shall be Single Bay Type (Single Door) or Double Bay
Type (Double Door) based on the Charger Rating (Voltage & Current Ratings)
and doors shall have handles with locking facility.
7.14
Cubical shall be provided with Two Compact Fluorescent Lamps (5 Watt)

working on 240VAC Supply. It shall be operated automatically by door limit
switch.
7.15
A Single Phase, 5 Amps, 5 pin Domestic Type Socket shall be provided in the
Cubical with ON/OFF Switch.
7.16
Panel Space Heater completes with ON/OFF Switch and Thermostat shall be
provided in the Panel. The Thermostat shall maintain the internal temperature
above the ambient temperature to prevent moisture condensation.
8.0
PAINTING
The Battery Charger cubicle shall be subjected to 7 tank processing before

painting. All sheet steel work shall be pre-treated, in tanks, in accordance with
1491 of 2461
PAGE 275 of 358
MMRDA
IS:6005. Degreasing shall be done by alkaline cleaning. Rust and scale shall
be removed by pickling with acid. After pickling, the parts shall be washed in
running water. Then these shall be rinsed in slightly alkaline hot water and dried.
The phosphate coating shall be `Class-C as specified in IS:6005. Welding shall
not be done after phosphating. The phosphating surfaces shall be rinsed and
passivated prior to application of stoved lead oxide primer coating. After primer
application, two coats of finishing synthetic enamel paint of shade-631 of IS:5
shall be applied, unless required otherwise by the Owner. The inside of the
chargers shall be glossy white. Each coat of finishing synthetic enamel paint
shall be properly staved. The paint thickness shall not be less than fifty (50)
microns.
9.0
9.1
TECHNICAL REQUIREMENTS
INPUT POWER SUPPLY

The Battery Charger shall be suitable for the following input power supply:
Voltage
415VAC 10%
Frequency
50Hz 5%
The Battery Charger shall work on 3 Phase, 3 Wire or 3 Phase, 4 Wire. Also,
Battery Charger shall be designed to operate satisfactorily while drawing input
power from an emergency diesel generator set.
9.2
9.2.1
DESIGN BASIS
The Battery Charger System shall be a Dual Float cum Boost Charger [Two
Float cum Boost Chargers (FCBC-1 & FCBC-2)] working on a 3 phase AC
Supply with a Microcontroller based Control Circuit. Advanced Microcontroller
shall be used for this purpose. This controller section shall not only provide
accuracy of operations but also shall add the ability of communication. The LCD
of suitable size shall be provided. Each Character size in LCD shall be at least
4.84mm x 9.66mm and such that it can be easily readable from distant.
9.2.2
The Battery to be connected to the Charger shall be of VRLA type. Battery

Chargers for VRLA Battery shall be sized to provide quick charging of the
Battery up to 90% of rated Ampere hours within duration of 24 hours and to
1492 of 2461
PAGE 276 of 358
MMRDA
100% within 4 days. Each Float cum Boost Charger shall be sized as specified
below:
For VRLA Battery
Size of FCBC-1 = Load Current + Online Battery Boost Charging Current

Online Battery Boost Charging Current = 10% of Battery Capacity
Size of FCBC-2 = Load Current + Online Battery Boost Charging Current
Online Battery Boost Charging Current = 10% of Battery Capacity
Float Voltage = 2.25VPC; Boost Voltage = 2.3VPC

Each Float cum Boost Charger shall be sized to supply Total
Load Current and Online Battery Boost Charging Current
9.2.3
Charger shall have a 3 phase Full Wave, Full Controlled Rectifier Bridge (6
Pulse Rectifier Bridge) with protective devices. Independent current limits shall
be provided for charger load current and battery charging current. Subsequent
to a discharge cycle and completion of quick charging, when battery is
connected to charger under float mode, the battery current shall be monitored,
controlled and limited to set value automatically irrespective of the value of load
current. Fast acting semi-conductor fuses shall be provided for protection
against internal short circuits. The high speed semi-conductor fuses used for
rectifier protection shall be complete with trip indication.
9.2.4
Filter circuits consisting of smoothing choke and condenser, complete with

protection to limit the ripple content at the output shall be provided.
9.2.5
Silicon Blocking Diode shall be provided at the Charger Output Circuit to

prevent back-feed from Battery into the Charger and Filter Circuit.
9.2.6
Indication for Reverse Battery connection and DC Earth Fault for Earth
Leakage Detection shall be provided.
9.2.7
Analog meter to detect the DC earth leakage shall be provided on Front panel
of Charger
1493 of 2461
PAGE 277 of 358
9.2.8
MMRDA
Internal Cooling of the Charger Unit shall be by Natural Ventilation (Natural Air
Cooling).
9.2.9
All Electronic & Electrical Components shall be appropriately rated for

satisfactory performance of the Battery Charger.
9.2.10 Battery Charger shall be galvanically isolated from the input power supply by
providing a double wound transformer at its input. The transformer shall be
natural air cooled, dry type suitable for location inside a panel
9.2.11 Battery Charger shall have RS-485 Serial Communication Port to interface
with SCADA.
9.2.12 Battery Charger shall have Auto Phase Reversal Operation.
9.2.13 Battery Charger shall have Soft Start/Slow Walk-in time facility on DC side.
9.2.14 Battery
Charger
shall
have
Automatic
Voltage
Regulation
using
Microcontroller.
9.2.15 Battery Charger shall have Remote Shutdown facility from SCADA.
9.3
CHARGER RATING
Sr.
Substation Type
DC Control Current Rating
No.
Voltage
in in Ampere
9.4
220/33/22kV Substation
Substation Battery Charger
220V DC
50A
ii
PLCC Battery Charger
48V DC
50A
132/33kV Substation (Turnkey / Wind / Solar Project)
Substation Battery Charger
220V DC
50A
ii
PLCC Battery Charger
48V DC
50A
CHARGER OPERATION
1494 of 2461
PAGE 278 of 358
9.3.1
MMRDA
The Battery Charger System shall basically consist of Two Float Cum Boost
Chargers with an Interlocking Circuit.
9.3.2 Each Float cum Boost Charger shall be capable to supply the Total Load
and
Battery Charging requirements.
9.3.3 In normal mode of operation, FCBC-1 shall float charge the battery and feed
the load and FCBC-2 shall be in OFF condition. When FCBC-1 fails, the other
Charger FCBC-2 shall come into operation automatically and shall supply to
the Load and Battery Bank.
9.3.4 Interlocking Circuit shall control entire Charger System by communicating with
FCBC-1 & FCBC-2 and activating them as per the requirement. It shall perform
the operations like when FCBC-1 has to work; when FCBC-2 has to work and
in which mode; when both FCBC-1 & FCBC-2 has to work etc.
9.3.5 Each Float cum Boost Charger shall have two modes of operation AUTO &
MANUAL.
9.3.6 Under AUTO MODE, each Float cum Boost Charger shall either act as an Auto
Float Charger or as an Auto Boost Charger depending on the Battery Current
requirement.
9.3.7 Manual intervention shall not be required when the Float cum Boost Chargers
are selected to AUTO MODE.
9.3.8 Float cum Boost Chargers shall be provided with provision of MANUAL FLOAT
and MANUAL BOOST Modes in which battery can be charged either in FLOAT
or BOOST by manual selection.
9.3.9 On failure of AC Mains Supply to Float cum Boost Chargers or if Float cum
Boost Chargers themselves fails for any reason, Battery shall supply the load.
9.3.10 Once the AC Mains Supply to both the FCBCs restores or if failed FCBCs get
rectified, FCBCs shall switch over to Float Mode or Boost Mode based on the
1495 of 2461
PAGE 279 of 358
MMRDA
Battery Charging current if the charger is kept in AUTO mode of operation.
9.5
CHARGER CONTROLS
The following below specified controls shall be provided in the Battery Charger:
Separate AC Input Circuit Breaker to connect the three phase AC Input

Supply to the Charger Input Transformers of both Charger-1 & 2.
Separate DC Output Circuit Breaker to connect the DC Outputs of both

the Charger-1 & 2 to Battery and to the Load.
9.6
Battery Input Fuses.
AC Socket ON/OFF Switch.
Heater ON/OFF Switch.
Door Lamp ON/OFF Push Button.
Key Pad with LCD Display having Keys to
Enter Parameters through LCD
Decrement Menu Parameters through LCD
Increment Menu Parameters through LCD
Enter Menu Process
Come out of Menu
CHARGER INDICATIONS
I.
Cluster LED Lamps shall be provided for AC Mains ON (R, Y, B) condition.
II.
The following Indications shall be provided in the charger system by 5mm

LEDs:
a. FCBC-1 AC Mains ON
Green LED
b. FCBC-2 AC Mains ON
Green LED
c. FCBC-1 ON
Green LED
d. FCBC-2 ON
Green LED
e. FCBC-1 Float ON
Green LED
f. FCBC-1 Boost ON
Amber LED
g. FCBC-2 Float ON
Green LED
h. FCBC-2 Boost ON
Amber LED
1496 of 2461
PAGE 280 of 358
MMRDA
i.
FCBC-1 AC Mains Fail
Red LED
j.
FCBC-2 AC Mains Fail
Red LED
k. FCBC-1 Over Voltage
Red LED
l.
Red LED
m. FCBC-1 Under Voltage
Red LED
n. FCBC-2 Under Voltage
Red LED
o. FCBC-1 SCR Fuse Fail
Red LED
p. FCBC-2 SCR Fuse Fail
Red LED
FCBC-2 Over Voltage
q. FCBC-1 Fail
Red LED
r. FCBC-2 Fail
Red LED
s. Battery Fuse Fail
Red LED
t. Battery Earth Fault
Red LED
u. Load Under Voltage
Red LED
v. Load Over Voltage
Red LED
w. Battery Under Voltage
Red LED
x. Battery Over Voltage
Red LED
y. Battery Reverse Polarity
Red LED (shall be provided at
Battery
Termination)
z. Group Alarm
Red LED
Also above indications shall be communicable to SCADA.
9.7
CHARGER DISPLAY (LCD)
The following Parameters shall be displayed in the Charger System LCD and
communicable to SCADA:
a. AC Input Voltage either Line to Line or Line to Neutral
b. AC Input Current in each phase
c. Charger Output Voltage
d. Charger Output Current
e. Battery Voltage
f. Battery Charge/Discharge Current
g. Load Voltage
h. Load Current
i.
Charger ON/OFF
1497 of 2461
PAGE 281 of 358
j.
9.8
MMRDA
Alarms
CHARGER ANNUNCIATION
The following below specified Annunciation [Alarms (LED/LCD) with Buzzer]

shall be displayed in the Charger System with RS-485 Serial Communication
Port for remote monitoring:
9.9
a. FCBC-1 AC Mains Fail/Out of Limit
Both LCD and LED Indication
b. FCBC-2 AC Mains Fail/Out of Limit
c. FCBC-1 SCR Fuse Fail
d. FCBC-2 SCR Fuse Fail
e. FCBC-1 Fail
f. FCBC-2 Fail
g. FCBC-1 Under Voltage
h. FCBC-2 Under Voltage
i.
FCBC-1 Over Voltage
j.
FCBC-2 Over Voltage
k. FCBC-1 Over Temperature
LCD Indication
l.
LCD Indication
FCBC-2 Over Temperature
m. FCBC-1 AC I/P CB Trip/OFF :
LCD Indication
n. FCBC-2 AC I/P CB Trip/OFF :
LCD Indication
o. FCBC-1 DC O/P CB Trip/OFF :
LCD Indication
p. FCBC-2 DC O/P CB Trip/OFF :
LCD Indication
q. FCBC-1 Filter Fuse Fail
LCD Indication
r. FCBC-2 Filter Fuse Fail
LCD Indication
s. Battery Fuse Fail
t. Battery Earth Fault
u. Load Under Voltage
v. Load Over Voltage
w. DC Overload
LCD Indication
x. Group Alarm
CHARGER POTENTIAL FREE CONTACTS (PFCs)
1498 of 2461
PAGE 282 of 358
MMRDA
The following below specified Potential Free Contacts (PFCs) shall be provided
in the Charger System to enable DCS connections in case LAN connection is
not available:
a. FCBC-1 Fail
b. FCBC-2 Fail
c. FCBC-1 Rectifier Fuse Fail
d. FCBC-2 Rectifier Fuse Fail
e. FCBC-1 DC Under Voltage
f. FCBC-2 DC Under Voltage
g. FCBC-1 DC Over Voltage
h. FCBC-2 DC Over Voltage
i.
FCBC-1 Float ON
j.
FCBC-2 Float ON
k. FCBC-1 Boost ON
l.
FCBC-2 Boost ON
m. Battery Over Voltage

n. Battery Under Voltage
o. Load Over Voltage
p. Load Under Voltage
q. Battery Fuse Fail
r. Battery Earth Fault
s. Group Alarm
9.10
PRINTED CIRCUIT BOARDS (PCBs)
PCBs used in the Charger shall be made of glass epoxy material. Components
shall be properly mounted without undue stress, torsion, bends, twists etc. All
PCBs shall be provided with a transparent epoxy coating on both sides for
environmental/anti-fungus protection and tropicalization. Industrial grade
components shall be used in the PCBs and electronic circuits. PCBs shall
preferably be wave soldered. Copper strips/prints on PCBs shall have smooth
edges free from hair line cuts and shall be provided with tin coating. Panel
Mounting Type PCBs shall be mounted inside the Charger System and shall be
suitable for easy replacement. They shall be located away from heat sources.
The PCBs shall be firmly mounted inside the Charger so that vibration or
1499 of 2461
PAGE 283 of 358
MMRDA
continued usage does not result in loose contacts. All PCBs shall be fitted in a
manner to avoid replacement of a PCB by a wrong spare card. The PCBs shall
be provided with test points and setting potentiometers in a readily accessible
location which is visible without removing the PCBs.
9.11
RECTIFIER TRANSFORMERS AND FILTER CHOKES

The Rectifier Transformer and Filter Choke shall be dry and air cooled (AN)
type. The rating of the rectifier transformers and filter chokes shall correspond
to the rating of the associated rectifier assembly. The rectifier transformer shall
be dry type, double wound with copper conductor. Both rectifier transformer and
choke shall have Class-F insulation with Class-F temperature limits.
9.12
RECTIFIER ASSEMBLY
The rectifier assembly shall be full wave bridge type and designed to meet the
duty as required by the respective Charger. The rectifier cells shall be provided
with their own heat dissipation arrangement with natural air. The rectifier shall
utilize thyristors (SCRs) and heat sinks rated to carry 100% of the load current
continuously and the temperature of the heat sink shall not be permitted to
exceed the junction temperature of the thyrisors considering the maximum
surrounding air temperature for these devices inside the charger panel
assuming air ambient temperature of 50C outside the panel. Necessary fast
acting semiconductor fuses shall be provided in any of the two arms out of three
of the rectifier connections.
9.13
CHARGER PROTECTIONS
The following below specified Protections shall be provided in the Charger

System:
a. AC Input Circuit Breaker

b. Fast acting Semiconductor Fuses for SCR Bridge
c. DC Over Voltage Cutback / Shut Down
d. DC Overload
e. DC Output Circuit Breaker
1500 of 2461
PAGE 284 of 358
MMRDA
f. Battery Input Fuses

g. Battery Current Limit
h. Charger Current Limit
i.
10.0
10.1
Blocking Diode
TESTS
TYPE TESTS for Battery Chargers (Ref. ANNEXURE IIA)
10.1.1 The equipment/material should have been successfully type tested in line with
the relevant IEC/IS and technical specification, within the last five years from
the date of opening of the tender. The bidder/manufacturer shall submit copies
of the type test reports along with the drawings submitted for MSETCL for
approval. In case these type tests are conducted earlier than 5 years, all
the type tests shall be carried out by the successful bidder/manufacturer
in the presence of MSETCLs representative, free of cost, before
submission of equipment drawings for approval.
10.1.2 If there is any change in the components or design in the equipment since its
earlier passing of the type test, the bidder/manufacturer shall bring out in his
offer all such change made in the component, materials, design etc. In such
cases, bidder/manufacturer shall carry out the type tests at his cost and in
10.1.4
If, the equipment/material has been type tested earlier, the MSETCL reserves
the right to demand repetition of one or more tests included in the list of type
test in presence of MSETCLs representative.
10.1.5 The MSETCL reserves the right to conduct tests included in the list of type
tests as per IS on requisite number of samples/items from any of the lots during
the tenure of the supply at MSETCLs cost in the presence of MSETCLs
representative. If the equipment/material does not withstand the type test, then
1501 of 2461
PAGE 285 of 358
MMRDA
the equipment/material supplied till then will be liable for rejection. The
Manufacturer, in such an eventuality shall be allowed to modify the equipment
and type test the same again at his own cost in the presence of the MSETCL's
representative. These type tests shall however be conducted by the
Manufacturer within a reasonable time. After successful passing of the type
tests, all the equipments/material supplied earlier shall be modified/replaced in
line with equipment /materials which has successfully passed the type test. In
case Manufacturer fails to carry out the type test within reasonable time or does
not agree to carry out the type test at his cost, his equipment/materials supplied
earlier shall be rejected and order placed shall be cancelled and payments
made earlier for these Manufacturers shall be recovered by the MSETCL.
The details of the type tests to be carried out by manufacturer are as per
Annexure IIA given below:
ANNEXURE IIA
Sr.
No.
Type Tests Particulars
1)
Voltage Regulation Test
2)
Load Limiter Characteristic Test
3)
Efficiency Test
4)
High Voltage Test
5)
Temperature Rise Test
6)
As per IS/IEC
Short Circuit test at No Load & Full Load at rated voltage for
IS 4540
sustained Short Circuit
7)
Degree of Protection Test
8)
Measurement of Ripple by oscilloscope
9)
Temperature Compensation feature Demonstration
10)
Electrostatic Discharge Field Immunity Test
IEC 61000-4-2
11)
RF Radiated Immunity Test
IEC 61000-4-3
12)
High Energy Surge Test
IEC 61000-4-5
13)
Power Frequency Magnetic Field Test
IEC 61000-4-8
14)
Dynamic ability to withstand Short Circuit test on Transformer
1502 of 2461
IS
11171-1985
& IS 2026-1977
PAGE 286 of 358
11.0
MMRDA
ROUTINE TESTS:-
All the routine tests, listed below shall be carried out on all the Battery Chargers
at the cost of the supplier on each Charger.
(i) Visual Inspection

(ii) Insulation Resistance Test
(iii) Efficiency Test at Full Load
(iv) Ripple Measurement Test at Full Load & at AC Nominal Voltage
(v) Voltage Regulation Test at Full Load
(vi) Battery Charge set points
(vii) Indications, Alarms and Potential Free Contacts
12.0
ACCEPTANCE TESTS:-
All the Acceptance tests, listed below shall be carried out on all the Battery
Chargers at the cost of the supplier on each Charger.
(i) Visual Inspection

(ii) Insulation Resistance Test
(iii) Efficiency Test at Full Load
(iv) Ripple Measurement Test at Full Load & at AC Nominal Voltage
(v) Voltage Regulation Test at Full Load
(vi) Battery Charge set points
(vii) Indications, Alarms and Potential Free Contacts
(viii) Operational Tests
(ix) Data Communication with RS 485 & RS 232.
13.0
DRAWINGS / DOCUMENTS:-
12.1 The tenderer / manufacturer shall furnish, complete set of technical

literature/manuals and typical schematic drawings in respect of all the
equipments offered by them.
12.2 After issue of LOI the contractor shall submit within two weeks, three sets of
1503 of 2461
PAGE 287 of 358
MMRDA
complete drawings along with detailed Bill of Quantity GTP, packing list, Type
Test Reports etc., for approval.
12.3 The manufacturing of the equipments shall be strictly in accordance with the
approved drawings and no deviation will be permitted without the written
approval of the Design Department. All manufacturing work which is not as per
the approved drawings shall be at the suppliers risk.
12.4 The approved drawings, Bill of Quantity and installation, operation, maintenance
& troubleshooting manuals shall be supplied. The total sets of literature and
drawings to be supplied by the contractor after approval shall be as indicated
below:
a)
3 Sets of G.A. Drawing of the equipment.
b)
Technical Literature/manuals on all major components
c)
Voltage/current characteristic curve of boost charger and float charger

up to at least 125% of the rated load.
d)
Circuit diagram of the battery charger annunciation, indication and

control circuits.
e)
Bill of Quantity / GTP indicating the complete list of materials,

components, makes of components, quantities and rating as specified
in the ANNEXURE - IIIA of this specification.
f)
Full description on the working and design of the system along with the
schematic.
g)
Transformer KVA and voltage rating calculation
h)
Fault current calculation for battery charger.
i)
Thyrister rating and fuse co-ordination calculation
j)
Filter circuit calculation
k)
AC power consumption in float mode and boost mode.
l)
Brief write up on the working of the system offered.
The data submitted shall be adequate to evaluate the performance/quality of the

equipment offered.
14.0 PERFORMANCE GUARANTEE
1504 of 2461
PAGE 288 of 358
MMRDA
The Battery Chargers offered shall be guaranteed for satisfactory performance

for a period of 72 months from the date of receipt of complete equipment at
site in good condition or 60 months from the date of satisfactory
commissioning
whichever
is
earlier.
The
Battery
Chargers
found
defective/failed within the above guarantee period shall be replaced/re-paired

by the Manufacturer free of cost within one month of receipt of intimation.
Transportation of failed /defective Material / Battery Chargers to the
manufacturers works shall be arranged by bidder/manufacturer & the cost for
the same shall be borne by bidder/manufacturer. If the defective/failed Material
/ Battery Chargers are not replaced/ repaired as per the above guarantee
clause, MSETCL shall recover an equivalent amount plus 15% supervision
charges from any bill of the Manufacturer / bidder.
15.0
TRAINING:The Bidder / Manufacturer shall arrange for onsite training of at least five
engineering personnel of MSETCL on operation and maintenance of the above
Battery Charger for VRLA type of batteries at free of cost. Every detail regarding
the intricacies of these chargers need to be imparted to the trainee engineers.
16.0 DISPATCH OF MATERIAL
No material shall be dispatched from its point of manufacture unless the material
has been satisfactorily inspected and tested.
Inspection and acceptance of any material under this specification by the

MSETCL shall not relieve the Manufacturer of his obligation of furnishing the
rejection, if the material is found to be defective.
17.0 QUALITY ASSURANCE PLAN
The manufacturer/bidder shall invariably furnish the Quality Assurance Plan for
approval, failing which his material shall be liable for rejection.
18.0 PACKING & FORWARDING

1505 of 2461
PAGE 289 of 358
MMRDA
The equipment shall be properly packed for transportation by ship/ rail or road.
It shall be wrapped in polythene sheets before being placed in crates/cases to
prevent damage to finish. The crates/cases shall have skid bottoms for
handling. Special notations such as Fragile, This side up, Center of gravity,
Weight, Owner's particulars, etc., shall be clearly and indelibly marked on
the packages.
The equipment may be stored indoors for long periods before installation. The
packing shall be completely suitable for indoor storage in areas with high
ambient temperatures, high humidity conditions etc.
19.0
DISQUALIFICATION NORMS

following reasons:
a) Poor quality and workmanship of the products previously supplied and
b) Manufacturer/Bidder against whom litigation is in progress.
c) Manufacturer/Bidder, who in the opinion of the MSETCL has malafied

d) Manufacturer/Bidder who is declared to be defaulter as per the terms and

Notwithstanding anything stated above, the MSETCLs decision in this regard
will be final.
GUARANTEED TECHNICAL PARTICULARS OF MICROCONTROLLER BASED

DUAL FLOAT CUM BOOST BATTERY CHARGER
Sr.
Description
No.
1.0
General
1506 of 2461
PAGE 290 of 358
Sr.
MMRDA
Description
No.
1.1
Make
1.2
Cat. No.
1.3
Type
1.4
Reference standard
2.0
A.C. Input
a) Voltage % variation volt.

b)
Phase
No.
c)
Frequency variation Hz
Input amps. at the following loads in addition to
supply the battery charging current.
d)
i)
50% rated load
Amp:
ii) 100% rated load
Amp:
iii)110% rated load
Amp:
e) Charger maximum inrush current.

f)
Maximum AC Power KVA requirements.
2.1
D.C. Output
Voltage
a)
i) Float mode
ii) Boost mode
iii) Regular
Amp:
Current
b)
i) Float mode
ii) Boost mode
iii) Regular
c)
Amp:
Total output
Current of battery charger
2.2
Type of cooling.
2.3
Maximum temperature within cubicle :-
a) Rectifier transformer Deg. C.

b)
SCR
Deg, C
c)
Filter chokes
Deg, C
d)
Electronic PCBs
Deg, C
1507 of 2461
PAGE 291 of 358
Sr.
MMRDA
Description
No.
3.0
3.1
3.2
Performance
Regulation for 0-100% rated load with 10% input
voltage and 5% input frequency variation
Ripple content in D.C. output
a) With battery
b)
Without battery
3.3
Guaranteed efficiency at
%
%
a) 50% rated load%

b)
100% rated load
3.4
Power factor at rated load %
3.5
Maximum fault current for the short circuit at output

terminals
a) With current limiting device operative
KA:
b)
With current limiting device inoperative
Miscellaneous
4.1
KA:
Whether charger provided with following features:
a) Automatic voltage regulation.

b)
Current limiting circuitry
c)
Soft-start feature
4.2
SCR/Diode elements provided with
a) Surge protection (Give type & rating)

b)
Fast acting HRC fuses (Give type and rating).
5.0
MCB.
5.1
Make
5.2
Type/Cat. No.
5.3
Reference standard
5.4
Rated current
6.0
A.C. Fuse (if applicable)
6.1
Make
6.2
Type/Cat. No.
6.3
Reference standard.
6.4
Current rating:
Amp:
1508 of 2461
PAGE 292 of 358
Sr.
MMRDA
Description
No.
a) Continuous
b)
Interrupting
7.0
A.C. Contactor
7.1
Make
7.2
Type/Cat. No.
7.3
Reference standard
7.4
Rated current
7.5
Utilization category.
7.6
Amp:
KA
Whether thermal overload with in-built singlephase preventer provided.
8.0
Rectifier Transformer
8.1
Make
8.2
Type/Cat. No.
8.3
Reference standard.
8.4
Whether transformers are type tested.
8.5
Ratings
a)
KVA
b)
Voltage
c)
8.6
Class of insulation
8.7
Method of cooling
9.0
Full wave fully Controlled Rectifier (SCR)
9.1
Make
9.2
Type/ Cat. No.
9.3
Reference Standard
9.4
RMS current rating
9.5
Surge current
a)
One cycle
b)
Repetitive cycle
9.6
Peak inverse voltage
a)
Continuous
Volt
b)
Surge
Volt
Reactance
Amp:
Amp:
Amp:
1509 of 2461
PAGE 293 of 358
Sr.
MMRDA
Description
No.
9.7
Type of Rectifier connection.
9.8
Filter Choke
a)
Make
b)
Type
c)
Rating
9.9
Filter condenser
a)
Make
b)
Type
c)
Rating
d)
Reference standard
10.0
D.C. fuse.
10.1
Make
10.2
Type/Cat. No.
10.3
Reference standard.
10.4
Current ratings
a)
Continuous
Amp.
b)
Interrupting
KA
11.0
By pass D.C. contactor
11.1
Make
11.2
Type/Cat. No.
11.3
Reference standard
11.4
Current rating.
11.5
Utilization category
11.6
Transistorized series regulator
a)
Type of transistor
b)
No. of transistors in parallel
c)
Voltage rating (Vce)
d)
Current rating (Ice)
12.0
Charger Blocker diode
12.1
Make
12.2
Type
12.3
Voltage rating
Amp.
1510 of 2461
PAGE 294 of 358
Sr.
MMRDA
Description
No.
12.4
Current rating
13.0
Charger failure relay
13.1
Make
13.2
Type
13.3
Rating
14.0
Load U/V & O/V relay
14.1
Make
14.2
Type
14.3
Actuating voltage
14.4
Resetting voltage
15.0
Indication lights
15.1
Make
15.2
Type / Cat. No.
15.3
Reference standard
15.4
Wattage
Watt
15.5
Series resistor
Ohm
16.0
Meters
16.1
Make
16.2
Type/Cat. No.
16.3
Reference standard
16.4
Size
16.5
Accuracy
16.6
Rating of meters
a)
AC Ammeter
b)
AC Voltmeter
c)
DC Voltmeter
d)
Battery Ammeter
e)
Load Ammeter
17.0
Charger-over switch (Float/Boost)
17.1
Make
17.2
Type/Cat. No.
17.3
Reference standard
1511 of 2461
PAGE 295 of 358
Sr.
MMRDA
Description
No.
17.4
Rating
17.5
No. of poles
18.0
MCB
18.1
Make
18.2
Type/Cat. No.
18.3
Reference standard
18.4
Rating
19.0
Charger panel
19.1
Make
19.2
Type
19.3
Reference standard
19.4
Enclosures:
a)
Degree of protection
b)
Sheet steel thickness in mm.
19.5
Panel provided with
a)
Internal lamp with door-switch
b)
Space heater with thermostat
c)
5A 3-Pin receptacle
19.6
Internal wiring
a)
Insulation
b)
Voltage grade
c)
Minimum conductor size
19.7
Power terminals
a)
Make
b)
Size/Cat. No.
19.8
Amp.
Control terminals
a)
Make
b)
Size/Cat. No.
c)
Whether 20% spare terminal furnished?
19.9
Whether ground terminal furnished?
20.0
Microcontroller
20.1
Make
1512 of 2461
PAGE 296 of 358
Sr.
MMRDA
Description
No.
20.2
Type
20.3
Reference standard
21.0
LCD Display
21.1
Make
21.2
Type
21.3
Reference standard
22.0
Overall dimension (L x B x H) mm.
23.0
Approx. weight
24.0
Whether general arrangement drawing furnished?
25.0
Kg.
Whether accessories as specified furnished with

battery charger?
TECHNICAL SPECIFICATION FOR 48V/110V/220V D. C. DISTRIBUTION BOARD
1.0 SCOPE:
This specification covers design, manufacture, assembly and testing at

manufacturer's works, packing and supply on for destination basis of Indoor
type 48V and 110V/220V standalone D.C. Distribution Board for EHV for
distribution of auxiliary DC power to PLCC panels, control panels, line bays ,
CBs ,Bus Bar panels,etc
2.0 STANDARD:
Sr.No.
Standard No.
1)
IS: 13947
2)
IS: 8836
Title
Degrees of protection provided by enclosures for low voltage
switchgear and control gear
1513 of 2461
PAGE 297 of 358
MMRDA
General requirements for switchgear and control gear for
3)
IS: 4237
4)
IS: 375
5)
IS: 694
6)
IS: 1554
7)
IS: 6005
Code of practice for phosphating of Iron and Steel
8)
IS: 5
Colour for ready mix paints
9)
IS: 9676
Reference ambient temperature for electrical equipments
3.0
voltages not exceeding 1000 Volts

Marking and arrangement for switchgear bus bars, main
connections and auxiliary wirings
PVC insulated cables for working voltages upto including 1100
Volts
CONSTRUCTIONAL DETAILS:
3.1
General Technical Requirement:
Boards shall be fabricated out of MS Sheet steel of thickness not less than
2.0mm. The Board shall be made dust and vermin proof with the help of
good quality long lasting neoprene anti-vibration gaskets of 15mm HCL at
the various openings and doors.
The box shall be of an already type tested design. Valid type test reports
shall be submitted for MSTECLs acceptance.
The distribution board shall be complete with cable lugs, circuit numbers,
earthing lugs, etc. to make the boards complete in all respect.
3.2
Mounting:
D. C. Distribution Board shall be Standalone type for 48V and 110V/220V

DCDB. All equipments on front of panel shall be flush mounted.
3.3
Busbars:
The bus bar chamber shall be so located that all the incoming and outgoing
feeders can be connected on either side. The bus bar shall be of electrolytic
tinned copper of size not less than 25mm x 3mm. The bus bars shall be of
uniform cross section throughout the length. The bus bar shall be mounted
on insulators. All bus bars shall be PVC sleeved and bus taps & joints shall
be covered with removable type epoxy shrouds. Painting and taping shall
1514 of 2461
PAGE 298 of 358
MMRDA
not be considered as adequate shrouding.
All cable connections to the bus bars shall be carried out with the help of
heavily tinned copper crimping type lugs bolted on to the bus bars. The
hardware used for the electrical connections shall be of non magnetic type.
The cable used for connections shall have multi strand copper conductor as
conducting medium. The copper lugs and steel bolts used shall be provided
for all connections so as to make the D. C. Distribution Board complete in
all respects.
4.0
The requirement of DCDB are to be supplied against this specification are as
per given in Tender document. The GTP and detailed Bill of Quantity for 48V
DCDB and 110V/220V standalone DCDB shall be as per Annexure-A&B
enclosed.
5.0
ANTICONDENSATION HEATERS & INTERNAL ILLUMINIATION:

In the D. C. Distribution Board, heating element of appropriate size with switch
control shall be provided. Internal illumination lamp along with door switch shall
be provided. These shall operate on 230V AC.
6.0
TERMINAL BLOCKS:
The terminal block shall be stud type with washers, nuts & lock nuts and
identification strips. At least 10% spare terminals after terminating all spare
cores of the cables shall be provided. All terminal blocks shall be covered with
transparent covers. All metal parts shall be made of brass including base
channel and shall be nickel plated. Hardware shall be of a non-magnetic
material.
Terminal blocks shall be adequately rated to carry the current of the associated
circuit.
7.0
EARTHING:
All equipment shall be provided with 2 nos. of grounding terminals of M12 size.
The earthing bolt shall be of galvanized iron and necessary spring washers shall
be electro galvanized.
1515 of 2461
PAGE 299 of 358
8.0
MMRDA
TESTS: The tests shall include but not limited to tests listed below:
8.1 TYPE TESTS:

1. Short time current withstand test
2. Temperature rise test
3. Verification of degree of protection
8.2 ROUNTINE TESTS:
1. High voltage test (3500 V AC for 1 minute)
2. Insulation Resistance test (with 500 V DC Megger)
3. Verification of wiring as per approved schematic
8.3 ACCEPTANCE TESTS:
1. High voltage test (3500 V AC for 1 minute)
2. Insulation Resistance test (with 500 V DC Megger)
3. Verification of wiring as per approved schematic
9.0
PAINTING:
All sheet steel work shall be phosphated in accordance with the following
procedure and in accordance with IS: 6005 Code of practice for Phosphating
Iron and Steel.
Oil, grease, dirt and swarf shall be thoroughly removed by emulsion/alkaline

cleaning.
Rust and scale shall be removed by pickling with dilute acid followed washing
with running water, rinsing with slightly alkaline hot water and drying
respectively.
The phosphate coating shall be Class-C as specified in IS:6005. Welding shall

not be done after phosphating. After phosphating, thorough rinsing shall be
carried out with clean water followed by final rinsing with dilute bi chromate
solution and oven drying.
The phosphate coating shall be sealed by the application of two coats of ready
mixed, stowing type zinc chromate primer. The first coat may be Flash dried
while the second coat shall be stowed.
After application of the primer, two coats of finishing synthetic enamel paint
shall be applied, each coat followed by stowing. The second finishing coat shall
be applied after completion of tests. Each coat of primer and finishing paint shall
be of a slightly different shade to enable inspection of the painting.
1516 of 2461
PAGE 300 of 358
MMRDA
A small quantity of finishing paint shall be supplied for minor touching-up

required at site after the installation of the panel.
The inside & outside panels should be powder coated by electrostatic method
and should be spray painted with light grey shade No-631 of IS- 5. The base
frame shall be powder coated in black colour.
Finished appearance of D.C.D.B. shall present an aesthetically pleasing

appearance free from dents and uneven surface.
10.0 DEGREE OF PROTECTION:
The Distribution Board shall be made dust and vermin proof with the help of
good quality long lasting neoprene gaskets at the various openings and doors.
The cubicle shall offer a degree of protection not less than IP-42 as per IS13947.
11.0 NAME PLATE:
The D.C. Distribution Board shall be provided with Name Plate lettered in
English and contain at least the following information. The name plate shall be
made of non-corrosive material:
a) Maharashtra State Electricity Transmission Co. Ltd.
b) Order Number
c) The Manufacturers name and trade mark
d) Year of Manufacturing
e) Type
f) Caution Notice
g) Operational precautions if any
12.0 DISPATCH OF MATERIAL:
No material shall be dispatched from its point of manufacture unless the material
has been satisfactorily inspected and tested.
Inspection and acceptance of any material under this specification, by the

MSETCL, shall not relieve the Manufacturer of his obligation of furnishing the
rejection if the material is found to be defective.
1517 of 2461
PAGE 301 of 358
MMRDA
13.0 PACKING AND TRANSPORT:
The equipment shall be properly packed for transportation by ship/rail or road.

It shall be wrapped in polythene sheets before being placed in crates /Cases to
prevent damage to finish. The crates/cases shall have skid bottoms for
handling. Special notations such as Fragile, This side up, Weight, Owners
particulars, etc. shall be clearly and indelibly marked on the packages.
The equipments may be stored indoor for long periods before installation. The
packages shall be completely suitable for indoor storage in areas with high
ambient temperatures, high humidity conditions, etc.
14.0 DISQUALIFICATION NORMS:

following reasons:
e) Poor quality and workmanship of the products previously supplied and
f) Manufacturer/Bidder against whom litigation is in progress.
g) Manufacturer/Bidder, who in the opinion of the MSETCL has malafied
h) Manufacturer/Bidder who is declared to be defaulter as per the terms and
Notwithstanding anything stated above, the MSETCLs decision in this regards

will be final.
ANNEXURE-A
Bill of Quantity for 220V & 110V DCDB
Sr.No
1.
Item
Incoming DC MCB
switch
2.
Outgoing DC Feeder
Switch
3.
Outgoing DC Feeder
Switch
Description
Quantity
100A MCB DP type
1 no.
63A MCB DP type
4 nos.
40A MCB DP type
2 nos.
1518 of 2461
PAGE 302 of 358
Sr.No
4.
Item
Outgoing DC Feeder
Switch
5.
Outgoing DC Feeder
Switch
6.
Emergency
Lighting
Feeder
7.
MMRDA
Description
Quantity
16A MCB DP type
6 nos.
10A MCB DP type
4 nos.
10A MCB DP type
2 nos.
Indicating LED Lamps For Incomer & Outgoing feeder

healthy indication
8.
Fuses,
19 nos.
links,
terminals,
control
wiring, cable glands,
---
As required
etc.
9.
(0-100A DC, Accuracy Class
DC Ammeter.
1.0)
10.
DC
SHUNT
for
Ammeter
11.
Current Transducer
12.
Transducers
and
auxiliary relays
1 no.
(100A/100mV)
1no
(4-20mA) O/P for SCADA
1no
For SCADA compatibility
As required
13.
Installation :
Indoor, Standalone
--
14.
Minimum Thickness:
2mm
--
15.
Degree of Protection:
IP-42
--
16.
Maximum
temperature of bus
bars when carrying 85C
---
rated current should

not exceed.
17.
Cable Glands suitable
As
per
for:
-----
requirement
18.
Gasket
Neoprene of 15x6mm min
---.
19.
Terminal
Clip on Stud type
36 nos.
(Outgoing)
Block
1519 of 2461
PAGE 303 of 358
Sr.No
MMRDA
Item
Description
Quantity
20.
Bus Bar Size
25 x 3 mm Copper
--
21.
Incomer
Stud type 8mm
2 nos.
Terminal
Block
22.
Internal wiring with

multi-strand
Copper
Cable (1100V Grade)
23.
Dimensions (LxDxH)
PVC Multi strand ISI mark

a) 16 A
2.5 sqmm
16 sqmm
b) 63 A
800mm x 700mm x 1800mm
---
Bill of Quantity for 48V DCDB
Sr.No
Item
Description
Quantity
1.
Incoming switch
63A MCB DP type
1 no.
2.
Outgoing DC Feeder
16A MCB DP type
4 nos
10A MCB DP type
12 nos
10A MCB DP type
2 nos
Switch
3.
Outgoing DC Feeder
Switch
4.
Emergency
Lighting
Feeder
5.
6.
Indicating LED Lamps
For Incomer & Outgoing feeder

healthy indication
19 nos.
Fuses, links, terminals,

control
wiring,
cable ---
As required
glands, etc.
7.
DC Ammeter.
(0-75ADC,
96x96mm,
Class 1.0)
8.
DC
SHUNT
for (75A/75mV)
1520 of 2461
Accuracy
1 no.
1no
PAGE 304 of 358
Sr.No
Item
MMRDA
Description
Quantity
(4-20mA) O/P for SCADA
1no
For SCADA compatibility
As required
Ammeter
9.
Current Transducer
10.
Transducers
and
auxiliary relays
11.
Installation
Indoor, standalone
--
12.
Minimum Thickness
2mm
--
13.
Degree of Protection
IP-42
--
14.
Maximum temperature
85C
---
of
bus
bars
when
carrying rated current

should not exceed.
15.
Cable Glands suitable -----
As
for:
requirement
16.
Gasket
17.
Terminal
Block
(Outgoing)
18.
Bus Bar Size
19.
Incomer
Terminal
Block
20.
Internal
wiring
multi-strand
with
Copper
Cable (1100V Grade)
21.
Dimensions (LxDxH)
Neoprene of 15x6mm min
---
Clip on Stud type
36 nos.
25 x 3 mm Copper
--
Stud type 8mm
2 nos.
PVC Multi strand ISI mark

a)16 A
b)63 A
800mm x 700mm x 1800mm
2.5 sq.mm
16 sq.mm
--
TECHNICAL SPECIFICATION FOR A. C. DISTRIBUTION BOARD
GENERAL TECHNICAL CONDITIONS
1.0 SCOPE:
This specification covers design, manufacture, assembly and testing at manufacturer's

1521 of 2461
PAGE 305 of 358
per
MMRDA
works, packing and supply on Destination basis of Indoor type 415V - 800A A. C.
Distribution Boards for 200/132kV Sub-station for distribution of power to Sub-station
lighting, battery charging, power line carrier communication equipment, compressors,
switchyard lighting and all other station accessories and lighting panels with
accessories for Auxiliary system. The system shall be A.C. 3 phase, 4 wires, 440 Volts
50 cycles effectively grounded.
2.0
STANDARD:
2.1
The equipment accessories covered in this specification shall be designed,

manufactured and tested in compliance with the latest relevant standard and
code of practice published by Indian Standard Institute, wherever available, and
suitable care shall be taken for suitability of the equipment for the weather
conditions mentioned in this specification elsewhere.
2.2
The equipment accessories for which Indian Standard and code of practices
are not available shall be designed manufactured and tested in accordance with
the latest standard and codes of practice published by any other recognized
national standard institute of latest publication of international electro-technical
commission.
2.3
Equipment meeting with the stipulations of equivalent IEC, ANSI, CSA, DIN
Standards which ensure equal or better quality than the standards listed in list
of standards, above, shall also be acceptable. In such cases the tenderer
should submit alongwith his offer, two copies of such Standards in authentic
English translation, if the language of the Standard is other than English. In
case of dispute, the stipulations in English translation, submitted by the tenderer
shall privet. Further, in event of conflict between the stipulations of the standard
adopted by the tenderer and corresponding Indian Standard specification, the
stipulation of Indian Standard Specification shall privet.
2.4
All electrical equipments used in A.C.D.B. shall conform to the latest Indian
Electricity Rules as regards safety, earthing and other essential provisions
specified therein for installation and operation of electrical plant.
1522 of 2461
PAGE 306 of 358
2.5
MMRDA
All equipments and installations shall comply with the relevant statutory
requirements of Government of India/State Govt. of Maharashtra.
2.4
LIST OF STANDARDS:
Sr. No.
1)
Standard No.
IS: 13947
Title
Degrees of protection provided by enclosures for low voltage
switchgear and control gear
2)
IS: 2208
HRC cartridge fuse links upto 650 Volts
3)
IS: 13947
A. C. Circuit Breakers Part I to V
4)
IS: 8836
5)
IS: 2705
Current transformers
6)
IS: 3156
Voltage transformers
7)
IS: 4047
Heavy duty air-break switches and composite units of airbreak switches and fuses for voltage not exceeding 1000 Volts
8)
IS: 4237
General requirements for switchgear and control gear for

voltages not exceeding 1000 Volts
9)
IS: 375
Marking and arrangement for switchgear bus bars, main

connections and auxiliary wirings
10)
IS: 1248
Electrical indicating instruments
IS: 2419
11)
IS: 694
PVC insulated cables for working voltages upto including

1100 Volts
12)
IS: 1554
1523 of 2461
PAGE 307 of 358
Sr. No.
MMRDA
Standard No.
Title
13)
IS: 2959
A. C. conductor for voltages not exceeding 1000 Volts
14)
IS: 6005
Code of practice for phosphating of Iron and Steel
15)
IS: 3231
Electrical relays for power system protection
16)
IS: 9224
Fuses
17)
IS: 3842
Electrical relay for A.C. system
18)
IS: 5
Colour for ready mix paints
19)
IS: 9676
Reference ambient temperature for electrical equipments
20)
IS: 8623
Low voltage switchgear and control gear assemblies
Part I
3.0
21)
IS: 13779
Standard specification for static energy meter
22)
IS: 1036
Standard specification for static energy meter
MEASUREMENTS AND WEIGHT SYSTEM:
Unless otherwise stated all dimensions shall be in S. I. Units.
4.0
4.1
DRAWINGS:
All drawings shall conform to International Standard Organization (ISO)À'

Series of drawing sheets/Indian Standard Specification IS 696. All drawings shall
be in ink and suitable for micro filming.
1524 of 2461
PAGE 308 of 358
4.2
MMRDA
Drawing submission schedule and programme of manufacturing shall be sent

within Ten days after the issue of Letter of Indent by the successful tenderer.
4.3
All drawings submitted by the tenderer including those submitted at the time of
the bid shall be in sufficient details to indicate the type, size, arrangement, weight
of each component the external connection, fixing arrangement, dimensions
required for installation and internal connection with other equipment and
material, clearance and space required for various operation of the equipments
and any other information specifically requested in this specification elsewhere.
3 sets of drawings/catalogue shall be submitted alongwith the bid.
4.4
The tenderer shall submit 6 sets of the following drawings to the Planning
Section for scrutiny and approval within 2 weeks time from the date of receipt of
Letter of Intent:
4.5
General arrangement drawing and assembly drawings of A.C. distribution Board

showing all details.
a)
Wiring diagram with terminal designations.
c)
Item wise Bill of Quantity listing all devices mounted on the Board. The make
and type of the devices shall also be furnished.
4.6
The successful tenderer shall furnish to M.S.E.T.C.L. 20 prints and 2

reproducible films of the approved drawing after incorporating all the
comments/corrections.
4.7
The fabrication work shall be strictly in accordance with this drawing and no
deviation shall be permitted without the written approval of the Chief Engineer
(Tr. Proj.). All manufacturing and fabrication work in connection with A.C.D.B.
prior to the approval of the drawing shall be at the supplier's risk.
4.8
Approval of drawings/works by M.S.E.T.C.L. shall not relieve the supplier of any

of its responsibility and liability under terms and conditions of M.S.E.T.C.L. The
equipment shall conform in all respect to high standards of engineering, design
1525 of 2461
PAGE 309 of 358
MMRDA
and workmanship and be capable of performing in continuous commercial

operation upto tenders guarantee in a manner acceptable to purchaser who will
interpret the meaning of drawings and specifications and shall have the power
to reject any work or materials which in his judgment are not in full accordance
therewith.
5.0
DEGREE OF PROTECTION:
5.1
The Distribution Boards shall be designed with a view to obtain the highest
practicable efficiency for the duties specified. They shall be capable of
operating continuously without necessity of a shut down and the design shall
be such as to ensure trouble free operation and conform to the typical
construction arrangement as shown in the enclosed drawing. Any other better
arrangement shall be acceptable subject to approval of M.S.E.T.C.L.
5.2
The Board shall be made dust and vermin proof with the help of good quality
long lasting neoprene gaskets at the various openings and doors.
6.0
PAINTING:
5.3
All sheet steel work shall be phosphated in accordance with the following
procedure and in accordance with IS: 6005 "Code of practice for Phosphating
Iron and Steel".
6.2
Oil, grease, dirt and swarf shall be thoroughly removed by emulsion cleaning.
5.4
Rust and scale shall be removed by pickling with dilute acid followed by washing
with running water, rinsing with slightly alkaline hot water and drying.
5.5
After cleaning in 7 tanks, the indoor equipment should be powder coated by

electrostatic method and outdoor equipment should be spray painted with light
grey shade No-631 of IS-5. The base frame shall be powder coating with black
colour.
5.6
Finished powder appearance of A.C.D.B. shall present an aesthetically
1526 of 2461
PAGE 310 of 358
MMRDA
pleasing appearance free from dents and uneven surface.
6.0
ANTICONDENSATION HEATERS & INTERNAL ILLUMINIATION:
6.1
In the A.C. Distribution Board heating elements of appropriate size with switch
control shall be provided. Internal illumination lamps/mercury tubes shall be
provided.
7.0
7.1
CONTROL AND BOARD WIRING:
All wiring shall be carried out by 1100 V grade single core stranded copper
conductor wires with PVC insulation and shall be flame, vermin and rodent
proof. The minimum sizes are 2.5 Sq.mm for all circuits.
7.2
All wiring inside the panel shall be carried out with 650V grade PVC insulated,
stranded conductor wires of at least 2.5 Sq.mm size. An air clearance of at
least 10mm shall be maintained in wiring right up to the terminal lugs.
Wherever this clearance is not available the live parts shall be insulated or
shrouded.
7.3
Panel wiring shall be securely supported, neatly arranged, readily accessible

and connected to equipment terminals and terminal blocks. Wiring gutters,
troughs shall be used for this purpose. Wire terminations shall be made with
solder less crimping type tinned copper lugs. Core identification plastic ferrules
shall be provided. The wiring and wire numbering scheme shall be as per IS375.
8.4
All wires forming part of a tripping circuit shall be provided with an additional
red ferrule marked T.
8.5
Spare auxiliary contacts of all equipment forming part of the switchgear shall
be wired up to the terminal blocks.
8.6
COLOUR CODING:
1527 of 2461
PAGE 311 of 358
MMRDA
The colour coding for the live parts of electrical connections shall be as follows:
Sr. No.
9.0
Particulars
Colour Identification
1)
Neutral
Black
2)
R Phase
Red
3)
Y Phase
Yellow
4)
B Phase
Blue
5)
Earth
Green
CABLE TERMINATION:
All external cable connections shall be terminated in the terminal blocks

provided in the control cubicle. The cable entries shall be through proper cable
glands with removable cable gland plate on the cabinet for cables. All
necessary cable termination accessories such as removable cable gland
plates, packing glands, crimping type tinned copper/Aluminium lugs as per the
cable sizes, supporting clamps and brackets etc., shall be provided. The
number of multicore cables required for termination shall be furnished after the
placement of letter of intent. The cable glands shall be of suitable size for PVC
insulated for unarmored cables. All cable glands shall be of brass nickel plated
material. The successful tenderer shall submit samples of the cable glands to
the Superintending Engineer (220kV Planning) M.S.E.T.C.L. for approval.
10.0
TERMINAL BLOCKS:
10.1
The terminal block shall be stud type with washers, nuts & lock nuts and
identification strips. At least 10% spare terminals after terminating all spare
cores of the cables shall be provided. These shall be at a minimum clearance
of 250 mm between the last row of terminals block and the cable gland plate.
1528 of 2461
PAGE 312 of 358
MMRDA
All terminal blocks shall be covered with transparent covers. All metal parts
shall be made of brass including base channel and shall be nickel plated.
Hardware shall be of a non-magnetic material.
10.2 Terminal blocks shall be adequately rated to carry the current of the associated
circuit. Minimum rate of the terminal block is 30A.
11.0
SWITCHES & PUSH BUTTONS:
11.1
Control and instrument switches shall be rotary type provided with escutcheon
on plates clearly marked to show operating position and suitable for flush
mounting with only the switch from plate and operating handle projecting out.
The connections shall be from backside. The contact assembly at the back of
the switch shall be enclosed in dust tight transparent removable covers.
(Minimum rate shall be 10A).
11.2
Push buttons shall be momentary contact type with rear terminal connections
and shall have minimum of 2 NO & 2 NC contacts. They shall be provided with
integral inscription plates engraved with their functions.
11.3
Ammeter selector switches shall have make before break type contacts so as
to prevent open circuiting of CT secondaries when changing the position of
switch.
12.0
INSPECTION, TESTS AND INSPECTION CERTIFICATE:
12.1
All tests and inspection of the equipment specified shall be performed to the
extent and in the manner as stipulated in the relevant standards and the
technical specification. Routine test certificates showing the results of all tests
performed on the individual components shall be furnished to the
Superintending Engineer (132kV Planning) M.S.E.T.C.L. for approval before
dispatch of the respective equipments.
12.2
Access to the supplier's works is to be granted by the tenderer and or his

representative at all reasonable times during manufacture or assembly to
1529 of 2461
PAGE 313 of 358
MMRDA
inspect, examine and test, at the works, the material and workmanship of the
equipment to be supplied under this specification. Such inspection, examination
or testing, if made, shall not relieve the supplier from the terms and condition
under the order.
12.3
The supplier should submit a suitable programme for inspection and tests at
least 4 weeks in advance to M.S.E.T.C.L. who shall attend/depute for
witnessing the tests/inspection or convey waival. However the A.C.D.B. shall
not be dispatched unless such waival is given in writing.
12.4
After the factory tests have been completed the supplier shall issue a certificate
to this effect within 2 weeks after completion of tests but if the tests are not
witnessed by M.S.E.T.C.L. representative the certificate shall be issued within
2 weeks of the receipt of the letter for approval. All certificates regarding type
tests have been conducted on the equipments used for assembly of A.C.D.B.
shall be submitted to Superintending Engineer (132kV Planning) for approval
within 30 days of order for approval.
13.0
POSITION OF WORK:
The supplier shall submit monthly position and progress about the work in the
proforma agreed between the supplier and M.S.E.T.C.L. The submission and
acceptance of these reports shall not prejudice the rights of M.S.E.T.C.L. in any
manner or absolve the supplier from his obligation under the order.
14.0
EARTHING:
14.1
All equipment shall be provided with suitable 2 nos. of grounding terminals of

M 12 diameter. Separate G.I. earthing bus bar 50x6mm for frame with
necessary nuts, bolts and spring washers shall be provided on the earth busbar.
The earthing bolt shall be of galvanized iron and necessary spring washers
electro galvanized.
14.2
Earth busbar shall be supported at suitable intervals.
1530 of 2461
PAGE 314 of 358
14.3
MMRDA
Positive connection between all the frames of equipment mounted in the

switchboard and earth busbar shall be provided by using insulated copper
wires/bare busbar of cross section equal to that of the earth bus bar, or equal
to half the size of circuit load current carrying conductor, whichever is smaller.
14.4
All instrument and relay cases shall be connected to earth busbar using 1100V
grade, 2.5 Sq.mm stranded, tinned copper earthing conductor.
15.0
NAME PLATE:
The A.C. Distribution Board shall be provided with Name Plate lettered in
English and contain at least the following information. The name plate shall be
made of non-corrosive material:
a)
Maharashtra State Electricity Transmission Co. Ltd.
b)
Order Number
c)
The Manufacturers name and trade mark
d)
Year of Manufacturing
e)
Type
f)
Caution Notice
g)
Operational precautions if any
16.0
GENERAL REQUIREMENT:
16.1
The supplier shall submit the Quality assurance plan along/with the offer for
approval of Superintending Engineer (132kV Planning) M.S.E.T.C.L.
16.2
Raw material procurement shall start only after approval of quality assurance
plan.
1531 of 2461
PAGE 315 of 358
MMRDA
17.0
IMPORTANT NOTES TO TENDERER:
17.1
The offers which are not complete in all respect as required in the specification
shall be considered incomplete and are liable for rejection.
17.2
Deviation from Specifications, if any, shall be clearly listed in the Schedule of

Deviation. In absence of which it will be considered that offer is strictly in line
with the specification.
17.3
The equipments should have been type tested and such equipments should be
in service for at least two years duration. Confirmation regarding this point and
the list of such Customers, to whom the supplier had already supplied the
equipment similar to the one being offered, shall be furnished alongwith the
offer.
17.4
Guaranteed Technical Particulars shall be filled in and submitted alongwith the

offer.
18.0
CLIMATIC CONDITIONS:
18.1
The A.C. Distribution Board and materials used in the same shall be suitable
for use under the following climatic conditions anywhere in Maharashtra. The
Board shall be suitable for use in the climatic conducive to the growth of fungi
and condensation of moisture.
Sr. No.
Particulars
Requirements
1)
Temperature range
from 4C to 50C
2)
Relative humidity
10 to 100%
3)
150 Kg/Sq.mm
45C ambient temperature in

4)
Maximum daily average
shade
1532 of 2461
PAGE 316 of 358
Sr. No.
5)
MMRDA
Particulars
Requirements
Altitude above mean sea level
10 to 1000 meters
Most of the substations are

situated in Industrial Areas and
the area is heavily polluted due to
6)
Pollution
Chemical Industries, Steel
Rerolling Mills, Ferro Alloys
Industries, etc.
All equipments shall be given

7)
Tropicalisation
tropical and fungicidal treatment
19.0
RECOMMENDED SPARES:
The tenderer shall furnish in his offer, a list of recommended spares with unit
rates for all types of panels that may be required for trouble free operation for a
period of 5 years. The purchaser reserves the right of selection of items and
quantities of these spares to be ordered. The cost of such spares shall not be
considered for tender evaluation. Similarly, special tools and jigs/testing
equipments if required for maintenance/testing of equipments offered shall be
quoted as optional items. Unit prices of such equipments shall be quoted.
20.0
PACKING AND TRANSPORT:
20.1
All equipment/material shall be suitably packed for transport, carriage at site

and outdoor storage during transit. The supplier shall be responsible for any
damage to the equipment during transit due to improper and inadequate
packing. The cases containing easily damageable material shall be very
carefully packed and marked with appropriate caution symbols. The contents
1533 of 2461
PAGE 317 of 358
MMRDA
of each packing shall bear marking that can readily be identified from the
package list and packing shall provide complete protection from moisture,
termites and mechanical shocks etc. Wherever necessary proper arrangement
for attaching strings for lifting shall be provided and all packages clearly marked
with gross weights, sign showing ÙP' and `DOWN' sides of boxes, contents of
each package, and any handling and unpacking instructions considered
necessary. Any material found short inside the intact packing cases shall be
supplied by the supplier without any extra cost. Fragile materials such as relay
cases, instruments and other glass materials shall be carefully covered with
shock absorbing protective material such as thermocole. The Distribution
Boards shall be transported by Road only.
20.2
The packing list and Bill of Quantity shall be got approved from the
Superintending (220kV Planning), M.S.E.T.C.L. before dispatch.
TECHNICAL SPECIFICATION
1.0
SCOPE OF CLIMATIC CONDITIONS:
As already been defined in the Part -I.
2.0
RATED VOLTAGE:
The rated voltage of the Distribution Board with switch fuse unit cable etc. shall
be 3 phase 4 wire A. C. 415Volts at 50Hz. The supply voltage may vary as
follows:
a) Voltage variation
+/ - 10%
b) Frequency variation
+/ - 5%
c) Combined voltage & frequency variation
+/ - 10%
As such, all devices, auxiliary equipments shall be suitable for continuous

operation over entire range of voltage.
1534 of 2461
PAGE 318 of 358
MMRDA
3.0 GENERAL TECHNICAL REQUIREMENT:
PRINCIPAL TECHNICAL PARAMETERS

Sr. No.
Particulars
1)
Installation :
i) Main AC Board
Requirements
Indoor
ii) AC Auxilliary Distribution

Outdoor
Board
2)
Phase to Phase and

As per IE Rules 1956
Phase to Earth clearance
3)
Minimum Thickness:
i) Frame
2.5 mm
(INDOOR BOARDS)
ii) Sheet Steel:
4)
a) Auxilliary Boards
2.64 mm (12 SWG)
b) Main AC Boards
2.03 mm (14 SWG)
Degree of protection:
i) Outdoor type boards
IP 55
ii) Indoor type boards
IP 52
iii) For 400kV Indoor Type

ACDB
IP 42
1535 of 2461
PAGE 319 of 358
Sr. No.
Particulars
5)
Maximum temperature of bus

bars when carrying rated
MMRDA
Requirements
85C
current should not exceed.
6)
Minimum rating of control,

selector switches and terminal
10 Amp
block
7)
Earth bus bar
50 x 6mm Galvanised M. S. flat
8)
Circuit Breakers
Fully drawout type/Non-drawout type
9)
Cable glands:
i) Indoor
Single compression
ii) Outdoor
Double compression
10)
Gasket
Neoprene of 15x6 mm min.
11)
Terminal block
Stud type
12)
The centre line of operating handle of knob or switch/push button shall

be at a minimum 750 mm for outdoor and 400 mm for indoor boards from
G. L.
3.1
The fabrication shall be carried out in not less than 14 SWG M.S. sheet for the
front & back side with supporting angle structure made out of cold rolled or bent
sheet section. The complete structure shall be rigid, self supporting free from
vibration twists & bends. Stiffeners shall be provided wherever necessary. The
perforated strips shall be provided at the rear for fixing the incoming cables.
The covers for the busbar compartment as well as other opening and doors
shall be bolted type with hot dip galvanized heavy duty wing nuts.
3.2
Outdoor type Boards shall be fabricated out of MS Sheet steel of thickness not
1536 of 2461
PAGE 320 of 358
MMRDA
less than 2.64mm (12 SWG).
3.3
All panel edges and door edges shall be reinforced against distortion by rolling,
bending or by the addition of welded reinforcement members.
3.4
Cut-outs shall be true in shape and devoid of sharp edges.
3.5
All hardware such as nuts, bolts, etc. except the one used for electrical
connection shall be hot dip galvanized as per the standard practice to protect
the same from corrosion. The Board shall be made dust and vermin proof with
the help of good quality long lasting neoprene antivibration gaskets of 15mm
HCL at the various opening and doors.
3.6
All the electrical devices shall be given tropical & fungicidal treatment to enable
its satisfactory operations in the highly polluted, hot and humid tropical climatic
conditions.
3.7
It is not the intent to specify completely herein, all details of design, &
construction of the equipment. However the equipment shall conform in all
respects to high standards of engineering, design & workmanship and be
capable of performing in continuous commercial operation upto tenderer
guarantee in a manner acceptable to M.S.E.T.C.L. who will interpret the
meaning of drawings and specifications and should have the power to reject
any work or materials which in his judgment are not in full accordance therewith.
3.8
The A.C.D.B. shall be designed with a view to obtain the highest practicable
efficiency for the duties specified. They shall be capable of operating
continuously without necessity of a shut down and the design shall be such as
to ensure trouble free operation.
3.9
The tenderer shall note that the A.C.D.B. shall be complete and include all
minor accessories not specifically mentioned in the Bill of Quantity, schedule,
specification, etc but essential for the completeness of the work. The supplier
shall not be eligible for any extra charges in respect of such accessories though
not specified in the Bill of Quantity with this specification.
1537 of 2461
PAGE 321 of 358
3.10
MMRDA
The A&B type Distribution Board shall be of free standing, floor mounting,
cubicle type design, modular but non-draw out type. The Board shall be dust
and vermin proof. The A.C.B.s and M.C.C.Bs will be door interlock type. The
compartment door will not open when MCCB is in ÒN' position. The metering
equipments for the both incomers shall be located in separate compartments.
3.11
3.12
They shall be divided into distinct vertical sections each comprising:
1)
a completely metal enclosed bus bar compartment running horizontally.
2)
individual feeder modules arranged in multitier formation.
3)
enclosed vertical busbars service modules in the vertical section.
4)
a vertical cable alley covering the entire height.
5)
a horizontal wire way for control wiring.
Metal sheet shall be provided between two adjacent vertical sections running
to the full height of the switchgear except for the horizontal busbar
compartment.
3.13
All equipment associated with a single circuit shall be housed in a separate

compartment in the fixed portion of the vertical section. The compartment shall
be enclosed on all sides with the withdrawable units in position or removed
except on the cable alley door. The rear of the compartment shall be covered
by metal or insulated sheets with slots to permit connection to the bus bars. All
other covers shall be of sheet steel.
3.14
Control and selector switches, indicating instruments and lamps, and protective
relays shall be mounted on the front doors of the respective compartments.
Current transformers on circuit breaker controlled circuits shall be mounted on
the fixed portion of the compartment. Current Transformers shall not be directly
mounted on the buses. All other equipments pertaining to a circuit shall be
mounted on a withdrawable chassis, which can be drawn out after
disconnecting all power and control connections to the chassis mounted
equipment. All control circuit connections to the chassis.
1538 of 2461
PAGE 322 of 358
3.15
MMRDA
The individual compartment doors shall be provided with suitable cut-outs as

necessary to permit operation of circuit breakers and circuit isolating switch
from the front without having to open the door. Such cuts outs shall be provided
with spring loaded gaskets for the purpose of dust moisture and vermin
proofing.
3.17
Suitable barriers shall be placed between circuit breakers and all control
protective and indication circuit equipment including instrument transformers.
External cable connections shall be carried out in a separate cable
compartment. Bakelite sheets should be provided to cover live parts which get
exposed after opening.
3.18
After isolation of the power and control connections of a circuit it shall be

possible to safely carry out maintenance in a compartment with the bus-bars
and adjacent circuit live.
3.19
Cable alleys shall be provided with suitable doors or removable panel covers.
It shall be possible to safely carry out maintenance work on cable connections
to any one circuit with the busbars and adjacent circuit live.
3.20
Removable panels shall be provided on rear side. It shall be possible for one
person to remove and fix the removable panel.
3.21
All doors shall be of the lift-off type, provided with concealed type hinges and
captive screws.
3.22
Fully drawout type withdrawable chassis:
1)
All the withdrawable chassis shall be of the fully drawout type.
2)
The withdrawable chassis shall be provided with a plate cover on the

side corresponding to the cable alley of the compartment, except for a
slot to permit wiring connections.
3)
In this type of construction, it shall be possible to draw out the

withdrawable chassis without having to unscrew or unbolt any
connections to the equipment mounted on the withdrawable chassis. It
1539 of 2461
PAGE 323 of 358
MMRDA
should be fully compartmentalized design. Both power and control

connections shall be of the self aligning type withdrawable contacts.
3.23
The distribution board shall be designed in such way that all component
equipment operates satisfactorily without exceeding their respective maximum
permissible rises in temperate under ambient temperature conditions as
specified elsewhere in this specification.
3.24
The A.C. Main distribution boards shall be complete with cable lugs, circuit
numbers, earthing lugs, foundation bolts etc. to make the boards complete in
all respect.
3.25
The overall dimensions of the boards shall be as small as practicable. The

overall dimensions shall be clearly indicated by the tenderer.
3.26
Whenever required the boards shall be matched with other boards in the control
room in respect of dimension, colour, appearance and arrangement of
equipments on the front.
3.27
CONSTRUCTIONAL FEATURES OF OUTDOOR TYPE DISTRIBUTION
BOARDS:
3.27.1 The A.C. auxiliary distribution board shall be outdoor type.
3.27.2 The distribution boards shall be sheet steel enclosed and dust, weather and
vermin proof. Sheet steel used shall be of at least 12 SWG (2.64mm thick) size
and be properly braced to prevent wobbling.
3.27.3 The enclosures of the boards shall provide a degree of protection of not less
than IP 55 as per IS: 13947. The rain sheds shall be provided for draining of
rain water.
3.27.4 The boards shall be of free standing or pedestal mounting type and provided
with four holes of suitable diam. at the bottom for fixing foundation bolts.
3.27.5 The cabinets shall be provided with a hinged door with padlocking arrangement.
In addition two switch board type locks with common key shall be provided.
1540 of 2461
PAGE 324 of 358
MMRDA
3.27.6 All doors, removable covers and plates shall be gasketed all around with
neoprene gaskets of 15x6 mm cross sectional area (minimum).
3.27.7 Cable entries shall be from bottom. Suitable removable cable gland plate shall
be provided on the cabinet for this purpose. Necessary number of screw on
type brass cable glands shall be supplied fitted on to this gland plate. Cable
glands shall be of double compression type suitable for earthing the armour, of
cables.
3.27.8 A socket shall be provided at a suitable location in the board for connecting to
the external 240 V single phase A.C interior illumination.
3.27.9 The distribution boards shall be complete with cable lugs, circuit numbers,
earthing lugs, foundation bolts etc. to make the boards complete in all respect.
3.27.10
The overall dimensions of each type of distribution board shall be clearly
indicated by the tenderer in his tender.
3.28 MOUNTING:
3.28.1 All equipments on front of panel shall be mounted flush.
3.28.2 The center line of operating handle/knob of switchgears and push buttons shall
be at a height not less than 350 mm or not more than 1900 mm from the ground
level.
3.28.3 Equipments shall be mounted such that removal and replacement can be
accomplished individually without interruption of service to adjacent equipment.
Equipment mounted inside the panel shall be so located that the terminals of
adjacent equipments are readily available without use of special tools.
3.28.4 Outdoor boards shall be mounted on Pedestal of 50x50x6 mm angle frame.
4.0
BUSBARS:
4.1
The bus bar chamber shall be so located that all the incoming and outgoing
feeders can be connected on either side. The bus bar shall be of electrolytic
tinned copper of size not less than 38mmx6mm for phases and 25mm x 6mm
for neutral. The bus bars shall be of uniform cross section throughout the length
upto the incoming terminals of the feeder circuit breaker/switch. The bus bar
shall be mounted on insulators and the minimum clearance in air between the
1541 of 2461
PAGE 325 of 358
MMRDA
phases and the phases and earth shall not be less than 25 mm. All bus bars
shall be PVC sleeved and bus taps & joints shall be covered with removable
type epoxy shrouds. Painting and taping shall not be considered as adequate
shrouding.
4.2
Bus bars shall be adequately supported and braced to with stand the stresses
due to the specified short circuit current for the associated switchgear. The
maximum temperature of the bus bars when carrying rated electrical current
shall not exceed 85 C. Bus bar supports shall be made of epoxy resin cast of
SMC/DMC. Risers/droppers to bus bars shall be of bolted type complete with
washers electro galvanized. Bus bars shall be thoroughly cleaned at the joint
locations and suitable contact grease, if required, shall be applied just before
making a joint. The busbar chamber shall be of a completely enclosed.
4.3
All cable connections to the bus bars shall be carried out with the help of heavily
tinned copper crimping type lugs bolted on to the bus bars. The hardware used
for the electrical connections shall be of non magnetic type. The cable used for
connections shall have multi strand copper conductor as conducting medium.
The copper lugs and steel bolts used shall be provided for all connections so
as to make the A.C. Distribution Board complete in all respects.
4.4
Busbar support shall be designed to with stand Breakers capacity of Board as

specified.
4.5
For 400V ACDB except as noted, all busbars shall be made of high conductivity
electrolytic tinned copper. In main AC Boards provision for the extension of bus
bars if required on both the sides should be made.
4.6
Busbar supports shall be having liberally designed to withstand breaking

capacity as specified with non hygroscopic material of SMC. Number of support
insulators its arrangement and design to withstand the stresses due to short
circuit current on the busbar should be submitted alongwith offer.
5.0
CONSTRUCTION AND SPECIAL REQUIREMENTS:
5.1
All control fuses shall be of the HRC cartridge plug-in type.
1542 of 2461
PAGE 326 of 358
5.2
MMRDA
It shall be possible to change fuses with the circuit alive without danger of
contact with live metal.
5.3
In À' type and 400V Distribution Board, Air Circuit Breakers of Electrically
operated closing mechanism should be used for Incoming and Bus coupler.
The interlocking of 2 incoming breakers and bus coupler should be as follows:
a)
In normal course both the incomers will be independently feeding the respective
circuits, with the bus-section remaining open.
b)
As and when one of the incoming supply (source) fails, the bus-section ACB
shall close automatically so that the entire load will be fed by the single (healthy
incomer).
c)
As and when the (failed) incoming supply is restored, the bus-section incomer
should trip automatically, thus changing over to the feeding arrangement as
under (a) above.
d)
Further, in case of DG source incomer interlock shall be provided with suitable

arrangement such that DG incomer ACB shall be closed only when both the
incoming sources are out & Bus coupler is ON and vice versa.
e)
Suitable change-over scheme using under voltage relays and contactor shall
be provided for the above.
5.4
In À' type and 400V Distribution Board, incomer and bus coupler should be
electrically operated Air Circuit Breakers and in `B' type Distribution Board, it
should be provided with moulded case circuit breakers. All outgoings in À' &
`B' type should be MCCB/MCB as specified in Bill of Quantity. Incoming and
bus coupler ACB for À' type ACDB should be fixed type electrically operated
(suitable for operation of 220V DC) door interlock type. The ACB and MCCB
should conform to IS 2516.
CIRCUIT BREAKERS:
5.6.1 Circuit breakers shall be:

-
of the air break drawout type
provided with motor wound spring charged stored energy type, operating
mechanism/with a standby provision for manual spring charging operation.
1543 of 2461
PAGE 327 of 358
MMRDA
provided with mechanically operated targets to show 'open' and 'closed'

positions of the circuit breaker.
provided with mechanically operated 'trip' push button, red in colour.
provided with locking facilities in the 'fully engaged', 'test' and 'isolated' position.
provided with 4 normally open and 4 normally closed, auxiliary contacts

exclusively for use of purchaser.
provided with 'red', 'green' and 'amber' indicating lamps to show 'closed', 'open'
and 'auto trip' conditions of the circuit breaker when breaker operation is
controlled by a control switch.
provided with electrically operated closing mechanism with a standby

arrangement for manual operation.
5.6.2 Circuit breakers shall be provided with the following interlocks:
5.6.2.1
It shall not be possible to plug-in a closed circuit breaker or to drawout a
circuit breaker in the closed position. A circuit breaker that trips on attempted
isolation will not be acceptable as a substitute.
5.6.2.2
It shall not be possible to operate a circuit breaker unless it is in the fully
plugged-in, test or fully isolated position.
5.7
Circuit breaker closing and trip coils shall be rated for satisfactory operation on
a control supply system indicated elsewhere in this specification.
5.8
Closing and trip coil shall operate satisfactorily under the following conditions
of supply voltage variation:
5.9
- Closing coils :
85% to 110% of rated voltage
- Trip coils
70% to 120% of rated voltage
The circuit breakers shall be fitted with the following devices:

a)
Protection against overload with adjustable inverse definite minimum

time (IDMT) settings.
b)
Protection against short circuit with built in time settings.
c)
Making current.
d)
Protection against under voltage.
1544 of 2461
PAGE 328 of 358
MMRDA
e)
Shunt releases (for remote operation)
f)
Prevention of closing of the bus section breaker in the event of tripping

of source 1 or source 2 breaker on fault.
5.10
The above devices shall be suitable to coordinate satisfactorily with the

outgoing feeders equipped with MCCBs, MCBS, breakers, HRC fuses etc.
complete details of the devices, relays, range of settings etc. offered shall be
furnished by the tenderer alongwith his tender.
5.11
The rated continuous and the short circuit currents for the breakers shall not be
less than those indicated in the drawings appended with this specification.
5.12
The range for short circuit setting shall be indicated by the tenderer in his
tender.
5.13
Short circuit releases shall be provided with at least four adjustable time delay
settings. If it is not possible to provide the specified adjustable current setting
range for the short circuit released, shunt trip circuit breakers together with
necessary protective relays shall be offered. However, the purchaser reserves
full rights of accepting/rejecting this arrangement.
5.14
Facilities shall be provided for blocking the under voltage release.
5.15
Each of the foregoing releases shall be provided with a single pole, double
throw and potential free alarm contacts.
5.16
The current transformers shall be of tape insulated dry type ring type design
having the technical particulars as 300/5A,15 VA, Class 1 and 800/5A, 15VA,
class-I and instrument safety factor of 5. The current transformers shall conform
to IS 2705.
5.16.1 It shall be the tenderer responsibility to co-ordinate the current transformer

burden with the requirements of breaker releases and leads associated with
that particular current transformer.
5.16.2 Test links shall be provided in both the CT secondary leads to easily carry out
current and phase angle measurement tests.
5.16.3 All current transformers shall be earthed through a separate earth link on the
1545 of 2461
PAGE 329 of 358
MMRDA
terminal block to permit easy measurement of the current transformer insulation

resistance.
5.17
The indicating instruments shall be of 96mm x 96mm (4"x4" approx). Square

dial flush pattern, moving iron design, conforming to IS-1248. The voltmeter
shall be scaled 0 to 500 V while the ammeter shall be scaled 0 to 300A and
800A. The indicating instruments shall conform to IS-1248.
5.18
The voltmeters and ammeters shall be provided with suitable selector switches
to read phase to phase voltages and line currents. The selector switches shall
be of rotary design with neat and compact configuration. They shall be mounted
on module doors.
5.19
The voltage supplied to the voltmeter as well as the energy shall be routed
through HRC fuses rated for 10A, 500V.
5.19 RELAYS:
5.19.1 The relays shall be:
-
enclosed in dust proof flush mounting drawout type cases.
accessible for setting and resetting from the front.
provided with positive acting hand-reset flag indicators visible from the front.
5.19.2 Access to setting devices shall be possible only after the front covers are
removed. Access to resetting devices shall be external to the case.
5.19.3 Under voltage auxiliary relays shall be rated to operate to satisfactorily between
70% and 110% rated voltage.
5.19.4 I.D.M.T. relays shall be rated to operate satisfactorily between 60% and 100%
of rating.
5.19.5 Each relay shall be provided with at least two separate potential free contacts,
for purchaser's use.
5.19.6 One alarm buzzer common to above protection shall be provided.
5.19.7 Make and type of relays shall be subject to the purchaser's approval.
5.20
The miniature circuit breakers shall have thermal and electromagnetic releases
in the event of overload and short circuit, and shall be of the ratings given
elsewhere in this specification.
1546 of 2461
PAGE 330 of 358
5.21
MMRDA
On each incomer, three indicating lamps rated for 240V for the phases shall be
provided with a push button. The indicating lamps shall be of LED type and of
low watt consumption. The indicating lamps shall be of translucent lamp covers
of RED & YELLOW AND BLUE colors. The indicating lamp shall be wired on
the incoming side of the incomer ACB/MCCB. Each lamp shall be provided with
a ballast resistor of suitable rating and wattage.
5.22
All identical equipments & corresponding parts shall be fully interchangeable

without having to carryout modifications.
5.23
Anodized aluminium labels shall be provided on all incomers/outgoing feeders,

instruments, indication lamps, switches etc. for their easy identification.
5.24
Provision shall be made for locking all switches and operating handles in the
ÒFF' position and mechanical indication shall be provided to indicate their
position.
5.25
The switch board shall be suitable for extension at either end. The operating
handle of any unit shall not be more than 1.95 meters from the floor and
continuous lifting angles shall be provided to facilitate the installation of the
Boards.
5.26
Push button shall not project beyond the shroud or mounting to prevent
inadvertent operation.
5.27
Heater shall have ÒN-OFF' switch on the Board.
6.0
DRAWINGS:
6.1
The tenderer shall submit 3 sets of drawing with the offer:
1.
Outline general arrangement drawing showing dimension, weights,

location of various equipment fittings and foundation layout.
2.
Schematic drawings.
3.
Technical leaflets of all equipment e.g. ACB, switch/fuse, meters, relays,

lamps contactors switch, etc.
4.
The Scheme with U/V relays as specified in Clause 5.2
5.
The installation arrangement of insulators & bus bars.
6.
The construction details of opening and doors.
The following drawings shall be submitted by the successful tenderer after the
1547 of 2461
PAGE 331 of 358
MMRDA
issue of letter of intent for scrutiny and approval to Superintending Engineer

(220kV Planning) within 2 weeks time.
1.
Drawing/technical leaflets as submitted during tender stage.
2.
Sub-assembly drawings.
3.
Wiring diagram.
4.
Foundation Plan.
5.
The Scheme with U/V relays as specified on Clause 5.2.
6.
The installation arrangement of insulators & bus bars.
7.
The construction details of opening and doors.
8.
Instruction manuals which shall clearly indicate the installation checkups
for commissioning, preventive and troubleshooting maintenance.
7.0
GENERAL REQUIREMENT:
7.1
The offer shall be complete with technical particulars, schedule of tests, ,

schedule of recommended spares, schedules of special tools tackles, test
reports and drawings/technical literature. The offer shall be in triplicate.
Incomplete offers are liable for rejection.
7.2
The offer shall be specify the detailed Bill of Quantity for A.C. Distribution Board
alongwith make of each component for technical evaluation.
7.3
The total height of A.C. Distribution Board A&B type should not exceed
2300mm.
7.4
All the type test reports, drawings, Quality Assurance Plan and Bill of Quantity
shall be submitted in Physical form alongwith the offer.
1548 of 2461
PAGE 332 of 358
MMRDA
8.0 ACCEPTABLE MAKE OF EQUIPMENT:
The following makes are preferred:
ACB - L&T/GE/VOLTAS/CROMPTON/SCHNEIDER/C&S
MCCB - L&T/SIEMENS/GE/VOLTAGE/CROMPTON/SCHNEIDER/C&S
HRC Fuses - L&T/SIEMENS/STANDARD/GE
Indicating Instruments - AE/IMP
Selector Switches - KAYCEE/SALZER/MICRON.rm70
Energy Meters - SIMCO/REMCO/UNIVERSAL/ELECTRIC/GEC/L&T/
HAVELLS (ELECTRONIC TYPE)
Current Transformers - AE/IMP/INDCOIL/PRECISE/IE/ASHMOR
Indicating Lamps - L&T/VAISHNO/MIMIC/TECHNIC/SIEMENS (LED type)
Push Buttons - SIEMENS/L&T/VAISHNO/TECHNIC
Cable Glands - BRACO/COMMENT/JENSON
Miniature Circuit Breakers - MDS/STANDARD/ERGON/SCHNERDER
Copper Lugs Crimping Type - DOWELL/JENSON
Relays - GE/ABB/ESSEN/L&T/JVS
10.0 TESTS:
1549 of 2461
PAGE 333 of 358
MMRDA
The tests shall include but not limited to test listed below:
LIST OF TESTS TO BE CARRIED OUT
(REF CL.NO.7.3)
Sr. No.
Name of the test
1)
TYPE TEST:
Standard to which it confirms
a) Short time current withstand test
IS: 8623
b) Temperature rise test
IS: 9676/IS 8623
c) Verification of degree of
IS: 13947
protection test
2)
ROUTINE TEST:
a) High voltage test
(3500 V AC for 1 minute)
b) Insulation Resistance test

(with 500 V DC Megger)
c) Electrical control interlock and

sequential operation test
d) Drawout module
interchangeability test
e) Verification of wiring as per

approved schematic
f) No Load test
1550 of 2461
PAGE 334 of 358
MMRDA
Sr. No.
Name of the test
Standard to which it confirms
3)
TYPE AND ROUTINE TEST INCLUDING BUT NOT LIMITED TO

THE FOLLOWING ASSOCIATED EQUIPMENT:
a) Test on A.C.B.
IS: 13947
b) Tests on fuse link
IS: 2208
c) Tests on A. B. Switches and

IS: 4047
composite switch fuse unit
d) Test on MCCB & MCB
IS: 13947
All instruments used during testing shall be approved and if required shall be calibrated
by a standard physical laboratory or such other body as may be approved by the
purchaser.
The switch boards shall be subjected to the following tests:
1.
Insulation Resistance tests before and after high voltage test
2.
High voltage test (3500 V per 1 minute)
3.
Operation test
4.
Mechanical operation test
5.
Verification of wiring as per approved schematic
6.
Type test and routine tests shall be carried out on all accessories
equipments as per relevant Indian Standards. Certified copies of the test
certificates alongwith the individual components test certificates shall be
submitted wherever possible. No switch board shall be dispatched
1551 of 2461
PAGE 335 of 358
MMRDA
without inspection and testing carried out to the satisfaction of the Board.
10.1 TYPE TEST:
10.1.1 The A.C. Distribution Board offered shall be fully type tested as per the relevant
standards at laboratories which are accredited by National Accreditation Board
of Testing & Calibration Laboratories (NABL) of Govt. of India to prove that the
equipment offered meets the requirements of specification. In case equipment
of the type and design offered has already been type tested in NABL accredited
laboratory, the bidder shall furnish two sets of type test reports alongwith his
bid. These tests must have been conducted within preceding five years from
the date of original NIT. In case these type tests are conducted earlier than
preceding five years all the type tests as per the relevant standards will have to
be carried out by the successful bidder in the NABL Accredited Laboratories at
bidder's own cost before commencement of supply. For any change in the
design/type already type tested and the design/type offered against this
specification, the Purchaser reserves the right to demand testing without any
extra cost. Irrespective of the above, the purchaser reserves the right to
demand repetition of some or all the type tests in the presence of his
representative at purchaser's cost. For this purpose the bidder should quote
unit rates for carrying out each type test in the proforma enclosed as schedule
`6'.
10.1.2 All route and acceptance tests as stipulated in the specified standards shall be
carried out by the supplier in presence of purchaser's representative at
supplier's cost. The acceptance tests, wherever possible, shall be performed
on the completed Board. The number of samples to be subjected to acceptance
tests shall be decided by the purchasers at the time of actual testing.
10.1.3 All the type tests shall be performed on the completed Board alongwith
accessories.
11.0
QUALIFYING REQUIREMENTS:
11.1
The bidder should be manufacturer of offered A. C. Distribution Board (ACDB).
1552 of 2461
PAGE 336 of 358
11.2
MMRDA
The bidder/supplies shall have proven experience of not less than 5 years of
Design, Manufacture, Supply and Testing at the works of equipment/materials
offered for equal or higher voltage class. The equipment/material offered by
bidder should be in successful operation at least for 2 years.
11.3
The bidders not meeting the requirement at clause 11.2 can also participate
provided they have valid ongoing collaboration with a manufacturer who has at
least 10 years experience in the Design, Manufacture and Testing of the
equipment of the type and class offered which have been in satisfactory service
for a period of at least 7 years. In such an event the bidder shall furnish along
with the bid the documentary evidence for the same and undertaking from the
bidder and collaborator accepting joint and several liability for all obligations
under the contract.
11.4
The bidder themselves not meeting the requirements at (11.2 & 11.3) above,
can also participate provided they are subsidiary company in India and their
principal is having majority share holding i.e. more than 51% in the bidder
(subsidiary). Further, the principal should be the manufacturer who has at least
7 years experience in the design, manufacture and testing of equipments of the
type and class offered or higher voltage class, which would have been in
satisfactory service for a period at least 3 years. In such an event, the bidder
shall have to furnish along with the bed, the documentary evidence for the same
and undertaking from the principal for accepting joints and several liabilities for
all obligations under contracts.
11.5
The bidder/supplier should have adequate in-house testing facilities for

conducting acceptance tests in accordance with relevant IS.
11.6
The bidder should have a minimum turnover of 60% of the estimated cost of
the offered item/items in any one financial year during the last 3 years.
11.7
The bidder should furnish all the relevant documentary evidence to establish
the fulfillment of the above requirements. Also all type test certificates as per
the clause 10.1 for the equipment/material offered shall be submitted along with
offer.
1553 of 2461
PAGE 337 of 358
11.8
MMRDA
The bidder is liable for disqualification on account of any of the following

reasons:
i)
Poor quality and workmanship of the products previously supplied and frequent
failures during warranty period as experienced by the purchaser.
ii)
Bidder against whom litigation is in process.
iii)
Bidder, who in the opinion of the purchaser has mollified intentions in the
conduct of business with the company (MSETCL).
iv)
Bidder, who is declared to be a defaulter as per the terms and conditions laid
down by the Company.
11.9
Notwithstanding anything stated above, the purchasers decision in this regard

will be final.
12.0
DOCUMENTATION:
12.1
After issue of detailed purchase order, the successful tenderer shall submit 4
sets of complete drawings along with detailed Bill of Quantity for approval to the
Chief engineer (P&D)/Chief engineer (Trans. O&M), MSETCL, Prakashganga,
Bandra-Kurla Complex, Mumbai 400 051. If any modification are required on
these, the same will be conveyed to the supplier who shall modify the drawings
accordingly and furnish final drawings for approval. In normal practice, the
documents submitted for approval will be commented upon or approved if in
order, within 30 days from the date of receipt of the same in the Projects &
Design/trans. O&M Department, MSETCL
12.2
The manufacturing of the equipments shall be strictly in accordance with the

approved drawings and no deviation shall be permitted without the written
approval of the Projects & Design/Trans. O&M department. All manufacturing
and fabrication work in connection with the equipments prior to the approval of
the drawing shall be at the supplier's risk
1554 of 2461
PAGE 338 of 358
MMRDA
13.0
INSPECTION:
13.1
No equipment against this specification shall be dispatched from the work of

the supplier without proper inspection by the representative of the MSETCL.
During the inspection all routine tests, including operational (functional) checks
shall be carried out on the equipment.
14.0
QUALITY ASSURANCE PLAN:
14.1
The tenderer shall furnish along with his offer the quality assurance plan (QAP)
adopted by him/his sub-supplier in the process of manufacturing all major
equipment/components.
14.2
Precautions taken for ensuring the usage of quality raw materials and subcomponents shall be stated in the Quality Assurance Plan.
15.0
PERFORMANCE GUARANTEE:
15.1
The equipments offered shall be guaranteed for satisfactory performance for a

period of 60 months from the date of receipt of complete equipment at
destination store/site in good condition or 54 months from the date of
satisfactory commissioning of equipment whichever is early. The equipments
found
defective/failed
within
the
above
guarantee
period
shall
be
replaced/repaired by the supplier free of cost within one month of receipt of

intimation. If the defective/failed equipments are not replaced/repaired as per
the above guarantee clause, the Board will recover an equivalent amount plus
15% supervision charges from any of the suppliers bill.
SCHEDULE - I
1)
GUARANTEED AND TECHNICAL PARTICULARS OF A.C. DISTRIBUTION

BOARD À TYPE
2)
1555 of 2461
PAGE 339 of 358
MMRDA
BOARD `B TYPE
3)

BOARD 400kV MAIN BOARD
4)

BOARD 400kV AUXILIARY OUTDOOR BOARD
5)

BOARD 400kV MAIN AC LIGHTING BOARD (INDOOR)
SCHEDULE II
SCHEDULE OF TESTS
Tests as per this specification, IS and Manufacturers Standards shall be

performed. Detailed list of tests shall be indicated in this schedule:
1.
Test during Manufacture:
2.
Routine Tests on completion of Manufacture:
3.
Site Tests during Erection, Testing and commissioning:
4.
Site tests for performance guarantee after commissioning:
5.
The reasons for not conducting any test/tests specified in the
specification shall be clearly stated:

SCHEDULE III
DEVIATION FROM TECHNICAL SPECIFICVATION - DELETED AND
NOT REQUIRED
1556 of 2461
PAGE 340 of 358
MMRDA
SCHEDULE IV
SCHEDULE OF RECOMMENDED SPARE PARTS FOR ERECTION,
COMMISSIONING, MAINTENANCE AND TWO YEAR OPERATION
FOR WHICH UNIT PRICES ARE QUOTED
Sr.
Description
Unit Price
Delivery
Remarks
No.
1)
Nature of spare be
indicated by a letter as
applicable
2)
Consumable spare
3)
Emergency spares
4)
Susceptible to damage
during erection testing
& commissioning
SCHEDULE V
TENDERER'S EXPERIENCE
Tenderer shall furnish here a list of similar jobs executed by him to whom a reference
may be made by Purchaser, in case he considers such a reference necessary.
1557 of 2461
PAGE 341 of 358
MMRDA
Name &
Sr. No.
Person to whom
Description of
Value of work
Client
reference may be
Work
made
SCHEDULE VI
SCHEDULE OF TYPE TEST CHARGES
Bidder's Name & Address To: _______________________
_______________________
Test charges of each type & rating

Sr. No.
Description of the Type test

of equipment offered
FIRE FIGHTING SYSTEM
1558 of 2461
PAGE 342 of 358
MMRDA
1.0 GENERAL REQUIREMENT
1.1 Fire Extinguishing/Fighting system envisaged against this specification is of the

manual (and portable) type. Automatic (electrical/mechanical type) is not envisaged.
All the fire extinguishers and fire fighting equipment to be supplied against this
specification shall be of very high quality and of robust and reliable design.
1.2 All fire fighting equipment shall be as per as per relevant Indian Standards as
described later in this section. The equipment shall successfully pass the relevant tests
as specified/ applicable. Approval of other statutory authorities like, BIS(Bureau of
Indian Standard),Department of Explosives, etc. wherever applicable, shall also be
available for the offered product.
2.0 CATEGORY WISE REQUIREMENT
2.1 For EHV Transformer bays, the Fire Extinguisher system to be supplied is as
follows:
Extinguisher Type
Transformer Details
50L
75 Kg
Mechanical
9L
Mechanical
DCP
Foam
For the first two
(sand/water)
Foam
2 (outdoor)
units
For every additional
9L Bucket.
4 each
(outdoor)
1 (outdoor)
two units or part
4 each
(outdoor)
thereof
1559 of 2461
PAGE 343 of 358
MMRDA
2.2 9L Mechanical Foam type Fire Extinguisher shall be provided 2 nos. for every 2
EHV bays near CT.
2.3 Fire extinguishers as indicated below shall be provided for the control room
building:
Sr. No.
Description of the area
Requirement of fire Extinguishers for

EHV S/S
Capacity
Type
Quantity
(Nos.)
1.
2.
Control Room
Cable trench in control
22.5 kg
CO2
6.5 kg
CO2
6.5 kg
CO2
9.0 kg
DCP
room
( Abc Type)
3.
Battery room
6.5 kg
CO2
4.
Communication room
6.5 kg
CO2
5.
Store room
9 kg
DCP
( Abc Type)
9L
1
M. Foam
6.
Auxiliary room
6.5 kg
CO2
9.0 kg
DCP
( Abc Type)
1560 of 2461
PAGE 344 of 358
MMRDA
3.0 SPECIFICATION
3.1
Dry Chemical Powder (DCP) Trolley mounted fire extinguishers shall be of gas
cylinder type and of capacity 75 kg These extinguishers are intended for upright
operation. The design shall be cylindrical, complete with cap assembly,
discharge nozzle and discharge hose. Anti corrosive treatment as per
IS:10658.The extinguisher shall be suitably mounted on a two wheel (rubber)
type trolley. Construction of material used for the fire extinguisher shall be
strictly as per IS 10658 . The gas cylinders shall be designed as per IS:10658
and should be ISI marked and PESO Approved . Dry powder charge should
have approval and certification mark IS: 4308.The equipment should withstand
a test pressure of 30 kgF/cm2.During inspection, pressure test and discharge
performance test as per IS:10658 shall be conducted in presence of
Purchasers representative. The scope of supply shall include initial charge and
accessories required for installation.
3.2
ABC Type Dry Chemical Powder (DCP) Portable fire extinguishers shall be of
Stored pressure type and of capacity of 9 kg. These extinguishers are intended
for upright operation. The design shall be cylindrical with no vertical weld on
body, complete with squeeze valve assembly, discharge nozzle and discharge
hose. Anti-corrosive treatment as per IS:15683. Construction of material used
for the fire extinguisher shall be strictly as per IS:15683. The cylinder shall be
ISI marked. Dry powder charge MAP 90% should have approval and
certification mark IS:14609. Fire rating shall be min 3A:21B as per IS:15683.
The extinguisher should pass Helium Leak Detector Test (HLDT). The
equipment should withstand a test pressure of 35kgf/cm. During inspection,
pressure test and discharge performance test as per IS:15683 shall be
conducted in presence of Purchasers representative. The scope of supply shall
include initial charge and wall bracket accessories required for installation.
3.3
Carbon Dioxide (CO2) Trolley mounted type extinguishers shall be of 6.5 kg

and 22.5 kg capacity. These are meant for upright operation. The extinguishers
should have cylindrical body with wheel type valve, wire braided high pressure
flexible hose fitted with discharge horn (non-conductor of electricity) . The
1561 of 2461
PAGE 345 of 358
MMRDA
extinguisher shall be suitably mounted on a two wheel (rubber) type trolley. The
material used for construction of various parts of the extinguishers shall be
strictly as per IS:2878. For valve IS:3224 and for CO2 gas, IS:15222 shall be
applicable. The equipment shall withstand a test pressure of 250 kgF/cm2. The
burst pressure of discharge hose with controlled discharge shall not be less
than 275kgF/cm2. The extinguisher and valve of the cylinder should be ISI
marked. CO2 cylinder design must be approved by the department of
explosives, Nagpur. At the time of inspection, pressure test on cylinder and
discharge hose and discharge performance test shall be conducted in line with
IS:2878.The cylinder should be fully charged with CO2 gas of 99.9% purity as
per IS:15222. The scope of supply shall include initial charge and accessories
required for installation.
3.4
Mechanical foam -Aqueous Film Forming Foam (AFFF)- type fire extinguishers
of 50L capacity shall be suitable for operation by holding the extinguisher
upright and piercing the gas cartridge (300gm). The body shall be cylindrical,
made of welded design. It shall be complete with cap assembly, piercing
mechanism, discharge nozzle with discharge hose. Anti corrosive treatment as
per IS:13386. The extinguisher should be suitably mounted on a wheeled
carriage (with rubber tyres). The material for construction shall be as per
IS:13386. The extinguisher shall be designed as per IS:13386 and the gas
cartridge should conform to IS:4947. AFFF (6%) should conform to IS:4989
(Part II). The extinguisher shall withstand a test pressure of 30kgF/cm 2 for two
minutes without leakage or distortion. Extinguishers, gas cartridges and AFFF
charge should be ISI marked. Pressure test, discharge performance test, burst
failure test and foam test as per IS:13386 shall be conducted at the time of
inspection. The extinguishers, duly painted and marked as per IS:13386, shall
be supplied with initial charge and spare charge.
3.5
Mechanical foam type-AFFF-fire extinguishers of 9L capacity shall be operable

by holding the extinguisher upright and piercing the gas cartridge. The body
shall be cylindrical made of welded design. It shall be complete with squeeze
Valve assembly, discharge nozzle with discharge hose.Anti corrosive treatment
as per IS:15683 The material for construction shall be as per IS:15683. The
extinguisher shall be designed as per IS:15683 and the gas cartridge should
1562 of 2461
PAGE 346 of 358
MMRDA
conform to IS:4947.filled with AFFF (6%) conform to IS:4989 (Part II) with ISI
marked.fire rating shall be 4A:34B as per IS:15683. The extinguisher shall
withstand a test pressure of 35kgF/cm2 for 1 minutes without leakage or
distortion Pressure test, discharge performance test, and burst failure test as
per IS:15683 shall be conducted at the time of inspection. The extinguishers
duly painted and marked as per IS:15683 shall be supplied with initial charge,
spare charge and wall bracket fittings/ fixtures.
3.6
The fire bucket shall be of 9 L capacity. The bucket shall be of round bottom
and having suitable handle for hanging on the stand The bucket shall be
designed as per IS:2546 and shall be painted white inside and red outside as
per IS specification.
LIST OF APPROVED VENDORS (FOR SUBSTATIONS) AS ON: 15/10/2015
S.
Vendors Name
Item Description
Rema
No.
1
rk
AC Distribution Board
KMG A to Z, Noida/ Maktel, Vadodara/ Panva,

Nashik/ Power Control System, Sangli/ Vimac,
Mumbai
Air Conditioners
Blue Star/ Carrier/ Kirloskar/ Lloyd/ Voltas
Aluminium Tube
BALCO/ BANCO, Vadodara/ Century, Kolkata/

Gujrat Metal/ HINDALCO/ INDALCO/ NALCO/
SUDAL
Bus Post Insulator
Aditya Birla, Halol/ IEC, Bhopal/ Modern, Abu
(132kV)
Road/ Prathmesh Ceramics, Nashik/ Sarvana,

Cuddalore/ WSI, Chennai
Circuit Breaker (132kV)
ABB,
Vadodara/
Alstom,
Chennai/
CGL,
Nashik/ Siemens, Aurangabad

6
Ceiling Fans
Clamps & Connectors
Bajaj/ Crompton/ Khaitan/ Orient/ Usha

Dharia, Pune/ Electromech & Transtech,
Kolkata/ Exalt, Mumbai/ Klemmen, Chennai/
National Refra/ Ramelex, Pune/ TM Power
Line, Kolkata/ Varad Engineering, Pune/
1563 of 2461
PAGE 347 of 358
S.
MMRDA
Vendors Name
Item Description
Rema
No.
rk
Vensun Techno Links, Chennai/ Vinayak,
Mumbai
Conductor (AAAC)
Apar, Silvassa/ Cabcon India, Kolkata/ Galada,

Silvassa/
Galaxy
Transmission,
Silvassa/
Gammon (formerly Transrail), Silvassa/ Gupta

Power Infrastructure, Bhubaneshwar/ Hind
Aluminium, Silvassa/ ICOMM, Hyderabad/ JSK
Ind., Sayli, Silvassa/ KJV Alloy, Boregaon
(M.P.)/ Lumino Ind. Ltd., Kolkata/ Sterlite,
Rakholi & Piparia (Silvassa)
9
Conductor (ACSR Zebra
Achyuta
Electricals,
Hyderabad/
Apar,
(Z), ACSR Panther (P)
Silvassa/ Cabcon India, Kolkata/ Diamond
and ACSR Moose (M))
Power, Vadodara (only Z & P)/ ERI Tech,

Kolkata/
Galada,
Silvassa/
Galaxy
Transmission, Sangli & Silvassa/ Gammon

(formerly Transrail), Silvassa/ Gupta Power
Infrastructure,
Bhubaneshwar/
Hind
Aluminium, Silvassa/ Hindustan Vidyut Product

Ltd., Faridabad/ JSK Ind., Rakholi & Sayli,
Silvassa/ Jyoti Power, Gondal/ Kalpesh, Dhule/
KJV Alloy, Nagpur/ Kataria Ind., Ratlam (only
Z & P)/ Lumino Ind. Ltd., Kolkata/ Lunkad Alu.,
Jalgaon (only Z & P)/ MMP, Bhandara/ Prem
Cables,
Pali
(Raj.)/
Prem
Conductors,
Gandhinagar/ Rajasthan Cables & Cond.,

Jaipur (only Z & P)/ Sterlite, Rakholi & Piparia
(Silvassa)/ Venkateshwara Wires, Jaipur
10
Conductor (HTLS
General Cables, Baddi (H.P.) (upto 132kV)
ACSS)
11
Conventional C&R Panel

for Augmentation/ Bay
extension (132kV)
ABB/ Alstom/ Amararaja, Tirupati/ Ashida/

Avana/
C&S,
Noida/
CG-ZIV/
ER/
GE,
Bengaluru/ Goenka Switchgear Pvt. Ltd.,
1564 of 2461
PAGE 348 of 358
S.
MMRDA
Vendors Name
Item Description
Rema
No.
rk
Nagpur/ Isosceles/ Schneider/ SCOPE T&M
Pvt. Ltd., Pune/ Siemens/ Venson
12
C. I. Pipe Earthing Set
Kapilansh Dhatu, Nagpur/ Nagpur Foundries,
(for Substation)
Nagpur/ R. S. Valves, Hyderabad/ Universal

Earthing Systems Pvt. Ltd. (UES), Chennai
(only for Hard Soil Strata & GIS substations)
13
Current Transformer (CT)
ABB, Vadodara/ AEP, Mumbai/ Alstom, Hosur/
(132kV)
BHEL, Jhansi/ CGL, Nashik/ Emmess Control,

Chennai/ Heptacare, Merrut/ Hivolt, Halol/ ITC,
Boisar/ Kapco Electric Pvt. Ltd., Noida/ Lamco,
Hyderabad/ Mehru, Bhiwadi/ Pragati Ele.,
Thane/ Siemens, Aurangabad (SF6)/ Techno,
Dombivali (E)/ Toshiba, Hyderabad
14
Capacitor Voltage
ABB, Vadodara/ Alstom, Chennai/ BHEL,
Transformer (CVT)
Jhansi/
(132kV)
15
CGL,
Nashik/
Mehru,
Bhiwadi/
Siemens, Aurangabad
DC Supply Systems
(a)
Battery, 220V DC
AAJCO, Kolhapur/ EXIDE, Kolkata/ HBL,

Hyderabad/
Manesh
Enterprises/
PALSAI
Batteries, Pune/ Union Batteries, Pune

(b)
Battery, 110V DC

Hyderabad/
Manesh
Enterprises/
PALSAI

(c)
Battery, 48V DC

Hyderabad/
Manesh
Enterprises/
PALSAI

(d)
Battery Charger,
220V DC
Amararaja, Tirupati/ Armo, Nagpur/ Caldyne,

Kolkata/ Chhabi, Jalgaon/ HBL, Hyderabad/
Panva, Nashik
(e)
Battery Charger,
110V DC

Panva, Nashik
1565 of 2461
PAGE 349 of 358
S.
MMRDA
Vendors Name
Item Description
Rema
No.
rk
(f)
Battery Charger
with DCDB, 48V DC

Panva, Nashik
16
Earthwire HDG
Bedmutha Industries, Nashik/ Bharat Wires,
(7/3.15mm and
Atgaon/ Geekay Wires, Hyderabad/ Jyoti
7/3.66mm)
Power Transmission, Ahmedabad/ Millenium

Structural, Dhar (M.P.)/ Ramasarup Ind.,
Kolkata/ Ratlam Wires, Ratlam/ UIC Udyog,
Kolkata
17
Exhaust Fans
18
Bajaj/ Crompton/ Khaitan/ Orient/ Usha

Fasteners & Washers
(a)
Nut & Bolts
Anand Bolts, Ludhiana/ Anshika Fasteners,

Nagpur/ ASP Pvt. Ltd., Howrah/ A. V. Forgings,
Mohali/ Bharat Ind., Howrah/ BRK Ind.,
Ludhiana/ Deepak Fasteners, Ludhiana/ Garg
Fasteners, Ludhiana/ H. R. Steel Ind., Kolkata/
Himalaya Engg. Works, Hyderabad/ Ishitva
Fasteners Pvt.
Ltd., Hyderabad/ Kadevi,
Hyderabad/ Karamtara Fasteners, Tarapur/

Kavcon, Bangalore/ Maheswari Fasteners,
Hyderabad/
Nexo
Millenium
Industries,
Structurals,
Ludhiana/
Indore/
Panchsheel
Fasteners, Ludhiana/ Paramhari, Nagpur/ Ravi

Engineers, Amritsar/ Remax India, Ludhiana/
Roshan Impax, Ludhiana/ Sagar Fasteners,
Ludhiana/ Techman (India), Chandigarh (Nuts
from M/s Techman Enterprise, Panchkula)
(b)
Plain Washers
BRK
Ind.,
Ludhiana/
Deepak
Fasteners,
Ludhiana/ Garg Fasteners, Ludhiana/ Kavcon,

Bangalore/ Maheswari Fasteners, Hyderabad/
Millenium Structurals, Indore/ Nexo, Ludhiana/
Remax India, Ludhiana/ Sagar Fasteners
1566 of 2461
PAGE 350 of 358
S.
MMRDA
Vendors Name
Item Description
Rema
No.
rk
(c)
Spring Washers
Chempromech Engineers, Nagpur/ Forbes &

Gokak, Mumbai/ Forex Fasteners, Ludhiana/
Garg
Fasteners,
Ludhiana/
Maheswari
Fasteners, Hyderabad/ Naveen Metal, Kolkata/

Om Fasteners, Nagpur/ Springlock, Vadodara
19
Fire Fighting Equipments
20
Gantry and Equipment
Aarati Structures Pvt. Ltd., Nasik (upto 220kV)/
Support Structures/
A. K. Power Industries Pvt. Ltd., Kolkata (upto
Lighting Masts/ Lightning
220kV)/ Akshar Engineering, Vadodara (upto
cum Lighting Masts
Kanadia, Bhavnagar
220kV)/
Amitasha
Enterprises
Pvt.
Ltd.,
Nagpur (765kV)/ Archon Egicon Pvt. Ltd.,

Gandhinagar
(upto
400kV)/
Associated
Transrail Structures, Vadodara/ Aster, Raipur/

B. G. Shirke, Pune/ B. S. Transcomm,
Hyderabad/
ECI
(upto220kV)/
Infra.,
Hyderabad
Electrotherm
India
Ltd.,
Vadodara (400kV)/ EMCO (formerly Urja),

Vadodara/ Encorp, Tarapur (upto 220kV)/
Gammon India, Nagpur (formerly Transrail)/
Global Towers, Pune/ Goodluck Fabricators,
Ghaziabad
(400kV)/
ICOMM
Tele.
Ltd.,
Hyderabad (765kV)/ Inabensa Bharat, Halol

(upto400kV)/ IVRCL, Nagpur/ JHT Power
Engg., Gondal (upto 220kV)/ Jyoti Structures,
Nashik/ K. R. Structures, Thane (upto 220kV
for Qty. upto 200MT)/ Kaytx Industries Pvt.
Ltd., Mandi Gobindgarh, Punjab (upto 220kV)/
Kadevi Ind. (P) Ltd., Hyderabad (upto 220kV)/
Kalpataru Power, Gandhinagar/ Karamtara
Engg.,
Mumbai
Bangalore/
KEC,
(upto
765kV)/
Nagpur/
KPTL,
Kavcon,
Raipur
(765kV)/ Linkson International Ltd., Nagpur
1567 of 2461
PAGE 351 of 358
S.
MMRDA
Vendors Name
Item Description
Rema
No.
rk
(upto 220kV)/ Maheshwari Structures (only
Equipment support structures upto 33kV)/
Meghraj Industries, Supa (220kV Line
100MT)/ Nandan Steel & Power Ltd., Raipur
(upto220kV)/ NEXO Structures, Ludhiana
(upto 220kV)/ Novelty Power & Infratech,
Mumbai/ Phoenix Structural & Engg. Pvt. Ltd.,
Nagpur (upto 220kV)/ Powerdeal Energy
System, Nashik (upto400kV)/ Prabhune Fab.
& Galv., Sangli & Karad (upto 220kV)/
Richardson & Cruddas, Nagpur/ Rounak,
Nagpur (upto 220kV for Qty. upto 200MT)/
Rukmini Electricals, Raipur (upto 220kV for
Qty. upto 200MT)/ Sawaria Pipes Pvt. Ltd.,
A.P. (upto 220kV)/ Shah Infra Towers (P) Ltd.,
Davangere (upto 400kV)/ Shanz Power, Wada
(upto 220kV)/ Shilpa Re Rollers, Nagpur/
Shree Vaishnav Industries Pvt. Ltd., Wada
(upto 220kV)/ Smitwin, Bangalore (upto
220kV)/ Sunrise Structures, Nagpur (400kV)/
Techno Craft Industries (I) Ltd., Murbad (upto
220kV)/ TKG Industries, Nagpur (upto 132kV)/
Unique Structural & Towers Ltd. (upto 400kV)/
Unitech Power Transmission, Gurgaon/ United
Industries, Jaysingpur (upto 400kV)/ Vatco,
Navi
Mumbai
(upto
765kV)/
Vijay
Transmission, Raipur (765kV)/ Vinfab Engrs.

India Pvt. Ltd. (formerly V. K. Engineers),
Mumbai (upto 220kV)
21
G. I. Cable Trays
CSR Industries, Pune/ Elcon, Pune/ Indiana

Gratings,
Mumbai/
Om
Ind.,
Nagpur/
Omkareshwar Engg., Thane/ Parmar, Rajkot/

Pentex Ferro Incorporate, Thane/ Rukmani
1568 of 2461
PAGE 352 of 358
S.
MMRDA
Vendors Name
Item Description
Rema
No.
rk
Electricals, Kolkata & Raipur/ S. N. Electricals
Ltd., Pune/ Vatco, Navi Mumbai/ Universal
Engg., Thane
22
Horn Gap Fuse
Electrolites (Power) Pvt. Ltd., Jaipur/ Kiron

Electrotechnic, Thane
23
Insulator Hardware and
A.
K.
Power,
Earthwire Accessories
ASBESCO,
Kolkata
Kolkata/
EMI,
(upto
220kV)/
Mumbai/
IAC,
Kolkata/ ITP, Bhandup/ Krsna Transmission,

Vadodara
(upto
220kV)/
MML,
Kolkata/
Mosdorfer India Pvt. Ltd., Nashik (upto400kV)/

National Refractories, Morbi (upto 220kV)/
Nike
Industries,
Varanasi
(upto
220kV)/
Ramelex Pvt. Ltd. (upto 220kV)/ Rashtra

Udhyog, Kolkata/ Sicame India Connectors,
Chennai (Spacer damper only)/ Swamiji
Transmission, Kolkata (upto 220kV)/ TLP,
Kolkata (upto400kV)
24
Insulators (Porcelain)
(a)
Disc Type
Aditya Birla Insulators, Rishra/ Allied Ceramics,

Kolkata (70KN (N) & (AF), 120KN (N) upto
220kV only)/ BHEL, Jagdishpur (Bangalore)/
Bikaner Ceramics, Bikaner (upto 220kV)/ IEC,
Bhopal/ WSI, Chennai
(b)
Long Rod Type
Modern Insulators, Abu Road/ Saravana

Global Energy Ltd., Cuddalore (upto 220kV)
25
Insulators
Deccan Ent. Hyderabad/ G. K. Xianghe Elect.
(Polymer Long Rod Type)
Pvt. Ltd., Bhopal (upto 220kV)/ Goldstone

Infratech Ltd., Hyderabad/ LAMCO, Hyderabad
(upto 220kV)/ Shree Radhe Ind., Vadodara
(upto 220kV)/ Yamuna Power, Haryana (upto
220kV)
26
Insulators
Global Group Co. Ltd., Yibin, Sichuan, China/
1569 of 2461
PAGE 353 of 358
S.
MMRDA
Vendors Name
Item Description
Rema
No.
rk
(Glass Type)
27
Isolators (132kV)
Sediver, China (Shanghai Unit)

Bimco, Hyderabad/ CGL, Nashik/ Electrolite,
Jaipur/ Engineers Enterprises, Jaipur/ Faraday
Ele., Jaipur/ GK Electricals, Bhopal/ G. Nandy,
Howrah/ GR Power, Hyderabad/ J. D. Ele.,
Howrah/ Kiron Electrotech, Thane/ Siemens,
Hyderabad/
Switchgear
and
Structurals,
Hyderabad/ Tritech, Nashik/ Universal Isolator,

Indore
28
Lighting Fixtures
Bajaj/ Crompton/ GEC/ Philips/ Shakti Fixtures,

Mumbai
29
Lightning Arrester (132kV) CGL,
Nashik/ Elektrolite,
Jaipur/ Lamco,
Hyderabad/ Oblum, Hyderabad

30
LT Cables
Anaraj Cables, Salem (H.P.)/ Cabcom Cables/

Chandresh Cables, Ahmedabad/ Colt Cables,
Pen (Raigad)/ Daksha Cable Ind., Kandivali/
Dashmesh Cables, Ulhasnagar/ Diamond,
Vadodara/ Gloster Cables Ltd., Secunderabad/
Grid India, Manesar (Haryana)/ Gupta Power
Infrastructure Ltd., Bhubaneshwar/ Hindustan
Vidyut Products, Ghaziabad/ Kanha Cables,
Jaipur/ KEC International/ KEI Ind. Ltd., Alwar/
Ketan Enterprises, Mumbai/ KNG Wires &
Cable Ltd., H. P./ Krishna Cables, Gwalior/
LASER
Cable,
Paramount
Kolkata/
Marco,
Communication,
Sinner/
Khushkhera/
Paragon Cable Ind., Delhi/ Polycab Wires,

Silvassa/
Revin,
Pune/
Satelite
Cables,
Bhiwadi/ Sriram Cables, Bhiwadi/ Suyog,

Panchmahal/
Teracom,
Kundaim
(Goa)/
Tirupati Plastomatic, Jaipur/ Vishal Cables,

Ambernath/ Zenium Cables, Valsad
1570 of 2461
PAGE 354 of 358
S.
MMRDA
Vendors Name
Item Description
Rema
No.
rk
31
Marshalling Boxes
Electrocare, Shahapur/ KMG A to Z, Noida/

Maktel, Vadodara/ Panva, Nashik/ Power
Control System, Sangli/ Tushar, Jalgaon
32
M. S. Flat/ G. I. Flat
Agarwal Structures, Raipur/ Pushpak Steels,

Pune/ Swastika Steel, Howrah/ Vatco, Navi
Mumbai/ Vijay Tr. Pvt. Ltd., Raipur/ Vithal Ind.,
Raipur
33
PLCC Equipments
(a)
Wave Trap
Alstom, Hosur/ BPL, Palghat/ Gyro, Hosur/

Quality Power Electrical Equipments Pvt. Ltd.,
Sangli
(b)
Coupling
Capacitors
ABB, Vadodara/ Alstom, Hosur/ CGL, Nashik/

Mehru/ Siemens, Aurangabad (for Specific
projects only)
(c)
H. F. Cables
Delton, Delhi/ Techno, Hyderabad
(d)
Coupling Device
ABB, Andheri/ Alstom, Delhi (for Specific

projects only)/ CG-ZIV/ Patson, Nashik
(e)
PLCC Terminal
ABB, Andheri/ Alstom, Delhi (for Specific
with Protection Coupler
projects only)/ CG-ZIV
(f)
ABB (Matrix), Vadodara/ Intellicon Pvt. Ltd.,
EPAX
Ahmedabad (Karel Make)

34
Power Transformer 765kV Alstom, Vadodara/ TBEA Energy (India) Pvt.

ICT & Reactors
35
Ltd., Vadodara
Power Transformer 132kV ABB Ltd., Vadodara/ Aditya Vidyut Appliances,

Class
Bhivandi/ Alstom, Allahabad/ Bharat Bijlee,
(a) 50MVA, 132/33kV
Thane/ BHEL, Jhansi/ CGL, Mumbai/ EMCO
(b) 50MVA, 132-110/33kV Ltd.,
Thane/
IMP,
Silvassa/
Indotech
(c) 50MVA, 132/22kV
Transformers Ltd., Chennai & Kanchipuram/
(d) 50MVA, 100/22kV
Kanohar,
(e) 25MVA, 132/33kV
Schneider/
Merrut/
Prime
Siemens,
Meiden
Kalwa/
Ltd./
Technical
(f) 25MVA, 132-110/33kV Associates, Sitarganj/ Tesla Transformers Pvt.

(g) 25MVA, 132/22kV
Ltd.,
Bhopal/
Transformers
1571 of 2461
&
Rectifiers,
PAGE 355 of 358
S.
MMRDA
Vendors Name
Item Description
Rema
No.
rk
(h) 25MVA, 132/11kV
Ahmedabad/ TBEA Energy (India) Pvt. Ltd.,
(i) 25MVA, 132-100/22kV Vadodara/ Victory Transformers, Chennai/

Vijai
Electricals,
Hyderabad/
Voltamp
Transformers Ltd., Vadodara

36
Power Transformer Accessories

(i)
Tap Changer Controller
a.eberle Gmbh/ Dynamic Rating/ Easun
cum Transformer Monitoring
MR (type TAPCON)/ Pradeep Sales &
Unit
Services
(ii)
Digital Tap Position
Indicator
(iii)
Remote Temperature
Indicator
Pradeep Sales & Services (type TDC

2001)/ Precimeasure
Perfect Control/ Pradeep Sales & Services
(type
OTC2003/
WTC2002)/
Precimeasure
(iv)
Microprocessor Based
Annuciator
(v)
RTD or Winding/ Oil
Temperature Indicator
Minilec/ Pradeep Sales & Services (type

P350/ P400)/ Precimeasure
Perfect/ Pradeep Sales & Services (type
RTD2000/
RTD2001)/
Precimeasure/
Qualitrol (AKM Brand), Noida

(vi)
Current Convertor Unit
(CCU)/ Transducer for 4 -
Pradeep Sales & Services (type CCU T203/ CCUPT-203)/ Precimeasure
20mA output
(vii)
OLTC
CTR (upto 400kV)/ Easun MR/ HMG

(SHPEL), China/ OLG (upto 132kV)
(viii)
145kV Condenser
Bushing for EHV Transformer
ABB, Vadodara/ Alstom/ CGL/ BHEL/

Trench, France/ Yash High Voltage,
Vadodara (upto 72.5kV Class)
(ix)
Optic Fibre Based
FISO, Canada/ Lumasense Technologies
Transformer Winding & Oil
(type
Thermoset)/
Opsense,
Canada
Temperature Measurement
make/ Qualitrol (Neoptix brand), Noida
System
(x)
Fire Protection System
for EHV Transformer
CTR Manufacturing Industries Ltd., Pune/

Vendere, Aurangabad
1572 of 2461
PAGE 356 of 358
S.
MMRDA
Vendors Name
Item Description
Rema
No.
rk
(xi)
On-Line Dissolved Gas
Monitoring System
a.eberle
(Hydrocal-1003)/
Avaco
(Callisto)/ BPL Global {model Serveron

TMI (optional)}/ PCI Ltd. {model HYDRANM@of GE Syprotec (Canada)}
(xii)
Buchholz (Gas
Press-N-Forge, Mumbai
Operated) Relay for EHV

Power Transformer
(xiii)
Radiator Valve (Throttle/ Press-N-Forge, Mumbai
Butterfly) for EHV Power

Transformer
(xiv)
Magnetic Oil Level
Gauge (MOG) for EHV Power

Transformer
(xv)
Silica Gel Breather (Air
Dehumidifier) for EHV Power

Transformer
(xvi)
Oil Surge Relay for EHV Press-N-Forge, Mumbai
Power Transformer
(xvii)
Pressure Release Valve Press-N-Forge, Mumbai/ Qualitrol, Noida
(PRV) for EHV Power

Transformer
(xviii)
Sudden Pressure Relay
Qualitrol, Noida
(SPR)/ Rapid Pressure Rise

Relay (RPRR) for EHV Power
Transformer
37
Potential Transformer (PT)
AEP, Mumbai/ CGL, Nashik/ BHEL,
(132kV)
Jhansi/ Heptacare, Merrut/ Hivolt, Halal

(Gujrat)/ ITC, Boisar/ Kapco Electric Pvt.
Ltd., Noida/ Mehru, Bhiwadi/ Pragati Ele.,
Thane/ Techno, Dombivali (E)/ Toshiba,
Hyderabad
38
Relay Panels with Bay
ABB, Bengaluru/ Alstom, Chennai/ CG-
1573 of 2461
PAGE 357 of 358
S.
MMRDA
Vendors Name
Item Description
Rema
No.
rk
Controller and SCADA (132kV) ZIV/
CTR,
Nashik
(with
ROCON,
Bulgaria)/ Easun Reyrolle, Hosur/ GE,

Bengaluru/ Isosceles, Pune (with Nanjing
Nari,
China)/
Schneider/
Siemens,
Mumbai
39
SCADA system for remote
ABB/ Alstom/ Ashida/ C&S, Noida/ CGL/
monitoring of consumer/ IPP
Chemtrols/ Eliop/ ER/ GE, Bengaluru/
substation
Goenka Switchgear Pvt. Ltd., Nagpur/

Isosceles/ Kalkitech/ Schneider/ Siemens/
Synergy
40
Transformer Oil (Uninhibited,
Apar Industries Ltd., Silvassa/ Raj Petro,
Naphtha base)
Mumbai/ Savita Oil Technologies Ltd.,

Mumbai
41
Transformer Oil (Paraffin base) Anamica Oil Pvt. Ltd./ Apar Industries Ltd.,
Silvassa/ Columbia Petrochem Pvt. Ltd.,
Mumbai/ Gandhar Oil Refinary India Ltd.,
Mumbai/
Raj
Petrospecialities
Ltd.,
Silvassa/ Savita Oil Technologies Ltd.,

Mumbai
1574 of 2461
PAGE 358 of 358
MMRDA
Table of Contents
SUB-SECTION 6B.5: INSTRUMENTATION CONTROL AND AUTOMATION
5.1
Introduction
5.2
Reference Standards
5.3
Statement of Compliance
5.4
Documents to be submitted during Bid Submission
5.5
Qualification Criteria for Instrumentation vendor/integrator and Automation Vendor/integrator
5.6
Design Requirements for Instrumentation, Control, Automation (ICA) Equipment
1
1
1
3
4
6
8
5.6.1
5.6.2
Site Conditions
Enclosure/Panel Details
8
10
5.6.3
5.6.4
Instruments and ancillaries

Cabling
28
33
5.6.5
5.6.6
5.6.7
5.6.8
5.6.9
5.6.10
Cable Termination Boxes

Junction Boxes
Cable Labeling
Cable Terminations
Cable Installation - General
Cable Installation Methods
40
41
41
42
43
47
5.7
5.8
5.9
5.10
Process Instrumentation
Control and Automation
Uninterruptible Power Supply (UPS)
Submissions by Contractor
55
73
83
83
1575 of 2461
MMRDA
SUB-SECTION 6B.5: INSTRUMENTATION CONTROL AND AUTOMATION
5.1
Introduction
This part covers the general requirements for the design, supply, installation,
inspection and testing of the instrumentation, Control, Automation and
Supervisory Control and Data Acquisition (SCADA/HMI) and associated plant
and materials.
5.2
Reference Standards
Unless otherwise approved, instrumentation shall comply with relevant quality

standards test procedures and codes of practice collectively referred to as
Reference Standards including those listed below in accordance with the
requirements detailed elsewhere in this specification.
BS
89-2:1990,
EN Direct acting indicating analogue electrical
600512:1989,
measuring instruments and their accessories.

IEC
60051-
2:1984
BS 1042 (Various)
Measurement of fluid flow in closed conduits.
BS 1646-1:1979, ISO Symbolic

3511/I-1977
representation
measurement
control
for
process
functions
and
instrumentation. Basic requirements

BS EN 837-1:1998
Pressure gauges. Bourdon tube pressure

gauges.
Dimensions, metrology, requirements and
testing
BS EN 60751:1996, IEC
Industrial platinum resistance thermometer
60751:1983
sensors
BS 3680 (Various)
Measurement of liquid flow in open channels.
BS 3693:1992
Recommendations for design of scales and

indexes on analogue indicating instruments
SECTION 6B5: ICA WORKS
PAGE 1 of 88
1576 of 2461
MMRDA
BS EN 60770-1:1999, Transmitters for use in industrial-process

IEC
control systems.
60770-1:1999
Methods for performance evaluation
BS 4675-2:1978, ISO Mechanical vibration in rotating machinery.

2954-
Requirements for instruments for measuring
1975
vibration severity
BS EN 60584-1:1996, Thermocouples. Reference tables

IEC
60584-1:1995
BS 5308 (Various)
Instrumentation cables
BS EN 60529:1992
Specification
for
degrees
of
protection
provided by enclosures (IP code)

BS ISO 11631:1998
Measurement of fluid flow. Methods of

specifying
flowmeter performance
BS
5863-1:1984,
IEC Analogue signals for process control systems.
60381-
Specification
1:1982
for direct current signals
BS
5863-2:1980,
IEC Analogue signals for process control systems.
60381-
Specification
2:1978
for direct voltage signals
BS EN 60654-1:1993, Industrial-process measurement and control

IEC
equipment.
60654-1:1993
Operating conditions. Climatic conditions
BS 6739:1986
Code of practice for instrumentation in

process control systems: installation design
and practice
BS EN 60073:2002
Basic and safety principles for man-machine

interface, marking and identification. Coding
principles for indicators and actuators
BS 1553 (Various)
Specification
for
graphical
symbols
for
general engineering
ISA-5.1-1984 - (R1992)
Instrumentation Symbols and Identification
ISA-5.4-1991
Instrument Loop Diagrams
PAGE 2 of 88
1577 of 2461
ANSI/ISA-7.0.01-1996
ANSI/ISA-18.1-1979
MMRDA
Quality Standard for Instrument Air

- Annunciator Sequences and Specifications
(R1992)
ISA-26-1968
Dynamic
Response
Testing
of
Process
Control
Instrumentation
ISA-37.1-1975
(R1982)
ISA-37.3-1982
(R1995)
- Electrical
Transducer
Nomenclature
and
Terminology
- Specifications and Tests for Strain Gage
Pressure
Transducers
ANSI/ISA-50.00.01-
Compatibility of Analog Signals for Electronic
1975 (R2002)
Industrial Process Instruments
ANSI/ISA-51.1-1979
- Process Instrumentation Terminology
(R1993)
ISO 9000 and 09004
Quality Systems
IEEE 60587
Power Supply Surge Protection
IEC 61131-3
Programming Languages for Programmable

Controllers.
IEC 61158-2
Communication Protocols
ISO 9075 (BS 6964)
Structured Query Language (SQL)
BS 5515
Documentation of Computer Based Systems
BS 7165
Recommendation for Achievement of Quality

in Software
BS EN 50081
Electromagnetic Compatibility
ISO 3511
Process measurement control functions instrumentation symbolic representation.
5.3
ISO-OSI
7 Layer Communication Model
IEEE 472-1974
Surge protection.
IEC-61850
Sub-station automation protocol
IEC-8705101
Modbus Protocol Conversion
PAGE 3 of 88
1578 of 2461
MMRDA
The Contractor shall provide a list of the reference standards used and shall
provide a compliance/non-compliance statement during the Bid submission and
FDS submission once the contract has been awarded. Failure to do so will be
treated as a non-responsive bid.
All standards which the Contractor intends to use but which are not part of the
above Standards or other listed Reference Standards, shall be submitted to the
Engineer for consent before any design against that standard proceeds.
5.4
Documents to be submitted during Bid Submission
1.
Include a complete Table of Conformance to each and every reference

standards or part of the specifications. Use a chart format with
specification part identified, indicate whether each part is in compliance,
a deviation or an exception to the specific part.
If an exception or
deviation, include a narrative description as to how the deviation or

exception can benefit the end-user of the system over that item
specified.
2.
Provide a block diagram of the proposed system showing all major

components and their interconnections and interrelationships. Label
each diagram and indicate all external power and communications
interfaces.
3.
Provide
written
overview
instrumentation system
of
the
proposed
SCADA
system,
describing the principal functions and
capabilities of the systems PC, PLCs, system communications and

general system capabilities (maximum number of network nodes, PLCs
and I/O points, communication protocols available, etc.).
4.
Provide an equipment list with descriptive literature for the proposed

system. Included on the list shall be all major hardware items. List shall
include as a minimum, the manufacturer, the quantity provided, and
model numbers for each. Technical schedules for instruments, PLC &
SCADA and Wireless communication systems shall be duly filled with
PAGE 4 of 88
1579 of 2461
MMRDA
relevant details.
5.
Provide an operating system and software applications list with

descriptive literature for the proposed system. Include all major software
items, supplier name, quantity, and model numbers. Indicate whether
any proposed software is proprietary and would not be turned over to the
owner.
Note: Proprietary software will not be accepted.
6.
Information is required for
Name and version of the proposed PCs operating system
Name and version of the proposed computer operator graphical

user interface software package (SCADA)
Name and version of the PLC on-line/off-line programming

software for all controllers
Name and version of any required communications software,

firmware, etc.
Name and version of the specified report application software,

operational data management software
Name and version of the specified maintenance application

software
Describe how system data points are linked from the system
database
into
maintenance.
various applications such
as reporting or
If via DDE (Dynamic Data Exchange) describe
specifically the steps required to import data automatically and

on-line into the proposed software applications
PAGE 5 of 88
1580 of 2461
MMRDA
Briefly describe the required procedure for configuration and/or

programming of the proposed system to add a simple remote PLC
and additional I/Os to the system in the future. Describe in detail,
specifically how communications are programmed for the future
remote PLC and the necessary changes required at the main
controller
Provide a description of any non-resident software required to

program, troubleshoot or diagnose any devices in the system
Provide a tentative construction schedule for completion of the

project within the specified Contract period. Indicate the following
activities with milestones: Mobilization, radio communications
licensing, submittal preparation, submittal review, equipment
procurement, equipment assembly, system configuration and
programming, factory testing, system delivery, system installation,
start up, field testing and training, and post acceptance routine
service intervals
Describe the system suppliers provisions for service, technical

assistance and re-placement parts for the proposed system.
Include the system suppliers 1-800-toll free number. Identify with
resumes, all personnel who will be providing technical support
services for the project after it is accepted.
The
Contractor
shall
details/documents
as
provide
qualification
the
criteria
above
required
during
the
bid
submission. Failure to do so will be treated as a non-responsive

bid and lead to technical disqualification.
The Contractor
should note the importance of the obligation.
5.5
Qualification
Automation
Criteria
for
Instrumentation
vendor/integrator
and
Vendor/integrator
The Manufacturers shall be operating under an accredited ISO 9001 or above

PAGE 6 of 88
1581 of 2461
MMRDA
Quality System. All hardware shall be of the most current technology and
Versions from the Manufacturer. All hardware and software shall be from the
system manufacturer.
The Instrumentation Manufactures / Suppliers shall be operating under an

accredited ISO 9001 or above Quality System. The instrumentation supplier
should have minimum 10 years of experience in India in the field of instruments
supply and service. They should have branch locally for service support at
Mumbai and should supply internationally reputed brands.
The SCADA /Automation sub-contractor shall be a reputed System

manufacturer or System integrator with a minimum of 10 years of experience of
having executed ICA projects within India or outside India and shall
demonstrate capability and resources for integrating/interfacing control systems
from different manufacturers as well as coordination with multiple agencies for
contract execution. They should have branch locally for service support at
Mumbai.
The system supplier must be an authorized system integrator for the named
PLC hardware/SCADA software supplier. Verification certificates shall be
submitted directly from the manufacturer of the PLC hardware/SCADA software
supplier. In addition, submit references for minimum of (5) locations where the
automation equipment has been successfully installed, including name,
address and telephone number for the appropriate utility person to contact.
The system supplier must submit evidence that they employ in excess of 25
personnel, including no less than 15 technical staff to include engineers,
programmers, and field technicians. Submit the qualification and license for a
minimum of five professional engineers in the direct employ of the system
supplier Identify with resumes all personnel who may be assigned the specified
project.
All hardware and software proposed shall have been successfully used in a
similar water application for a period of at least five (5) years and be from
established and reputable suppliers. Refer Approved Vendor List in Particular
PAGE 7 of 88
1582 of 2461
MMRDA
specifications of Instrumentation, Control & Automation (ICA) equipment.
Upgrades and improvements to the manufacturers standard system that are

released before the expiration of the warranty period shall be supplied, installed
and commissioned at no additional cost.
These shall include all hardware and software necessary to implement the
upgrade.
5.6
Design Requirements for Instrumentation, Control, Automation (ICA)

Equipment
The instrumentation, control, automation SCADA / HMI installations shall fully

comply with design standards, regulations and the material and workmanship
requirements of the Specification.
The electrical plant installations associated instrumentation control and

automation (ICA) equipment shall also comply with and be tested in
accordance with the latest edition of BS 7671 or equivalent Indian standards.
All equipment and materials incorporated in the system shall be selected,

designed and rated to operate under the defined performance duties and
specified site conditions and to maintain a high level of operational reliability.
The instrumentation control and monitoring system equipment and materials

shall have an operational life of not less than 15 years, unless otherwise
approved by the Engineer.
5.6.1 Site Conditions
A.
Temperature and Humidity Range
The equipment shall be installed in an environment having a

temperature range of 0 C to 55 C and a maximum relative humidity of
100 % (non- condensing). The Contractor shall use, where required,
PAGE 8 of 88
1583 of 2461
MMRDA
fans, heaters, and air conditioning units to maintain a correct working

temperature for his equipment. All Parts of the equipment shall be
constructed of materials or treated to prevent the formation of mould,
fungus or any corrosion over the temperature and relative humidity
ranges specified.
B.
EMI/RFI Noise Immunity
The equipment to be provided shall be adequately protected against

interference from the use of radio transmitters, at any point external to
the equipment housings and no malfunction of the equipment shall result
from this cause. Responsibility for the correct and reliable operation of
the
equipment shall rest with the Contractor, who must ensure that
the equipment is adequately protected against the ingress of radiated,

mains-borne signal-borne interference.
C.
Generated Interference
The Contractor shall ensure that the computer, instrumentation and

communications equipment conforms to BS EN 50081-1or equivalent
Indian Standard for noise emissions.
D.
Coordination
The Contractor shall check with other trades to ensure that equipment
and material can be installed in space provided. Provide other trades
with information necessary for them to execute their work. Details on
Drawings, which are specific regarding dimensions and locations, are for
information purposes. Coordinate with other trades to ensure work can
be installed as indicated.
E.
Sequencing
The Contractor shall make applications to the local telecommunications

Service Provider for provision of communications and coordinate with
PAGE 9 of 88
1584 of 2461
MMRDA
the sub contractor responsible for installation of power supply services

under this contract. Applications shall be made in time to ensure
services are available for installation and commissioning of the telemetry
equipment.
5.6.2 Enclosure/Panel Details
I.
Enclosures and Mounting Boards
Enclosures shall be any form of board, cabinet, panel, desk, box

or case used to protect, contain or group instrumentation,
telemetry or control equipment.
All equipment in or on enclosures shall be arranged logically and,

as far as possible, symmetrically, with projections kept to a
minimum. Each enclosure and board shall be designed on
ergonomic principles and shall permit in-situ and safe access for
any normal adjustment, maintenance and servicing. The tops of
plant-mounted enclosures shall be sloped downwards from front
to rear.
Enclosures mounted inside buildings shall have a minimum rating

of protection to IP 54.
Enclosures for use outside buildings or in places where splashing

may occur shall have a minimum rating of protection to IP 65 and
have tops which project sufficiently to protect the vertical faces of
the enclosure and any component mounted thereon from
splashing, inclement weather and direct sunlight. Also, when
enclosures for use outside buildings are located where exposure
to direct sunlight will give rise to high top-panel surface
temperatures such that the internal temperature rises above the
manufacturers recommendation (normally 40C), the enclosure
shall include a sun shield fitted to the top of the enclosure. The
sun shield shall prevent direct sunlight from reaching the
PAGE 10 of 88
1585 of 2461
MMRDA
instrumentation for the full day throughout the year, and shall
have louvered ventilation.
Fixing arrangements for surface-mounting enclosures shall be

external to the enclosure and shall ensure that the rear face of
the enclosure is not in contact with the surface to which it is fixed.
Enclosures shall have hinged access doors, fitted with recessed

lockable handles.
Doors shall be of rigid construction and provided with close-fitting

flexible seals in recesses to prevent the ingress of liquids,
moisture, dust and vermin. Hinges shall be of the lift-off pattern
and one hinge shall engage before the other for ease of fitting.
Wherever necessary, removable access covers secured by quickrelease fasteners shall be provided to ensure ease of
maintenance for all installed apparatus.
Mounting plates, brackets and racks shall be provided for all other
internal equipment which shall be hinged or otherwise arranged
with quick-release fasteners or captive screws to give quick and
easy access to equipment, securing screws, terminals and wiring.
Enclosures for two or more devices with electrical circuits shall

have gland plates and terminal blocks as specified elsewhere.
Each enclosure shall be designed for the safe testing and

servicing of equipment with the power on. Each part which may
be live under any circumstances shall be so covered or shielded
as to prevent inadvertent contact.
II.
Panel Design and Construction
Unless otherwise specified, all instrument panels, instrument

cubicles, control panels, control consoles and desks, associated
PAGE 11 of 88
1586 of 2461
equipment
and
MMRDA
terminal
racks,
telemetry
and
electronic
equipment racks and the like shall be free-standing, floor

mounted units and shall conform to the requirements of this part
and will hereafter be referred to as
panels.
The design and dimensions of control consoles and desks shall

be determined according to their intended function and shall be in
accordance with the requirements of the Specification. The height
shall not exceed 1400mm above the finished floor level.
Unless otherwise specified the height of panels shall be not

greater than 2130mm overall (excluding lifting devices) above
finished floor level.
Controls, switches and push-buttons shall be positioned below or

adjacent to any associated reading instrument. Panels for use in
locations such as pumping stations and machinery rooms shall
have anti-vibration mountings.
The clearance between the extremities of apparatus mounted on

the internal walls shall allow safe and unobstructed access to all
terminals and to parts requiring maintenance.
Panel layout drawings shall normally include a list of all

instruments, accessories and components contained therein. If
the drawings have insufficient space for the list, a separate
schedule of instruments, accessories and components shall be
provided and the panel drawing shall contain a cross reference to
the contents list and an indication of the panel location of each
item on the list.
III.
Panels - Major
Panels shall be constructed generally as specified in the

preceding clause. Panel material shall be prime-quality, coldSECTION 6B5: ICA WORKS
PAGE 12 of 88
1587 of 2461
MMRDA
rolled and annealed mild steel or zinc-coated mild steel sheet,

suitably braced and stiffened as necessary with flat bar or angle
to form a rigid structure.
Panel fronts shall be flat and free from bow or ripple. Exterior
corners and edges shall be rounded or welded and ground to give
a smooth overall appearance.
Flanged edges shall be straight and smooth.
Materials shall be chosen with due regard to the panel size,

number of cut-outs, instrument weight and position of center of
gravity and method of fabrication, with the following minimum
thickness:
Instrument bearing surfaces, gland plates and pneumatic

distribution plates, 3mm;
Internal mounting plates, 3mm;
doors, covers and filler panels, 2mm.
No design involving the use of externally-visible assembly or

fixing bolts and screws or any design resulting in dust or watercollecting crevices will be accepted.
When a panel is constructed in sections, the sections shall be

designed for ease of assembly during installation and, in any
case, shall not exceed 2m in length. All necessary nuts, bolts,
washers and the like shall be supplied and included in the same
shipment as the relevant sections. Sections exceeding 1m in
length shall be provided with double doors.
Each panel shall be mounted on a self-draining base frame

fabricated from 150mm deep, steel channel section which shall
be drilled or provided with clamps for bolting to the floor. The
PAGE 13 of 88
1588 of 2461
MMRDA
base frame shall be set back from the panel front face to give a
toe space of not less than 25mm. The outside of the base frame
shall be covered with an approved kicking strip.
Ceiling and other filler panels shall be fabricated from sheet steel
and adequately stiffened. Each section shall have 50mm
returned edges along all four sides and shall be braced to the
main steelwork of the panel.
A chequer-plate floor shall be provided inside and above the

level of the base frame, having openings suitable for the bottom
entry of cables when applicable.
Sufficient
removable un-drilled gland plates, in
sections
convenient for handling, shall be fitted close to the appropriate

terminal blocks and not less than 230mm above the panel floor
or not less than 230mm below the panel top. The gland plates
shall have removable side covers giving access to both sides of
the gland plate and ensuring vermin-proof and dust-proof
construction. Gland plates of a surface mounted enclosure may
form a part of the base or top.
Panels containing instruments using a fluid as the transmission

medium shall have distribution plates with bulkhead unions for
the termination of internal and external pipework.
All doors shall open outwards and all doors in one panel
assembly shall use the same lock and key combination.
Panel design shall ensure adequate ventilation and air

circulation without permitting the entry of vermin or dust. Panels
installed in control rooms or other clean condition areas shall
have louvres to allow air circulation. Temporary closures shall be
provided to prevent the entry of dust and vermin during transit
and installation. After commissioning has been completed, all
PAGE 14 of 88
1589 of 2461
MMRDA
entries except air circulation louvres shall be sealed.
No equipment other than front-of-panel items shall be mounted

on panel wall surfaces.
If electrical and non-electrical instruments are mounted in the

same panel, the panel shall be subdivided internally to separate
the electrical and non-electrical sections.
All connections shall be arranged to ensure that no accidental

damage to cabling or electrical components can occur in the
event of failure of any non-electrical component or connection.
Provision shall be made for safe and easy handling during transit
and installation.
If lifting eyes are provided, they shall be reversible and panel

tops shall be reinforced where necessary.
Where equipment is specified to be installed at a future date,

space shall be allocated, and cut-outs with removable masking
plates, brackets, supports, wiring, terminals and piping and the
like shall be provided.
Panels shall be finish-coated at the place of manufacture before

commencing the installation of apparatus and other fittings.
IV.
Panels - Minor
Panels for installation on the Plant which contain relatively few

items of equipment, or where so specified elsewhere, shall be
classed as minor panels and shall be constructed generally as
specified in the preceding clause and comply with this Clause.
Panels shall be fabricated from sheet steel or other approved

PAGE 15 of 88
1590 of 2461
MMRDA
material less than 2.5mm thick suitably braced to form a robust

and rigid structure. Exterior corners and edges shall be rounded
to give a smooth overall appearance and assembly bolts,
screws or rivets shall not be visible on the front face.
The design shall be such as to ensure adequate ventilation and

air circulation where required, without permitting the entry of
vermin. Openings for cables shall be made vermin-proof. Doors
shall be hinged and shall be provided with close-fitting flexible
seals in recesses to prevent the ingress of liquids, moisture,
dust and vermin. Unless otherwise specified, panels shall be
suitable for floor mounting and shall not exceed 2130mm in
height. Where surface-mounted panels are provided, the fixing
shall prevent the ingress of moisture and the rear of the
enclosure shall be not less than 10mm from the wall.
Lifting eyebolts shall be removed, issued to the Purchaser and

subsequently replaced with bolts after installation.
Panels shall be extensible, and symmetrically arranged as far as

possible with projections kept to a minimum. Where two or more
panels are fitted together, they shall form a flush-fronted
continuous panel of uniform height. Front door and top cover
dimensions shall match. Instruments, relays, and control devices
shall be mounted at a height not more than 2000mm and not
less than 300mm from floor level.
The arrangement of equipment within each enclosure shall be

such as to permit easy access for installation and maintenance.
No instruments, relays or other components shall be mounted
on rear access doors or removable covers.
V.
Panels - Composite
In situations where space limitations preclude the use of

PAGE 16 of 88
1591 of 2461
MMRDA
separate instrumentation, control and automation (ICA) and

switchgear panels and, at the sole discretion of the Engineer,
ICA equipment may be combined within a single enclosure
subject to the following conditions:
The observance of all other clauses herein relating to

enclosures, mounting boards and minor panels;
The written assurance of each supplier of ICA equipment that

the proximity of the switchgear will have no detrimental effect
on the life or performance of any ICA component;
The total segregation of ICA equipment and switchgear

including the glanding and termination facilities;
The absence of any voltage exceeding 250vac or 50vdc from

any compartment containing ICA equipment;
The use of the full height of the panel (excluding the bus bar
chamber and Cable space) for any ICA equipment
compartment.
VI.
Panel Protection
Adequate facilities for isolation and protection by miniature

circuit breaker or fuse for each instrumentation and control
circuit and sub-circuit shall be provided and shall be so arranged
that any interruption causes minimum disruption of plant,
operates the appropriate alarm and cannot result in any unsafe
operating condition.
All fuses shall be of the cartridge pattern and main fuses shall
be of the high rupturing capacity type. Fuse and solid-link
carriers and bases shall be of plastic molded insulating material
of an approved make. Ceramic materials will not be accepted.
Live connections shall be efficiently shrouded and it shall be
PAGE 17 of 88
1592 of 2461
MMRDA
possible to change fuses with power on without danger of

contact with live metal. The fuses shall be rated to give
maximum protection to the equipment in circuit and the rating
shall be permanently inscribed on the fuse label and on the fuse
carrier. Unless necessary for the protection of particular
equipment, miniature circuit breakers used for individual circuits
in a panel or control desk shall not trip on over-voltage or undervoltage.
Bases for solid links shall not be interchangeable with those for
fuses. Fuses and links in the same circuit shall be mounted
opposite each other in separate adjacent rows and shall not
alternate in the same row. At least 10% and not less than two
unallocated miniature circuit breakers or fuses and links shall be
provided in each panel distribution board. Miniature circuit
breakers and fuses of similar size and rating shall be of the
same make and type.
At least 10%, and not less than two, spare fuses and links of
each rating shall be provided and fitted in clips inside the panel.
Each instrument requiring a power supply shall be individually

wired and protected so that, in the event of a failure in one
circuit, the remainders are unaffected. Power supply circuits
shall be of sufficient rating that any protective device may
operate without reducing the voltage at the terminals of any
other component to an unacceptable level.
VII.
Panel Isolation
Clearly-labelled isolating circuit breakers shall be provided for

each incoming power supply. Switches shall be of the quick
make-and-break type with spring loaded contacts that close fully
without requiring full operation of the handle. The handle and
cover shall be interlocked so that the handle cannot be operated
PAGE 18 of 88
1593 of 2461
MMRDA
when the cover is open and the cover cannot be opened unless
the switch is in the off position. The on and off positions of
each switch shall be indicated clearly.
Circuit breakers for panel power supplies shall be mounted near

an access point and in positions where they may be operated
easily from a standing position.
Plug-in isolating links or devices of an approved type shall be

provided in any circuit that may still be live when the power
supply isolators are in the off position, as, for example, in
circuits
controlling
equipment
whose
power
supply
is
independent of the panel. Such links or devices shall be properly

screened and, if not incorporated in or adjacent to their
associated outgoing terminals, shall be labeled with suitable
warning notices.
Any item of panel equipment to which panel internal wiring is

connected with a plug and socket instead of terminals shall be
wired in flexible cable of adequate rating between the free plug
and a socket mounted adjacent to the device.
The power supply connector shall be a socket.
VIII.
Panel Terminal Blocks
External wiring for panel power supplies shall be terminated on

the appropriate isolator. Signal cables from strain gauges,
analysers, resistance thermometers, retransmitting slide-wires
and thermocouples may be terminated at their appropriate
instruments.
A terminal block shall be provided as the interface between the

corresponding conductors of each internal and external wire and
each internal and external connection except those listed above.
The terminal blocks shall be mounted vertically where possible
PAGE 19 of 88
1594 of 2461
MMRDA
and not nearer than 230mm to the floor or less than 230mm
from an incoming cable gland.
Terminal block rows shall be spaced apart by not less than

150mm and arranged to permit convenient access to wires and
terminals and to enable ferrule numbers to be read without
difficulty.
Other circuits shall be grouped on the terminal blocks according

to the classification given in the clause for Panel internal wiring
which shall be clearly marked along the corresponding section
of each terminal board. Groups of different voltages on the same
board shall be separated by insulated barriers.
All connections shall be made from the front of terminal blocks

and no live metal shall be exposed at the back. All terminal
blocks shall be of the type which clamps the wire securely and
without damage between two plates by means of a captive
screw and which permits removal of any terminal without
disturbance to adjacent terminals. Pinch-screw type terminal
blocks will not be accepted. Terminal moldings shall be in
melamine to BS 1322, polyamide or equivalent. Terminal rails
shall be hot-dip galvanised. Current bars between the two
connection points of each terminal block shall be of copper or
brass with tin/lead alloy plating. All steel parts shall be zincplated and passivated with a yellow chromate layer. Terminal
blocks for input and output analogue signals and for circuits
containing volt-free contacts internal or equivalent which permit
the connection of a test milliammeter or continuity meter without
disconnecting any wiring. Terminal blocks for power supplies for
equipment external to the panel shall permit the isolation of the
item of external equipment without affecting the operation of any
other circuit within or outside the panel.
No more than one core of external cables or two internal wires

PAGE 20 of 88
1595 of 2461
MMRDA
shall be connected to any terminal. If terminal blocks are used

as common points for two or more circuits, individual terminals
with the appropriate number of permanent cross connections
shall be provided. The lengths of exposed cable cores shall be
sufficient to reach any terminal in the appropriate row or rows.
The cores shall be formed into a neat loom and a separate loom
shall be provided for each cable.
Each row of terminal blocks shall contain at least 25% spare

terminals over the number required for terminating all cores of
external cables in that row. Unless otherwise specified, each
external cable shall contain at least 20% spare circuits, with a
minimum of one spare circuit.
Terminal blocks shall be numbered consecutively in a sequence

different from that used for identifying wiring. The terminal
numbers, voltage grouping and terminal board layout shall
correspond precisely with wiring diagrams so that quick and
accurate identification of wiring can be made.
All the terminal boards shall be provided with covers of

transparent insulating material that does not sustain combustion
and shall be sectionalized where possible to give access to
groups of terminals without uncovering all boards. Terminals
which may be live when the panel is isolated from its main
supplies shall be suitably labelled to minimize the risk of
accidental contact.
IX.
Panel Internal Wiring
Panel circuits shall be segregated into the following categories:
Group 1: Power control and very-high-level signal wiring (above

50V):
1.1 ac power supplies;
PAGE 21 of 88
1596 of 2461
MMRDA
1.2 dc power supplies;

1.3 ac current signals above 50mA (such as CT circuits);
1.4 ac voltage and control signals above 50V (such as PT
circuits).
Group 2: High-level signal wiring (6V to 50Vdc):

2.1 signals from conventional electronic transmitters and
controllers (such as digital or 4mA to 20mA);
2.2 circuits to alarm annunciators and other solid-state devices
2.3 digital signals;
2.4 emergency shut-down and tripping circuits;
2.5 on/off control circuits;
2.6 intrinsically safe circuits;
Group 3: Low-level signal wiring (5V dc and below):

3.1 signals from thermocouples;
3.2 signals from resistance thermometers and re-transmitting
slide-wires;
3.3 signals from analytical equipment and strain gauges.
For Group 3 wiring, internal connections to the instruments shall

be made by one of the following methods:
a) The twisted, screened conductors of the external cable shall

be led direct to their appropriate instruments via ducting
systems installed for this purpose during construction of the
panel;
b) The conductors of the external cables shall be terminated on

terminals segregated from all other categories and the
connections to the appropriate instruments shall be made
using twisted pairs with individual screening installed for this
purpose during construction of the panel.
Internal wiring for all circuits in Group 2 except those sharing a

PAGE 22 of 88
1597 of 2461
MMRDA
common connection shall be multi-stranded, twisted pair,

0.75mm minimum copper conductor with HPDE or PVCinsulated cable of adequate grade and rating.
Wiring for circuits in other Groups or sharing a common

connection shall be run in stranded, 1.5mm minimum copper
conductors with 250V grade, PVC-insulated cable of adequate
grade and rating.
Wiring sheath colors shall be black for ac circuits, and grey for
dc circuits (excluding thermocouple circuits) and blue for Group
2.6 circuits. Circuits supplied at 240V, between 240V and 110V
dc shall also be physically segregated from each other and from
other circuits. Access to wiring and components of circuits
having voltages exceeding 240V shall not be possible unless
and until the circuit has been isolated.
Separate ducts, trunking, cable looms, tray work and the like
shall be provided within the panel for each category with at least
150mm between parallel paths of Group 1 and those of any
other Group. Intrinsically-safe circuits and their terminals shall
be segregated from other circuits and terminals.
All wiring shall be neatly and securely fixed by insulated cleats,

bunched and secured by approved plastic strapping or run in
approved insulated wiring trunking or non-corrodible flexible
tubing. Not more than 75% of the capacity of trunking, ducts,
looming, or tubing shall be used. Insulated earth wiring shall be
so arranged that access to any equipment or connection point or
the removal of any item of equipment is unimpeded.
Wiring for future equipment shall be secured and terminated on

terminal blocks. Lacing for wiring looms shall be of rot-proof cord
or plastic strips. Inter-section wiring in multi-section cabinets
shall be via a terminal block in each section.
PAGE 23 of 88
1598 of 2461
X.
MMRDA
Panel Wiring Identification and Termination
Identification ferrules shall be fitted at both ends of each wire.

The numbers or letters used shall correspond with the
appropriate wiring diagram. The ferrules shall be of plastic
insulating material with permanent black characters on a color
coded background for numbers and on a white background for
letters, unaffected by oil or water. They shall be so arranged that
they can be read logically from left to right when viewed
normally.
The system of wire identification shall be such that wires in the

same circuit on opposite sides of a terminal shall have the same
reference, and this system shall be continued through all
external cabling.
Terminal ferrules (spade, tongue, crimped connections) shall be

provided on each conductor.
XI.
Panel Earthing
A continuous copper earth bar of not less than 25mm x 6mm

cross section shall run the full length of each panel and shall be
securely fixed and bonded electrically to the main frame. The
cable gland-plates and the earth bar shall be provided with
suitable brass terminals of not less than 6mm diameter for
connecting the metal cladding or armouring of all incoming and
outgoing cables to the station earthing system.
A second continuous copper earth bar of not less than 25mm x

6mm cross section, electrically isolated from the steelwork of the
panel and metal cladding and armouring of cables, shall be
provided for earthing the signal earth connection of each
instrumentation and control device and the screen(s) of each
PAGE 24 of 88
1599 of 2461
instrument
cable
MMRDA
not
earthed
elsewhere
to
the
station
instrumentation earth plate. The earth bar shall have sufficient

brass terminals as specified above for each instrumentation and
control device and the screen of every shielded cable plus 25%
spare terminals. In multi-section panels, each earth bar shall be
electrically bonded to the corresponding bars in the adjacent
section(s).
The earth pit for instrumentation system shall be separate.

Electric earth pit shall not be used for earthing of instrumentation
equipment. All signal cable screens (analogue and digital) shall
be terminated onto the instrument earth bar.
Signal cable
screens shall be earthed at the control panel end only. Screens

at the field end shall be tied back and insulated.
SPDs (Surge Protection Device) associated with the control and

instrumentation system shall be earthed to the instrument earth
in accordance with the SPD manufacturers recommendations.
XII.
Panel Lighting
Each panel shall be adequately illuminated internally, as evenly

and as free from dazzle as possible, by fixed fluorescent lighting
controlled from totally-enclosed light switches and by totallyenclosed door-operated switches positioned so as not to
interfere with access. There shall also be one installed
inspection lamp per three metres of panel length or part thereof
with adequate flexible connection cable to reach any point in the
panel. The control switch for an inspection lamp shall form part
of the lamp assembly. Lighting circuits shall be fused
independently of any instrumentation and control circuit and
designed to allow lamps to be replaced safely and shall be fed
from a distribution board and circuit breaker connected on the
live side of the main panel ac supply circuit breaker.
PAGE 25 of 88
1600 of 2461
XIII.
MMRDA
Panel Ventilation
Each panel shall be provided with ventilation fans as required to

ensure that equipment within the panel is maintained within
manufacturers recommendations, with due regard to the
environment in which the panel will be mounted. Fans shall be
controlled by a suitably-labelled enclosed switch mounted
internally in an accessible position.
Fans shall be mounted with their axes horizontal and shall be

arranged to draw clean air into the panel. Air entries shall have
filters which can be renewed from outside the panel and shall be
designed to prevent the entry of rain, spray, injurious fluids,
sand or dust.
XIV.
Panel labels
All control gear shall be fully labelled with the KKS code
identifying the equipment designation/function, all external and
internal components, all rating data, detailed equipment
operating data and for danger and hazard warning.
Labels shall be provided for every panel to describe the duty or

otherwise identify the panel and its sections and every
instrument, component and item of equipment mounted
internally and externally. Where applicable, front-of-panel labels
shall be as detailed in the Specification. Wording shall be clear,
concise and unambiguous and shall be subject to review by the
Engineer before manufacture. Each label shall be permanently
secured to the surface near the item to which it refers.
Externally-fitted labels shall be of Perspex or other approved
transparent plastic, with letters and numbers rear-engraved and
filled with black.
The rear surface of each Perspex label shall be finished with a

PAGE 26 of 88
1601 of 2461
MMRDA
coat of paint of the same colour as the panel external finish.

Instrument duty labels fitted externally shall be below the item to
which they refer. Embossed tape or similar adhesive labels will
not be approved.
Laminated materials or rear-engraved and filled plastic shall be

used for internally fitted labels, which shall be white with
engraved black letters.
Labels conforming to the requirements of the preceding

paragraphs or other approved means shall be provided:
To describe or identify circuits or circuit components;
To identify dc polarity;
To warn or remind about dangerous or potentially-dangerous

circumstances;
Wherever elsewhere specified.
Unless otherwise specified, all engraving shall be in plain block

letters, 4mm high.
The minimum practicable number of different sizes shall be

used.
Manufacturers nameplates shall not be fitted on panel external
surfaces.
XV.
Panel finish
For control and instrument panels, desks and cubicles a hard,

smooth, durable finish, free of blemishes, shall be provided.
Before painting, all external welds and any rough areas shall be
PAGE 27 of 88
1602 of 2461
MMRDA
smoothed, and all surfaces shall be thoroughly cleaned and free

from scale, contaminates, corrosion or grease. If rust-proof or
Zintec steel has not been used in the construction, the panel
shall be treated with a passivating agent such as phosphoric
acid. All internal surfaces shall have a minimum of three coats of
paint of which the first shall be an approved anti-rusting priming
coat and the final coat shall be an opaque gloss white enamel.
All external surfaces shall have not less than five coats of paint
of which the first shall be an approved etch-priming coat, and
the second and third suitable undercoats, all of which shall be
rubbed smooth when dry before application of the next coat. The
undercoats shall be easily distinguished in shade or colour from
the priming and finishing coats. The two final coats shall be of
stove enamel paint, gloss or semi-matt finish, to a colour and
finish to be advised by the Engineer. Stoving shall be carried out
in
accordance
with
the
recommendation
of
the
paint
manufacturer.
The overall dry film thickness (DFT) shall be between 85 and

120 microns.
Nuts, bolts, washers and other fixing devices which may have to
be removed for transit or maintenance purposes shall be
galvanized or otherwise finished to an approved standard.
5.6.3 Instruments and ancillaries
a) General
All instruments, gauges and control equipment which perform

similar duties shall be of uniform type and manufacture throughout
the Works in order to facilitate maintenance and the stocking of
spare parts.
All equipment shall be fully tropicalised and suitable for the worst
PAGE 28 of 88
1603 of 2461
MMRDA
environmental operating conditions. Panel-mounted instruments

shall be of the electrically operated flush mounted type and shall
have damp-proof and dust-proof cases.
Instruments
mounted
outside
instrument
panels shall have
weatherproof and dustproof cases. Instrument cases shall be of

corrosion-resistant material or finish.
Instrument screws (unless forming part of a magnetic circuit) shall

be of brass or bronze. Access to terminal compartments of
instruments mounted outside panels or other enclosures shall not
expose any working part. Moving parts and contacts shall be
adequately protected from the ingress of dust. Where applicable
instruments shall be easily withdraw able from its housing for
maintenance without interrupting its signal.
Unless otherwise specified, instruments shall be finished in the

manufacturers standard color. Instrument dials shall be of such
material that no peeling or discoloration will take place with age
under tropical conditions.
Plant-mounted indicators and gauges shall be sized to give full

legibility when viewed from a position with convenient and easy
access or from the point at which any operation requiring
observation of the gauge is performed. The minimum diameter for
any gauge shall be 150mm except where forming part of standard
instruments and accessories such as air-sets.
Dials and bezels shall be of bronze and internal components shall

be of stainless steel, bronze or other corrosion-resistant material.
Unless otherwise specified, all functions shall be transmitted

electrically and all analogue signal-transmission systems shall be in
accordance with BS 5863: Part 1 or equivalent and shall use a
signal of digital or 4mA to 20mA dc. Where possible, measuring
PAGE 29 of 88
1604 of 2461
MMRDA
systems shall be designed so that any necessary power supply is

taken from the appropriate instrument panel.
Transmitting devices shall have integral indicators to monitor the

output signal or connections suitable for use with a portable test
meter, and shall be capable of meeting the performance
requirements specified in the appropriate part of BS EN 60770-1or
equivalent. For the important and critical processes the transmitting
devices, such as pressure, temperature and level gauges, shall
have a reference gauge installed locally for easy reference for the
operation and maintenance staff. The transmitters shall be provided
with LCD meters.
Equipment mounted in enclosures shall be suitable for continuous

operation at the maximum internal temperature possible in service,
due account being taken of internally-generated heat and heat
dissipated by other plant. All components shall be rated adequately
and circuits shall be designed so that change of component
characteristics within the manufacturers tolerances shall not affect
the performance of plant. All equipment shall be designed to
operate without forced (or fan) cooling.
Equipment provided with anti-condensation heaters shall be

capable of operating without damage if the heaters are left on
continuously. Unless provided with unalterable factory configured
ranges,
measuring
instruments
shall
have
zero
and
span
adjustment.
Field mounted instruments shall be mounted such that they are

easily viewable and easily accessible for maintenance.
Instruments not mounted in panels shall be supplied complete with

all brackets, stands, supporting steelwork and weatherproof
enclosures (separate from the instrument cases) necessary for
securing them in their working positions and affording complete
PAGE 30 of 88
1605 of 2461
MMRDA
protection at all times including periods of servicing, adjustment,

calibration and maintenance.
Each installation shall incorporate a valve and pipework for

obtaining a sample representative of the fluid at the position of the
permanent meter and drain. If the measuring and sampling points
are remote from each other, the test and sample facilities shall be
provided at both points.
In order that maintenance and inspection may be carried out safely

and conveniently instruments mounted in elevated and open work
areas shall be provided with safety ladders and a sufficiently sized
working platform with sun shading.
b) Indicating Instruments and Meters
All instruments and meters shall be flush mounted and generally of

the same pattern and appearance throughout and those which
perform similar duties shall be of uniform type and manufacture.
Indicating instruments shall be fitted with an externally accessible

zero adjuster. They shall have no parallax error and their normal
maximum reading shall be approximately 60% full scale deflection.
Ammeters in motor starter circuits shall be capable of withstanding

the starting current and shall have a compressed overload scale.
The ammeter shall have an adjustable and sealable red pointer set
to indicate normal full load current. The ammeter physical size shall
be in keeping with the size of the starter concerned. The minimum
size to be used is 0.25 DIN.
Indicating instruments shall comply with IS 1248, BS 89 or IEC

60051 and shall be of industrial grade accuracy.
Kilowatt-hour meters shall comply fully with IS 722 or BS 5685

PAGE 31 of 88
1606 of 2461
MMRDA
Class 2 and shall have industrial grade accuracy (2.5%). Three

element units shall be used for 3 phase 4-wire systems. Two
element units shall be used for 3 phase, 3-wire systems.
c) Indicator Lights
Indicator lights shall be not less than 20 mm diameter and shall be

panel mounted types with metal bodies adequately fastened so that
the lamps shall be capable of replacement from the front of the
apparatus without disturbance to the lamp holder or panel wiring.
Lamp holders shall be keyed into panels to prevent rotation. Lens
colours shall comply with BS EN 60037 as follows:
power on
white*
green
tripped/alarm
red
status (open, closed, etc)
blue
ready to start
blue
warning (no imminent danger)
amber
running
Note:*white may be used where doubt exists as to which other

colour to use.
The lights shall be under-run to give long life either by use of a

resistor to limit voltage to 90% normal value or by using higher
voltage lamps.The indicating lamps on control panel shall be
cluster of LED's.
d) Pushbuttons
Colours of pushbuttons shall generally comply with IS 6875, BSEN

60947, 60037 or IEC 60073 and in particular shall be as follows:
Stop, emergency stop
red
PAGE 32 of 88
1607 of 2461
MMRDA
Start
green
jogging/inching
black
reset (when not also acting as a -
blue
stop)
lamp test
blue
override/alarm accept
yellow
5.6.4 Cabling
a) Instrumentation Cabling
Cables from conventional measuring transmitters and analogue

process controllers, such as digital or 4mA to 20mA dc output from
a constant-current source, (hereinafter referred to as high-level
signals) shall be polyethylene or PVC insulated with stranded
conductors and laid up as twisted pairs with one twist per 30mm
approx. Each cable shall have an overall screen of braided copper
or Mylar backed aluminum foil giving a minimum coverage of 85%,
a steel wire armoring insulated from the screen and from any
ducting and an overall PVC sheath. For runs exceeding 30 meters
or for all inputs to a data logger, computer or microprocessor, multicore cables shall have an individual screen of braided copper or
Mylar-backed aluminum foil for each signal pair. The minimum
conductor size shall be 24/0.2mm but shall be of greater crosssectional area if required for the satisfactory operation of associated
plant. Cables for intrinsically safe systems shall comply with BS
5308 and the relevant certificate.
Cables from strain gauges, analyzers and the like, such as 0 to

100mV (hereinafter referred to as low-level signals see also
below) shall be as specified above and shall have an individual
screen for each signal pair.
Cables from indicating devices to alarm or tripping circuits shall be

as specified above for high-level signals but shall use cables, cable
PAGE 33 of 88
1608 of 2461
MMRDA
trays, ducts and conduit separate from those for other high-level
circuits.
Cables
for
high-level
signals,
low-level
signals,
resistance
thermometers and thermocouples shall be segregated from each

other and each shall be separated from cables for power,
communications and other electrical services. Other cables run in
the vicinity of instrumentation cables shall be twisted at the rate of
one twist per 50mm approximately and shall be separated from
instrumentation cables by a distance of not less than 300mm.
Initiating devices for plant protection and personnel safety shall be

connected by individual cables direct to the tripping or safety device
and shall not be routed via any intermediate junction, marshalling
box, cabinet, relay or similar. The outer sheaths of such cables shall
be coloured orange.
Technical Particulars:
(a)
Contractor shall include in his scope the supply, laying of
cables and
(b)
associated civil/mechanical work.
Cables shall be capable of satisfactorily withstanding without

damage, transportation to site, installation at site, and
operation under normal and short circuit conditions of the
various systems to which the respective cables are connected
when operating under the climatic conditions prevailing at the
site as indicated in this specification.
(c)
Cable joints in instrument signals and power supply cables

shall not be permitted.
(d)
Cables shall be capable of satisfactory performance when laid

on trays, in trenches, conduits, ducts and when directly buried
in the ground.
PAGE 34 of 88
1609 of 2461
(e)
MMRDA
Cables shall be capable of operating satisfactorily under the

specified power supply system voltage and frequency
variation.
i)
Cables for Analogue Signals
The cables shall comply with the following requirements:
Cables of 1100V grade, multi-pair/multi-triad cable, annealed,

tinned, high conductivity, 1.5 sq. mm. stranded copper
conductor, extruded PVC insulated two/three cores twisted
into pair/triad, laid up collectively, individual pair/triad shielded
and overall shielded with aluminium mylar tape, ATC drain
wire run continuously in contact with aluminium side of the
tape, inner sheathed with extruded PVC,
armoured with
galvanised steel wire and overall sheathed with extruded PVC

conforming to IS 1554, IEC 189 & BS 5308 shall be used for
analog signals.
ii)
Cables for Digital Signals
Cables of 1l00V grade, multi core cables, annealed, tinned,

high conductivity, 1.5 sq. mm. stranded copper conductor,
extruded PVC, overall shielded with aluminium mylar tape,
inner sheathed with extruded PVC, armoured with galvanised
steel wire, overall sheathed with extruded PVC conforming to
IS 1554,IEC 189 & BS 5308 shall be used for digital signals.
iii)
Cables for Instrument/Equipment Power Supply
PAGE 35 of 88
1610 of 2461
MMRDA
Cables of 1100V grade, multicore cable, annealed, tinned,

high conductivity, 2.5 sq. mm. stranded copper conductor,
extruded PVC, inner sheathed with extruded PVC, armoured
with galvanised steel wire, overall sheathed with extruded
PVC conforming to IS 1554, IEC 189 & BS 5308 shall be
provided for Instrument/Equipment power supply.
b) Telemetry Cabling
Telemetry cabling between a master station and an outstation,

unless otherwise specified, shall consist of a minimum of 6 signal
pairs, of which two pairs shall be allocated to the telemetry system,
one pair shall be allocated to a speech circuit and three pairs shall
be spare. Each conductor shall be multi-stranded with an equivalent
diameter of not less than 0.9mm. Conductors shall be laid up in
starquad formation. The dc resistance of any pair of conductors
shall not exceed 55 ohms per loop Km at 10C and the difference
between the resistances of the conductors of any pair shall not
exceed 0.5% of the loop resistance of that pair. Telemetry cables
shall be designed for burying in water-logged ground.
Conductors
shall
be
plain
annealed
copper
with
aluminium/polythene laminate sheath moisture barrier, copper or

brass tape pest barrier, single galvanised steel wire armour and
overall polythene sheath. The cable shall have a solid filling of
petroleum jelly.
The characteristic impedance of each signal circuit shall have a

nominal value of 600 ohms at 800Hz and the circuits shall be
suitable for signal input levels of between 30dbm to +4dbm (0dbm
= 1mW into a load of 600 ohms). The overall attenuation between
the terminations of any circuit at the mean frequency of the band
width specified elsewhere shall not exceed 20dbm and the
attenuation at any two frequencies within this band width shall not
differ by more than 6dbm. The transmission time for any two
PAGE 36 of 88
1611 of 2461
MMRDA
frequencies within the band width specified elsewhere shall not

differ by more than 1 / (4 % B) seconds, where B is the transmission
speed in bauds, as specified elsewhere.
The signal-to-noise ratio within the bandwidth specified elsewhere

shall be better than 12db. The frequency of any received signal
shall not differ from the frequency of the corresponding transmitted
frequency by more than 1% of the transmission speed in bauds
specified elsewhere.
Loading coils as necessary to meet the performance requirements

detailed herein shall be supplied and installed at equally-spaced
points.
i) Fiber optic cable
To facilitate the proper and efficient co-ordination of the Works the

Contractor shall sublet all Cabling Works to one Sub-Contractor
who has proven and successful experience in fiber optic cable
installations on projects similar to the one now proposed.
If cable sizes are not indicated on Drawings or in schedules,

determine the correct size based on total end to end signal
attenuation not to exceed 40 dB, including all splices and
termination losses, and after taking into consideration.
a) Type of fiber
b) Ambient conditions
c) Method of installation
d) The disposition of each cable relative to others
All cables and wires shall be suitable for installation and continuous
PAGE 37 of 88
1612 of 2461
MMRDA
services in the ambient conditions described elsewhere in this

document.
Shop Drawings and Product Data shall be submitted for the

approval of the Engineers as follows;
Submit full technical details of each type of cable proposed
Submit copy of test certificates from the manufacturer or an

independent testing authority confirming that cables comply with
the specification
Submit exact route of the cable run and relevant Sections in the
shop drawings
Each drum length of cable shall be allotted a distinct and separate

reference number. This number shall appear on the test certificate
covering the respective length of cable and shall also be clearly
marked on the cable drum.
The Contractor shall advise the Engineer upon delivery to site of

each drum length, quoting the reference number, the test
certificates shall be handed to the Engineer for examination and
approval.
All cables shall be delivered to site with the manufacturer seals,

labels or other proof of origin intact. These labels and seals shall not
be removed until the cable is required for use and shall be retained
for inspection by the Engineer.
The Contractor shall be responsible for the off-loading and handling

of the cables on site, and shall ensure that cables are delivered to
site on drums and properly protected against mechanical damages.
Where lengths are cut from cables, the open ends shall be sealed.
PAGE 38 of 88
1613 of 2461
MMRDA
The contractor shall be aware of the need to supply and install all
cables for this Contract which is most suitable for the special
environmental conditions prevailing in this project.
The cable shall comprise 8 fibers, loose tube, two fibers per tube
with central 1.5 mm nominal steel central strength member, moister
barrier, steel tape armored in continuos lengths up to a maximum of
6.0 km or as dictated by cable joint chamber locations and route
survey.
Single Mode
Type of fiber
Single mode, doped silica
Core Diameter
9.0 0.5 micro m
Cladding Dia
125 2.0 micro m
Coating
(outer) 250 15 micro m Material UV curable
Diameter
acrylate
Numerical aperture
0.11 micro m
Attenuation
<0.4 dB/km @ 1300 nm <0.2 dB/km @

1500 nm
Bandwidth
1000 MHz @ 1300 nm
Chromatic Dispersion
3.5 ps/nm x km @ 1300 nm 20 ps/nm x km

@ 1500 nm
Operating temperature
-30 to +80 deg. C
range
Crush resistance
>200N/cm
Weight
500 kg/km (maximum)
Tensile strength
2000 N (minimum)
Multi mode
Type of fiber
Multi mode, doped silica
Core Diameter
62.5 3.0 micro m
Cladding Diameter
125 2.0 micro m
Coating (outer) Dia
250 15 micro m Material UV curable

acrylate
Numerical aperture
0.275 + 0.15 micro m
PAGE 39 of 88
1614 of 2461
Attenuation
MMRDA
<3.2 dB/km @ 1300 nm <0.9 dB/km @

1500 nm
Bandwidth
500 Mhz x km @ 1300 nm
Operating temperature
-30 to +80 deg. C
range
Crush resistance
>200N/cm
Weight
500 kg/km (maximum)
Tensile strength
2000 N (minimum)
5.6.5 Cable Termination Boxes
Cable termination boxes shall have double-ended screw terminals with

removable links to facilitate core isolation during testing. Each box shall
contain sufficient terminals for every conductor plus 20% spare
terminals. Cable termination boxes shall have cable sealing chambers
and insulated glands with earthing terminals so that the armouring may
be earthed or isolated from earth, as circumstances dictate.
Termination boxes for use within buildings shall be of sheet steel with
hinged or removable front covers. All other termination boxes shall be
cast steel or heavy gauge sheet steel construction giving protection to
IP55. All termination boxes shall be hot-dip galvanised or approved
equivalent finish. Each terminal box shall have a removable, un-drilled
gland plate and the Contractor shall supply and fit the requisite number
of cable glands.
At each cable termination box, each cable core (including spares) shall
be identified by a numbered slip-over type collect. The numbering for a
particular cable core shall be the same throughout its length.
Cable joints shall be at points approved by the Engineer.
Each cable joint shall be of the straight-through type. The conductors

shall be ferrule-jointed with the insulation maintained by heat-shrink
sleeving. Joint closure shall be made with epoxy resin and the
PAGE 40 of 88
1615 of 2461
MMRDA
completed joint shall be impervious to water if submerged or in

waterlogged ground. If cast iron joint boxes be used, they shall be
provided with cable glands and, after installation and testing, shall be
covered with Densomastic HD compound or equal; so that all sharp
corners, bolts and projections are moulded to a smooth surface. Two
lappings of Densopol grade ZN 50mm tape, or equal, shall then be
applied overall. Jointing shall be carried out on each conductor,
including any provided in excess of the minimum quantity specified. All
materials and things of every kind required for the cabling jointing shall
be provided by the Contractor.
5.6.6 Junction Boxes
In order to make the most economic use of cable ladder/tray and duct
capacity, multicore cabling shall be utilised in order to connect
instrumentation groups by using suitably located sub-distribution
junction boxes. The junction boxes shall have weather protection
suitable for the area in which they are to be installed and for the type of
circuit. They shall be readily accessible for maintenance and clearly
labelled. Junction boxes shall be constructed of die cast aluminium
and with IP65 degree of protection.
Separate cables shall be used for digital and analogue signals.
Wires and terminals for the digital and analogue signals shall be
segregated within junction boxes.
All Cable entries shall be from bottom side only in all Junction Boxes.
5.6.7 Cable Labeling
At each end of each cable, in a uniform and visible position, a label

shall be fixed on the cable to indicate the site cable number and route,
and the number and size of conductors. Labels shall be made of brass,
aluminium, lead or copper strip, engraved and retained by suitable nonSECTION 6B5: ICA WORKS
PAGE 41 of 88
1616 of 2461
MMRDA
rusting or non-corrodible binding wire passing through two fixing holes,

one at either end of the label. If the cable gland is not normally visible,
then the label shall be fixed inside the panel by means of screws.
Three-phase power cable cores shall be identified A, B, C or colourcoded red, yellow, blue so that the correct three-phase sequence is
preserved throughout the system. Single-phase power cable cores
shall be colour-coded red and black.
Control cables shall have individual cores identified by means of

suitable permanent ferrules bearing the same number at both ends.
Core identification shall occur at every point of termination using an
approved system of colour-coded ferrule markers. The size of these
ferrule markers shall be such as to match the overall diameter of
conductor plus insulation. Numbering shall read from the termination
upwards on all cores.
Each cable and core shall bear the same number at both ends of the
cable and core respectively.
(a) Power terminations colour, number or letter
(b) Control terminations letter or number or both
5.6.8 Cable Terminations
All cables shall be terminated with mechanical glands which shall

comply with BS 6121. They shall seal the inner and outer cable sheaths
against ingress of dirt and moisture and provide adequate mechanical
support. Each cable gland shall be protected by corrosion-resistant
molded PVC hoods, covering the entire assembly from the overall
sheath to the gland neck.
Glands for armoured cables shall provide a positive armour clamp to

the enclosure so that no tension is applied to the termination. The
PAGE 42 of 88
1617 of 2461
MMRDA
clamp shall also provide a high level of earth continuity and be of

adequate size to withstand the full fault current of the system for one
second.
All glands shall be provided with an earthing tag. For cables of 4mm or
less, a serrated washer may be used instead for earth continuity.
The cable termination and sealing equipment shall be obtained from

the cable manufacturer, or other approved supplier, and shall be
purpose-made for the type, size and grade of cable concerned. The
application of these materials shall be strictly in accordance with the
manufacturers instructions.
Through joints shall be permitted only on long cable runs outside

buildings. Where such joints are necessary; the cables shall be jointed
with epoxy or acrylic resin Cold-setting compound which has been premeasured and pre-packed ready for use.
The boxes shall be of a split moulded plastic type with filling vents for
compound.
Bonding straps shall be fitted with armour clamps across the joint and
inspected by the Engineer prior to filling the box with compound.
Wrapped pressure type joints shall not be accepted.
Conductor cores shall be jointed number to number or color to color.
5.6.9 Cable Installation - General
Cables which are to be run on walls, ceilings or other building

structures shall, unless otherwise agreed by the Engineer, be secured
on cable trays and ladders or enclosed in conduit or trunking.
Every cable shall be neatly run vertically or parallel to adjacent walls,

beams or other structural members. Cables shall not be installed in
PAGE 43 of 88
1618 of 2461
MMRDA
areas of direct sunlight.
Where this is unavoidable, approved sun shields shall be supplied and

installed.
Where the building structure incorporates purpose-built covered duct or

trench systems for main cables, instrumentation cables shall be
segregated and installed on tray work or otherwise secured to the sides
of the duct or trench.
Where the structure incorporates general service ducts or trenches

containing pipework, chemical lines and other services, all cabling shall
be segregated from the other services and shall be run on the walls
unless otherwise agreed by the Engineer.
Cables shall be spaced to prevent interference between power and
signal cables, and to avoid unnecessary crossovers.
The spacing of clips, saddles and cleats shall prevent the sagging of
the cables during their installed life. The method of fixing clips and the
like shall be by means of non-corrodible screws inserted into approved
wall fixings, such as rawl plugs.
Cable hangers, cleats, saddles, brackets and similar supporting

devices shall be of an approved type and of adequate strength for the
cables they are supporting. They shall be treated to withstand Site
conditions without corroding. Self-locking plastic buckle clips and
strapping shall not be used. The arrangement and fixing of each cable
shall permit the removal and replacement of any cable without
disturbance to any other cable or the fixings thereof.
When cables are terminated in any particular item of equipment,

special care shall be taken to ensure that the cables finally approach
the equipment from a common direction and are individually terminated
in an orderly and symmetrical fashion.
PAGE 44 of 88
1619 of 2461
MMRDA
Submissions which the Contractor shall submit the following in relation

to cable installations in addition to submissions detailed elsewhere in
the Specification.
a) Drawings and Schedules
Block diagrams to show control cabling systems with each cable

and terminal equipment being identified as in the cable schedules.
Cable route and layout drawings. For those items which are
underground, these drawings shall include the following:
Route plans and sectional views for all cable runs, cable trays,
cable ducts and cable trenches;
The position of all markers, joints, draw pits and the like;
Cable schedules shall detail the cable number, type, voltage,

size, route length and number of cores or pairs. Control-cable
schedules shall detail the connected and spare core numbers,
diagram number for connected equipment, core ferrule and
terminal reference number
b) Data and Calculations
Manufacturers catalogues and data sheets for all cables and

fittings. Cable sizing calculations.
c) Test Certificates
Test certificates for all witnessed and routine tests carried out at
the manufacturers works and at Site.
d) Cable Trays and Ladders

PAGE 45 of 88
1620 of 2461
MMRDA
Cable tray and cable-support ladders shall be of heavy-gauge

galvanised steel and with an overall PVC coating when required to
the approval of the Engineer.
Cable tray and ladder systems shall be installed using factory-made

supports, joints and junction/bend pieces. Wherever tray and ladder
sections are cut and shaped on Site, cut edges shall be dressed
and painted with at least two coats of cold galvanising compound or
lead-based anti-corrosive paint.
Ladder systems shall be secured to walls and ceilings by preformed galvanized interlocking channel.
e) Flexible Conduits
Flexible conduit shall be of the waterproof galvanised type of PVC

wire-wound type with cadmium-plated mild steel couplings. Lengths
of flexible conduit shall be sufficient to permit withdrawal,
adjustment or movement of the equipment to which it is attached
and shall have a minimum length of 300mm. Flexible conduit shall
not be used as a means of providing earth continuity. A single earth
conductor of adequate size shall be installed external to the conduit
complete with earth terminations.
Where conversion from rigid conduit to flexible metallic conduit is to

be made, the rigid conduit shall terminate in a trough-type box. The
flexible conduit shall extend from this box to the equipment; the
earth continuity cable shall be secured to the box and to the piece
of equipment. The use of lid facing screws and the like will not be
permitted. Adaptors shall incorporate a grub screw or a gland to
prevent the flexible conduit becoming loose.
f) PVC conduit
Where galvanised conduit would be liable to corrosion, PVC conduit

PAGE 46 of 88
1621 of 2461
MMRDA
shall be installed.
PVC conduit shall be of the oval or round high impact non-flamepropagating type as specified and self-extinguishing, to BS EN
61386-21. Surface and concealed installations shall be generally as
described for steel conduit.
PVC conduit fittings shall comply with BS 4607. They shall all be
white unless specified otherwise.
Jointing shall be carried out using PVC solvent and socketed

accessories.
Expansion couplers shall be fitted in straight surface runs every

12m. The free end shall be sealed with non-setting mastic to form a
waterproof seal.
Purpose-made bends may be used providing that the cable bending

radius is maintained. Cracked or crinkled conduit will be rejected.
The conduit shall be suitable for use in ambient temperatures of

between 5C and +60C and shall not be installed in areas that
receive direct sunlight. A separate protective conductor (earthcontinuity conductor) shall be installed.
Adaptable boxes and accessories shall be made from heat-resistant

insulating material. The minimum wall thickness of boxes having a
nominal internal depth of 16mm or less shall be 1.5mm. For deeper
boxes, the minimum wall thickness shall be 2mm. All boxes which
are intended to support luminaires or other heat sources shall have
either external fixing lugs riveted to the metal inserts or utilize steel
insert clips.
5.6.10 Cable Installation Methods
PAGE 47 of 88
1622 of 2461
MMRDA
a) General
All cabling installation methods shall be subject to the approval of

the Engineer.
Installation directly into the ground
Where cables are buried in the earth, the bottom of the excavated
trenches shall be freed of sharp stones and other projections and
covered with sand to a depth of 50mm.
Cables shall be unrolled from drums without loops and kinks, and
care shall be taken when laying to avoid damage to the outer
sheath by drawing over sharp projections.
Cables shall be snaked into the trenches to avoid tension in the

cables during backfilling or from subsequent settlement. After
laying, cables shall be covered to a minimum depth of 100mm of
compacted sand and shall have a layer of protective interlocking
concrete cable tiles. The tiles shall be overlaid with marker tape.
When cables of different voltages are laid together at the same

depth, vertical cable tiles shall be used to segregate the cables.
ICA and communication cables shall be laid not closer than

1000mm to high voltage cables.
A sufficient number of rollers shall be provided so that the cable

does not touch the ground or twist during pulling.
b) Installation in Underground Ducts
Underground ducts shall be constructed of impact-resistant uPVC

and laid at a minimum depth of 500mm (to the duct center),
surrounded by at least 75mm of sieved sand. At road crossings,
uPVC ducts of minimum diameter 100mm shall be laid at a
PAGE 48 of 88
1623 of 2461
MMRDA
minimum depth of 1000mm (to the duct center). The ducts shall be
encased by 150mm concrete on all sides.
When installing cables in ducts, the following measures shall be

observed:
Cables shall be pulled in a straight line;
Rollers shall be positioned at the edges of draw pits both at the

drawing-in and drawing-out points over which the cables shall
be drawn;
uPVC pipes and cable sheaths shall be coated with an approved

lubricant;
Sufficient draw-in points shall be provided and adequate room

allowed for installation of cables;
The pulling rope shall be guided by rollers
Only one power cable shall be drawn into each duct
Whenever a duct is laid in the ground, a draw-wire shall be pulled

through with at least 1000mm excess at each end and the drawwire left in position if the duct is not to be used immediately.
c) Sealing Cable entries into Buildings
Whenever cables pass through walls below ground level, the point
of entry shall be sealed against the ingress of water. This shall be
achieved with silicone foam or similar.
All cable entries into a building shall be in ducts and where the
cables pass in or out of ducts, together with any spare ducts, the
ducts shall be sealed against the ingress of moisture by means of
PAGE 49 of 88
1624 of 2461
MMRDA
duct stoppers and bituminous compounds or by any other method

approved by the Engineer. The stopper shall have a fire resistance
of at least 30 minutes.
d) Marking of Underground Cables
The location of all underground cables shall be identified by:
Brass plates fixed to the exterior surface of all walls of buildings

300mm above ground level and directly above the point where
cables pass through the wall;
Marker posts in road verges and the like at intervals of not more
than 100m and at all junctions and changes of direction along
the route;
Marker posts at 10m intervals within an enclosed site and at all

junctions and changes of direction along the route
Marker posts shall be of concrete, not less than 200mm high above
ground with an inscribed brass or enamel metal plate. The
inscription shall indicate the presence of a cable below, the depth,
classification and voltage rating.
A drawing or sample of a typical marker post shall be submitted for

the approval of the Engineer.
e) Installation in Cable Trunking
Cable trunking shall be manufactured from mild steel of not less

than 1.25mm and shall be hot-dip galvanised. The Contractor shall
ensure that the size of the trunking is adequate for the number of
cables to be installed together with 50% spare capacity. Trunking
shall have minimum dimensions of 50mm % 50mm.
PAGE 50 of 88
1625 of 2461
MMRDA
Segregation of cables shall be carried out if required using

continuous sheet steel barriers with the bottom edge welded to the
trunking. The trunking shall have two return flanges for rigidity.
Where necessary, additional strengthening straps shall be fitted
internally. The cover shall overlap the trunking and be made of the
same gauge. Fixing screws for covers shall be recessed and be of
the self-retaining quick-fix type. All bends, tees and intersections
shall be of the gusset type and shall, wherever possible, be
purpose-made by the manufacturer and of a matching design to the
main trunking.
Cables shall be retained in the trunking when the cover is removed

by means of straps. Internal connecting sleeves shall be fitted
across joints in the trunking and earth continuity ensured by
bonding each section of trunking to a continuous earth wire.
Non-flammable fire barriers shall be inserted where the trunking

passes through walls or floors. Conduit connections to trunking
shall be made by flanged couplings and male bushes.
Trunking shall be supported at intervals not greater than 2m

horizontally or 2.5m vertically.
Crossings over expansion joints shall be made in flexible conduit.
Should it be necessary to cut or drill a section of trunking, the bared

ends shall immediately be given a coat of zinc-rich cold galvanising
paint.
Cable and trunking runs shall be determined by the Contractor and

agreed by the Engineer before any work is started. The run shall be
at least 150mm clear of plumbing and mechanical services.
Trunking systems erected outside a building shall be weatherproof.
f) Installation in Troughs and Trenches

PAGE 51 of 88
1626 of 2461
MMRDA
Where the building structure incorporates purpose-built covered

trench systems, power distribution cables may be laid on the floor of
the trench. Control and instrumentation cables shall be segregated
and installed on supporting steelwork or cable trays secured to the
walls of the trench.
Where the building structure incorporates general service trenches

containing pipework, chemical lines and other services, all cabling
shall be segregated from other services and run on the trench walls.
Crossovers shall be kept to a minimum and cabling shall be taken
above wet service pipework.
Cable trays shall be of perforated steel with formed flanges and of

minimum thickness not less than 1mm for trays up to 100mm width,
not less than 1.25mm for trays from 100mm to 150mm width and
not less than 1.5mm thickness for trays from 150mm to 300mm
width.
Cable-tray supports shall be of sufficient strength to maintain rigid

support to the fully-laden cable tray along its entire length. All
brackets and tray work shall be suitable for withstanding a
temporary weight of 125kg.
Wherever possible, cable trays shall be installed in full lengths

without cutting.
Should it be necessary to cut or drill a length of tray, the bared ends

shall be dressed and immediately be given a coat of zinc-rich cold
galvanising paint. Similarly for PVC-coated trays, the bared end
shall be immediately sprayed using a PVC aerosol.
All cables shall be firmly secured to the tray using purpose-made

saddles, as approved by the Engineer, together with proprietary
cable cleats.
PAGE 52 of 88
1627 of 2461
MMRDA
g) Installation in Buildings
Cables required to be run on walls, ceilings, or other structures shall

be carried on substantial cleats, either in groups or simply at
spacings determined by rating requirements, supported on tray or
ladder racks or enclosed in conduit or trunking.
All cables shall be neatly run vertically or parallel to adjacent walls,

beams or other structural members.
The spacing of clips, saddles and cleats shall be such as to prevent

the sagging of the cables during their installed life. The method of
fixing clips and the like shall be by means of non-corrodible screws
inserted into approved wall fixings.
Cable hangers, cleats, saddles, brackets and similar supporting

devices shall be of an approved type and of adequate strength for
the cables they are supporting. They shall be treated to withstand
site conditions without corroding. Self-locking plastic buckle clips
and strapping shall not be used.
Hangers shall be spaced according to recommendations in the IEE

Wiring Regulations. Allowance shall be made for expansion and
contraction of the cables.
Cables shall be located between 50mm pegs spaced at 40mm

centres across a rung so that a 40mm or 80mm space is
maintained between cable centres. Cleats shall be used where the
ladder racking is vertical.
Cables shall be run at least 150mm clear of plumbing and below

heating and hot water pipework.
Cable installation in conduits

PAGE 53 of 88
1628 of 2461
MMRDA
Conduits shall be either galvanised heavy-gauge steel screwed

type or light-gauge steel non-screwed type, steel or PVC.
Accessories shall either be malleable cast iron or pressed steel.
A space factor of 40% shall not be exceeded and, in any case,

conduit shall have a minimum diameter of 20mm. The tubing is to
be perfectly smooth inside and out and free from imperfections.
Both ends of every length of tubing shall be reamed and all sharp
edges removed before erection.
Where conduits converge, adaptor boxes shall be used. Conduits

shall be connected by means of male brass bushes and couplings.
Where conduits are greater than 25mm diameter, straight-through
joint boxes shall be of the trough type. Where conduit or fittings are
attached to equipment casings, the material of the casing shall be
tapped for a depth of not less than 10mm or male bushes and
flanged couplings may be used.
Hexagonal lock nuts shall be used at running joints. They shall seat
firmly and evenly on to mating faces. All function boxes, draw-in
boxes, and inspection fittings shall be placed so that the cables can
be inspected, withdrawn and re-wired during the life of the
installation.
Generally not more than two bends or offsets or one coupling will
be permitted without a suitable inspection accessory. Fish wires
shall not be left in conduits during erection. The whole of the
installation shall be arranged for a loop-in type of system with joints
being carried out at switches, isolators or appliance fittings.
Ends of conduits which are liable to be left open for any length of
time during building operations shall be plugged to prevent the
ingress of dirt and covers shall be fitted on all boxes.
PAGE 54 of 88
1629 of 2461
MMRDA
Generally, conduits shall not cross expansion joints of buildings.

Where they cannot be installed in any other manner, a galvanised
flexible conduit shall be used across the expansion joint. A total of
150mm movement shall be allowed.
5.7
Process Instrumentation
I.
General
Instrumentation system shall be designed, manufactured, installed and

tested to ensure the high standards of operational reliability. All
electronic components shall be adequately rated and circuits shall be
designed so that change of component characteristics shall not affect
plant operation.
All instrumentation equipment shall be new, of proven design, reputed

make, and shall be suitable for continuous operation. Unless otherwise
specified, all instruments shall be tropicalised. The outdoor equipment
shall be designed to withstand tropical rain. Wherever necessary space
heaters, dust and water proof cabinets shall be provided. Instruments
offered shall be complete with all the necessary mounting accessories.
Electronic instruments shall utilise solid state electronic components,

integrated circuits, microprocessors, etc., and shall be of proven
design.
No custom made hybrid type integrated circuits shall be used.
Unless otherwise stated, overall accuracy of all measurement systems

shall be 1% of measured value, and repeatability shall be 0.5%.
Unless otherwise specified, the normal working range of all indicating

instruments shall be between 30% and 80% of the full scale range. On
resumption of the supply following a power failure the instruments and
associated equipment shall start working automatically.
PAGE 55 of 88
1630 of 2461
The
instruments
shall
MMRDA
be
designed
to
permit
maximum
interchangeability of parts and ease of access during inspection and

maintenance.
The field instruments i.e., the instruments mounted outside the control
panel shall be mounted at a convenient height of approximately 1.2
metres above grade platform. Unless otherwise stated, field mounted
electrical and electronic instruments shall be weatherproof to IP-65.
The instruments shall be designed to work at the ambient conditions of

temperature, humidity, and chlorine contamination that may prevail but
in any case not less stringent than those conditions detailed in the
Project Requirements. Instruments shall be resistant to corrosion in the
atmosphere in which they are expected to operate.
Lockable enclosures shall be provided for all the field mounted

instruments.
All field instruments, and cabinets/panel mounted instruments shall

have tag plates/name plates permanently attached to them. Details of
proposed inscriptions shall be submitted to the Engineer for approval
before any labels are manufactured.
All coated parts of sensors shall be made out of non- corrosive material
capable of working with chlorine content of 5 ppm.
For all instruments installed in the field, surge protection devices (SPD
s) shall be provided at both ends of the connecting cable for protection
against static discharges / lightning and electromagnetic interference.
Individual pair screened, overall screened, armoured cables shall be

used for analog signals and armoured, and overall screened cable
shall be used for digital signal cables.
PAGE 56 of 88
1631 of 2461
MMRDA
Pressure transmitters, pressure switches and hydrostatic head type

level transmitters shall be provided with two valve manifold and a test
port, so that in site calibration can be carried out.
II.
Flow Measuring Systems
Flow measuring system shall consist of flow sensor / transducers, flow

computer and flow transmitter.
Flow transducers shall be rugged in construction and shall be suitable

for continuous operation.
Flow transducers shall have waterproof
construction and shall be suitable for installation in underground/above

ground pipelines.
To avoid the effects of disturbances in the velocity profile, a straight

and uninterrupted run, upstream as well as downstream from the
location of the flow sensor shall be provided in accordance with the
requirements of the flow meter manufacturer.
The flow transmitter shall be suitable for field or panel mounting and
shall accept an input from the flow sensor. It shall process the input
signal and provide 4-20 mA dc output proportional to flow rate. The
flow range shall be adjustable. The flow meter shall be suitable for
measuring flow at water velocities from 0.5 to 5 m/sec.
A zero span adjustment facility shall be provided for flow transmitter

and indicator.
The overall accuracy of flow measuring systems shall be at least 1 %
of the measured value.
1.
Electromagnetic Flow meter

Electromagnetic flow meters shall operate on Faradays law of
electromagnetic induction principle and shall consist of a
PAGE 57 of 88
1632 of 2461
MMRDA
detector head and signal converter system which shall comply

with BS EN ISO 6817 and Traceability Group A1 of BS ISO
11631. The flow metering system shall provide pulse and
analogue current outputs proportional to volume and rate of flow
respectively.
The detector head shall have a stainless steel metering tube

and non-conductive, abrasion-resistant lining to suit the fluid
being metered. For potable water applications, the lining
material shall be WRc-approved neoprene or EPDM suitable for
an operating temperature of up to 65Deg C. Electrodes shall be
AISI 316Ti stainless steel.
Detector heads shall be flanged to BS EN 1092. The flanges

shall be compatible with those specified for the associated pipe
work. Detector heads shall be fitted with an anti-roll system to
prevent damage during storage. The flow meter shall have an
empty pipe detection facility.
Power and signal cables to the detector head shall be factory

sealed only, potting on Site shall not be acceptable.
Detector heads installed within a chamber shall have a degree

of protection IP68 and shall be suitable for indefinite submersion
under a head of water equal to the chamber depth or 3 meters,
whichever is the greater. Detector heads shall be installed on
steel cradle or concrete plinth with at least 5 pipe diameters of
straight pipe upstream and 3 diameters downstream unless
otherwise agreed with the Engineer. When fitted in lined,
nonmetallic or internally-coated pipe work, the detector head
shall have an earthing electrode or corrosion-resistant earthing
rings.
The instrument and pipe work shall be designed and installed in

such a way that air or other gases will not be trapped in or
PAGE 58 of 88
1633 of 2461
MMRDA
around the sensor.
The flow meter body shall be bonded by tinned copper braid

links at each end to the adjacent pipe work to ensure a good
connection between the body and the metered liquid.
If the pipe work has cathodic protection the manufacturers
recommendations for bonding and protecting the instrument and
its signals shall be adhered to.
a) Signal Converter
The signal converter shall be suitable for operation on a

240V 50Hz power supply unless otherwise specified and
shall provide a precise current input to the field winding of
the detector head and shall convert the resultant signal from
the electrodes to analogue and pulse outputs to comply with
BS 5863. The signal processing facilities of the converter
shall ensure that the output signals are unaffected by
interfering voltages, stratified flow, changes in fluid electrical
conductivity within the limits stated, non-homogeneity of the
fluid or the presence of ferrous particles. The instrument zero
shall be set at the manufacturers premises and thereafter
this
zero
shall
be
maintained
automatically
without
interruption of flow or output signals. The zero and output

signals shall be unaffected by partly fouled electrodes.
The signal converter shall be mounted in an enclosure. In

order to ensure the operation of the signal converter is
unaffected by ambient conditions the enclosure shall have
sufficient cooling and fan filters and shall be placed away
from direct sunlight.
The following signal converter features shall be provided as

a
minimum;
additional
requirements
may
be
stated
PAGE 59 of 88
1634 of 2461
MMRDA
elsewhere in the Specification
Pulsed dc field excitation;
Scaled pulse output for integration counter drive;
Capability of bi-directional measurement with differing

forward and reverse ranges and with local and remote
indication of flow reversal;
Contact operation at a programmable measured value;

Integral display of current flow and integrated quantity;
Galvanic isolation between each output circuit and

between the electrode circuit and output circuit;
Each output circuit to be isolated from earth within the

instrument but suitable for earthing at any point in the
external circuit;
Key entry for basic parameters, such as range;
Commissioning and re-scaling to require no special

programming knowledge;
An adjustable low-flow cut-off;
Self-diagnosis;
Terminals to have a compartment separate from the

electronic components;
Minimum fluid conductivity 80 micro-siemens/cm or less;
PAGE 60 of 88
1635 of 2461
MMRDA
Continuously-adjustable velocity range setting 0.5m/s to

5m/s or better.
Each converter shall be completely interchangeable with any

other electromagnetic flow meter converter of the same
design. Diagnostic checking facility shall be provided.
Plant-mounted signal-converter enclosures shall have a

degree of protection of not less than IP67 to BS EN 60529.
Signal converters installed within an instrument panel located
in a building may be of the rack-mounted type having a
degree of protection not less than IP20.
Signal converters shall not be located in flow meter

chambers or areas subject to flooding
b) Performance
The following performance shall be available as a minimum;

superior standards shall be met where stated elsewhere in
the Specification or where so required by the metering and/or
control requirements.
The accuracy of the flow meter shall be 0.5% of reading in

velocity range 5m/s down to 0.5m/s and 0.5% of f.s.in
velocity range 0.5m/s down to 0.2m/s.
The repeatability of the flow meter shall be 0.2% for

velocities of 0.5m/s and above.
c) Testing
Each detector head and converter shall be wet-tested and

calibrated in the presence of the Engineer, with the velocity
programmed to a value not exceeding that appropriate to the
PAGE 61 of 88
1636 of 2461
MMRDA
specified application in a permanent test rig having a valid

Quality Assurance Certificate or Calibration Certificate issued
by the National Standards or Calibration Authority of the
country of origin of the flow meter.
2. Open Channel Flow meter
Open channel flow measuring systems shall consist of one

level transducer, flume, flow computer and flow transmitter.
The flume shall be measured by the ultrasonic level with
transducer
considering
there
is
no
back
pressure
downstream. The level measured shall be used along with

the physical characteristics of the flume to compute the flow
rate.
I. Level Measuring System
1. Ultrasonic Level Meters
Ultrasonic level measuring devices applied to open channel

flow or liquid level measurement shall comprise a transducer
and control unit.
The transducer shall be suitable for flange or bracket

mounting as required and shall be environmentally protected
to IP 67. The accuracy of the sensor shall be 0.25% or
better.
It shall be programmable with an integral programming

keyboard and provide a digital display of the measured
variable. It shall be provided with diagnosis facilities and
shall provide an isolated 4 to 20 mA d.c. output signal
proportional to the range of measurement.
The design and application of ultrasonic level meters shall

PAGE 62 of 88
1637 of 2461
MMRDA
take into account the vessel or channel construction, the

material, size, shape, environment, process fluid or material,
the presence of foam, granules, size etc. The installation
shall avoid any degradation of performance from spurious
reflections, absorption, sound velocity variations, sensor
detection area, temperature fluctuations, specific gravity
changes and condensation. For applications where spurious
reflections are unavoidable the control unit shall be provided
with facilities for spurious reflection rejection.
If turbulence exists, shielding, stilling tubes or other

measures shall be provided to avoid effects on the
measurement.
2. Radar Type Level Transmitter:
1) 2-wire, Non-contact Radar type level Instrument shall be

used when the physical properties of the medium between
the sensor and the measured interference may vary. 4-wire
type shall be considered only when necessary.
2) The Radar type level instrument shall be microprocessor

based with HART protocol of field bus based and shall use
digital signal processing techniques for signal conditioning.
Possible to calibrate through universal HART calibrator.
3) Suitable Antenna shall be considered for the intended

application.
4) Radar type level transmitter shall have facilities for storing

echo profile, manipulation of the echo profile to remove nose,
multiple profile averaging etc.
5) The transmitter shall have the capability to use statistical

filtering techniques, wherever required, to compensate for
PAGE 63 of 88
1638 of 2461
MMRDA
rotating agitator blades or to supress false signal due to

heavy dust or fill stream interference.
6) Transmitter / control unit shall be preferably single channel or

a maximum of two channels.
7) The sensor shall have inbuilt temperature sensor for ambient

temperature compensation.
8) Chemical compatibility of the sensor material with the

process material shall be ensured to avoid corrosion.
9) In applications, where material build-up on the sensor is

expected, the transducer shall have suitable build-up
compensation (i.e repetitive, pulsating displacement at its
face shall be used to remove the material build-up)
10) Necessary software, cables, connectors, HART to 232C

converter etc. for calibration, noise suppression, etc. of
Radar type level transmitters through windows based
desktop PC / Laptop shall be supplied.
11) Suitable protection box for mounting Radar type level

transmitters shall be provided for mechanical protection &
dust. Swiveling arrangement shall be provided for propoer
aiming / focussing of radar type level transmitters for solid
level measurement in big bunkers / silos.
12) Provision for the nitrogen / compressed air purging facility in

the level sensor shall be provided for cleaning the build-up of
the material in antenna in case of dusty service.
3. Conductivity Level Switches
The electrodes used for conductivity level switches shall be

PAGE 64 of 88
1639 of 2461
stainless steel.
MMRDA
Single electrode systems (one electrode per
holder) shall be used (except where their use is impractical) with

insulated electrodes such that only the tip of each electrode is
exposed to the liquid at the operating level.
Relay or control units operating with level electrodes shall have

adjustable sensitivity. Electrodes for use in fluids of low or
variable conductivity shall be fitted with conductivity discs.
Where relay or control units are not mounted in control panels,

they shall be provided with surface mounting enclosures with a
degree of protection to IP 52 for indoor locations or IP 65 for
outdoor locations.
4. Float-operated level meters
Float-operated level meters shall comprise a float and

counterweight or tension device. Floats and counterweights
shall be of corrosion-resistant material or shall be coated with
epoxy resin. The float shall be suspended by a stainless steel
wire or perforated tape which shall operate the transmitter
installed above the float stilling well or measuring chamber.
The transmitter shall provide a digital or 4mA to 20mA dc output

signal proportional to the level range of the instrument and shall
be provided in an enclosure with protection to BS 5990, IP 55 or
equivalent standard.
II. Pressure Measuring System
a) Pressure Gauges and Transmitters
Pressure gauges shall comply with BS EN 837-1 or equivalent

and have concentric scales. For specially arduous duty where
the gauge is subject to pressure pulsations and/or vibration, it
PAGE 65 of 88
1640 of 2461
MMRDA
shall be provided with a glycerine-filled dial and line snubbers

shall be used. Bourdon-tube type differential-pressure gauges
shall be capable of withstanding full line pressure on any side
with the other side vented to atmosphere without damage to or
effect on the calibration. No plastic material shall be used in their
construction. Internal parts shall be of stainless steel, bronze or
approved corrosion-resistant material.
The minimum diameter for round pressure gauges shall be

150mm unless specified otherwise or where the gauge forms
part of a standard item of equipment.
Unless specified elsewhere the accuracy for pressure gauges

shall be 1% of range, for diaphragm gauges 1% of range and for
differential gauges 1.5% of range or better.
Where compensation of more than 2% of the instrument span is

needed for the difference in level between the instrument and
the tapping point, the reading shall be suitably adjusted and the
amount of compensation shall be marked on the dial.
The zero and span of a pressure transmitter shall not change by

more than 0.1% of the span per Celsius degree change in
ambient temperature. After application for 10 minutes of
pressure at 130% of maximum pressure, the change in zero and
span shall not exceed 0.1% of the span.
Pressure transmitters shall have an accuracy typically better

than 0.1% of span, depending on the application and shall be
protected to BS EN 60529: IP 65 standard or higher standard.
For transmitters installed in meter chambers liable to flooding or
underwater applications, they shall be to BS EN 60529: IP 68
standard and shall operate up to maximum submergence of 20
metres of water.
PAGE 66 of 88
1641 of 2461
MMRDA
Pressure transmitters shall provide a digital or 4mA to 20mA dc

output proportional to the pressure range.
Pressure gauges and transmitters shall have primary isolating

valves, 2 or 3 way valve manifold and vents, in such a way that
it has the facility to calibrate the gauges or transmitters without
removal.
b) Strain-gauge pressure transducers and transmitters
Strain-gauge pressure transducers shall use thin film sensors

without bonding.
Each instrument housing shall be of all-welded Grade X 4
CrNiMo 17 12 2 stainless steel or equivalent and hermetically
sealed. Non-interacting, zero and span adjustments shall be
provided on each transducer. The measuring diaphragm shall
be isolated from the process fluid by a non-corrodible barrier
diaphragm. The mean time between failure for any model of
strain-gauge transducer shall be not less than 15 years, and the
performance of the measurement system shall be as given
below, or higher performance:
accuracy: 0.1% of calibrated span, including linearity

hysteresis and
repeatability;
repeatability: 0.05% at maximum span;
stability: 0.1% of upper range limit over 6month period;
over-pressure:
sustain
400%
over-pressure
without
damage;
RFI / EMI effect: less than 1% of span with 500MHz at 5W

direct contact;
PAGE 67 of 88
1642 of 2461
MMRDA
Power-supply variation effect: 0.01% per volt variation.
load variation effect: 0.0002% per ohm of loop-resistance

variation.
temperature: 29C to +82C range; total thermal error of

0.75% of span over 0C to 50C;
protection: IP 65.
Strain-gauge transducers which do not have terminals for their

cable connection, shall have integral sealed-cable assemblies,
installed in conduit and terminated at weatherproof junction
boxes, protected to IP 65 each mounted near to its associated
process transmitter. A digital or 4mA to 20mA dc output signal
proportional to the transducer range shall be provided.
Strain-gauge pressure transmitters shall be generally as the

transducer except that it shall incorporate a waterproof pressure
transmitter producing a digital or 4mA to 20mA output signal.
Provision for transducer venting shall be provided.
III. Online Analytical Instruments
a) On Line Turbidity Measuring System
Turbidity
transducers
measurement principle.
shall
operate
on
Nephelometric
Turbidity transducer shall have
ratiometric measurement system and shall be suitable for

insertion / flow through type mounting. It shall be possible to
calibrate the turbidity meter at site, with a formazine standard or
a glass cube.
Turbidity transducer shall be rugged in construction and shall be

PAGE 68 of 88
1643 of 2461
MMRDA
suitable for continuous operation.
It shall have an integral
bubble trap arrangement.
They shall provide an isolated 4-20 mA dc output proportional to

turbidity. Turbidity transmitters shall have LED/LCD display to
indicate turbidity
b) On Line Residual Chlorine Measuring System
The residual cell shall work on Amperometric principle.
All
wetted parts of sensor shall be of non-corrosive material. The

residual cell shall be provided with a facility which ensures selfcleaning of the electrodes. The cell shall be provided with
integral shut off and pressure regulating valves and a pressure
gauge.
c) On Line pH Measuring System
Each pH-metering system shall comprise electrode assembly,

pre-amplifier (if appropriate) and analyser transmitter.
The pH electrode assembly shall be of the same manufacturer

as the associated pre-
amplifier and analyser and, unless
otherwise specified, shall be of the flow- through type.
Electrode assemblies shall comprise a glass electrode, a

calomel reference electrode and a resistance thermometer for
temperature compensation in immersion type housing.
The measuring electrode shall be of glass and shall be designed

for resistance to breakage and low electrical resistance. The flow
direction in flow-through electrode assemblies shall be such as
to give a self-scouring action at the electrodes.
Electrode assemblies shall be easily detachable from their cells

PAGE 69 of 88
1644 of 2461
MMRDA
for buffering. Flow-through electrode mountings shall be

designed to accommodate a breaker for containing
buffer
solutions and two such breakers shall be supplied with each

flow-through electrode assembly.
The pre-amplifier shall, according to the particular application,

be:
Integral with the electrode assembly;
In a separate enclosure mounted in the vicinity of the

electrode assembly
The pH analyser when mounted externally to a panel shall be

housed in a watertight,
GRP housing protected to IP56 or
better and shall be suitable for surface mounting.
The
Analyser shall have an integral indicator and shall produce an

isolated 4-20mA output which is linear to pH.
The analyser span shall be adjustable after installation and the

range shall be easily varied to cover a minimum pH range of 2 to
12. Calibration adjustments shall be provided for each end the
overall accuracy of the pH meter shall be better than +/-0.1pH
and the repeatability shall be better than +/- 0.05pH. This
performance shall be maintained without manual intervention for
a minimum period of 30days. The response time shall not
exceed 15 seconds.
Controls shall be provided on the front of the analyser or at the

side of the panel-mounted pull-out module for:
Automatic /manual temperature compensation;
Calibration arrangement
PAGE 70 of 88
1645 of 2461
MMRDA
The analyser shall have a run /test switch, to isolate the input
from the electrode assembly during fault finding and adjustment.
The switch shall have auxiliary contacts for external use when
required.
Each analyser shall be provided with two sets of fully-adjustable

relay contacts which may be set to operate anywhere in the
range of the analyser.
Where
specified,
pH-metering
systems
shall
incorporate
equipment for automatic pH control in conjunction with

equipment specified elsewhere.
IV. Surge Protection Devices
Surge protection devices (SPD s) shall be suitable for

withstanding the surge arising out of high energy static
discharge / lighting strikes and protect the instrument to which it
is connected against damage. SPD s shall provide protection
through the use of quick acting semiconductors like Tranzorb,
zener diodes, varistors and an automatic disconnect and reset
circuit.
SPD s shall be passive and shall require negligible
power for operation. During the occurrence of a surge it shall

clamp on the allowable voltage and pass the excess voltage to
the ground. The SPD shall be self- resetting to minimise the
down time of the measurement loop.
SPD s shall be provided to protect devices transmitting and

receiving analogue and digital signals derived from field devices
located out doors.
The surge protection device shall be rated for surge rating of 10

kA.
V. Alarm Systems/Alarm Annunciators

PAGE 71 of 88
1646 of 2461
MMRDA
Alarms shall be initiated by the opening or closing of volt-free

contacts which shall remain unchanged throughout the periods
in which the alarm conditions exist. Alarm circuits shall be
capable of conversion from open-healthy to open-alarm or vice
versa by a simple modification after installation requiring no
additional parts or special equipment.
Each alarm shall initiate the operation of both visual and audible
devices.
The sound intensity of each audible device shall be suitable for

the maximum sound level of its environment.
Audible devices in the same room or area shall have

distinguishable sounds and adjustable sound levels.
a) Matrix Type alarm Annunciators
Each alarm shall initiate a visible and audible indication of the

specified condition. Unless otherwise specified, alarm indicators
shall be grouped together in annunciator units each having at
least 20% spare ways. Alarm indicators shall be of similar design
to indicator lamps and shall have screens engraved with legends
approved by the Engineer. The legend area of each indication
shall not exceed 40 mm high and 75 mm wide.
When any alarm condition occurs, an audible device common to

an alarm annunciator system shall sound and the appropriate
indicator shall flash on an off. The flashing rate shall not be less
than 2 Hz and shall not exceed 5 Hz. On pressing an accept
pushbutton, the audible device shall be silenced and the flashing
light shall become steady.
The alarm indicator shall remain
illuminated until the alarm condition ceases and a reset

pushbutton has been operated.
PAGE 72 of 88
1647 of 2461
MMRDA
The operation or acceptance of one alarm shall not inhibit the

operation of the audible device or the flashing of the appropriate
alarm indicator if a further alarm condition occurs. At unmanned
locations alarms operated on two or more annunciators shall
require acceptance at each annunciator.
Alarms shall be
accepted automatically and the appropriate audible device

silenced after an adjustable period of 1 to 5 minutes.
An integral test pushbutton shall be provided to illuminate each
lamp in the appropriate group and to operate the audible device
but shall not cause a spurious alarm condition on any other
annunciator. Alarm circuitry shall be arranged so that spurious or
transient alarm states persisting for less than 0.5 seconds do not
initiate any action.
Alarm annunciator / indicator legends or labels shall be arranged

with three lines of text as follows:
topline
location
middle line
parameter
bottom line
status
e.g.
reservoir 1
level
high
5.8
Control and Automation
Programmable Logic Controllers
PLC shall be provided as a Hot Standby controller to perform

combinational and sequential
logic functions, status monitoring and
reporting functions with counter and timer facilities.
The
same
hardware configuration of PLC system shall be protected under Internal

Wiring Front Glass Door CPU Control Panel located at respective
PAGE 73 of 88
1648 of 2461
MMRDA
Control Rooms of Raw Water
Pumping
Station
(RWPS),
Clear
Water Pumping Station (CWPS) and Water Treatment Plant (WTP)
The Remote Input Output (RIO) modules along with Internal Wiring
Control Panels shall be applicable for sub process systems of WTP
except RWPS and CWPS.
PLC shall comprise of necessary processors, input/output (I/O)

modules, communication interface modules and Human-machine
interface (HMI) required performing the desired functions.
PLC shall have the following attributes as a Hot Standby controller.
carry out sequential logic implementation for operations of plant;
carry out direct digital control, which performs process control in

accordance with set point;
carry out computation and interfacing for data acquisition, data

storage and retrieval;
it shall accept downloaded program from a programmer;
it shall have different functional modules to perform the desired

functions;
it shall scan the inputs in time cycles and update the status of its
outputs.
The PLC system shall be expandable and shall be modular in

construction, so as to capable of future expansion without hardware
modifications.
PLC
System
shall
be
IEC-61850,
IEC875101
Compatible.
PLCs shall use open protocols and structures so that they can
PAGE 74 of 88
1649 of 2461
MMRDA
communicate with third partys PLCs.
In case of system failure or power supply failure the outputs shall attain
a predetermined fail safe condition (this shall normally be off). The
PLC used shall have a proven record in the type of application
concerned and in the prevailing environmental conditions.
a) Redundancy Levels for WTP:-
i.
Controller Level
ii.
Power Supply Level
iii.
Communication Network level from RIO panels to Controller /

CPU Panel over by TCP / IP Ethernet by Using Fibre Optic
Cable (F.O.C)
iv.
SCADA / HMI System Level
b) Redundancy Levels for RWPS & CWPS:-
i)
Controller Level
ii)
Power Supply Level
iii)
c) Redundancy Levels for Substation Automation System (SAS)

at Kawdas and Suryanagar.
i.
Controller Level
ii.
Power Supply Level
iii.
PAGE 75 of 88
1650 of 2461
MMRDA
d) Redundancy Levels for Substation Automation System (SAS)

at Dahanu.
i.
Controller Level
ii.
Power Supply Level
iii.
Note:- SCADA System for remote
monitoring of switchyard
installed at at Kawdas, Suryanagar and at existing 132 kV
to be
Dahanu
substation,
All equipments materials etc., required for above work d) shall be as per
supply
companies
specifications
and
requirements.
Supervision,

companies representatives.
Contractor shall be
responsible for

O & M of above works d) shall be done by MSETCL.

supervision).
i.Central Processing Units
The central processing units (CPU) shall be a high performance

processor with modular configuration suitable for real time
process applications
PAGE 76 of 88
1651 of 2461
MMRDA
The following additional features shall be provided.
Communication between CPU and peripherals shall be by an

I/O bus. The individual device, interfaces shall be capable of
being plugged into the I/O bus.
On resumption of power following a power failure the PLC shall
automatically restart its controlling function.
CPU shall have a real time clock capability to accept a time

synchronisation pulse and adjust its internal clock with the pulse.
CPU shall have extensive self- diagnostic facilities and watch

dog timers to identify faults at card levels.
ii.
Memory Unit
Memory unit shall comprise of highly reliable memory chips

which are industry standard, proven design with fast random
access and suitable for operation in process environments.
Main memory shall be modular and facility shall be provided for
the upgrading and expansion of memory to meet future
demands.
Not less than 50 % spare program memory and data memory

space shall be provided. System initialisation and application
software shall be stored in EEPROM or EPROM.
Operating
data shall be stored in a RAM fitted with an internal battery backup. The battery backup provided shall support the memory on
loss of power for at least one month. The battery life shall be at
least 2 years.
iii.
I/O Modules
I/O Modules shall be of the same series of the PLC CPU.

Standard rack mounted plug in I/O modules shall be provided.
PAGE 77 of 88
1652 of 2461
MMRDA
Field wiring shall be terminated in screwed terminal blocks and

interconnected to the processor I/O system with prefabricated
cables and plug in card type connectors.
10% extra modules of installed capacity for each type of module

shall be provided as spare. Provision shall be made for future
expansion of additional 20% extra I/O modules of the installed
capacity.
I/O modules shall be as follows:
inputs shall be opto isolated.;
filters shall be provided for noise rejection;
output status shall be indicated by an LED;
all outputs shall be fuse protected and have fuse failure

indication the fuses may be
mounted externally from the
output module;
iv.
all the modules shall be of addressable type.
Analogue Input Modules
They shall consist of an input isolation unit, signal conditioning

unit and an analogue to digital converter (ADC). In addition, the
following features shall be provided.
16 Bits resolution minimum
provision for monitoring of the ADC for overflow detection
gain amplifier with high common mode rejection ratio
PAGE 78 of 88
1653 of 2461
v.
MMRDA
accuracy for analogue signals shall be 0.5%
Analogue Output Modules
They shall consist of signal conditioning unit and a digital to

analogue converter (DAC). In addition, the following features
shall be provided.
vi.
16 bits resolution minimum
provision for monitoring of the DAC for overflow detection
Digital Input Modules
The following design features shall be provided.
vii.
contact bounce protection
choice of type of contacts
Digital Output Modules
The digital output module shall provide contact closure output by

driving relays. The features to be provided are as follows:
contact bounce protection shall be provided
relay output shall be provided to operate pump motors and

motorised valve actuators
fail safe position in case of output module failure and fault
PAGE 79 of 88
1654 of 2461
MMRDA
indication
viii.
Wireless Communication Gateways / systems
The WTP-PLC data (i.e. the integration of RWPS-PLC &

CWPS- PLC data to WTP-PLC by using Fiber Optic Cable)
shall be transferred to MMRDA office by using Wireless
communication Gate Ways of VSAT and GSM / GPRS
systems
Each MBR-PLC data shall be transferred to WTP-PLC by

VSAT
The Data from junction of Kashidkopar and NH-8 shall be

transmitted to MBR at Kashidkopar by using ISM band Radio
communication
For further details refer the System Network Architecture

Drawing of VSAT
ix.
PLC Programming
PLC programming shall be carried using Ladder Logic. The logic

shall be prepared using proprietary programming software and
shall be comprehensively annotated with subroutine and rung
comments to assist further development and maintenance.
a) Programming Unit
A laptop computer (Industrial Type, suitable for rugged use) shall

be provided to program the PLC.
The computer shall be provided complete with proprietary PLC

programming and documentation software. The software shall
provide facilities for:
PAGE 80 of 88
1655 of 2461
MMRDA
carrying out program revision management;
insertion of comprehensive program subroutine and rung

comments;
search and find and search and replace contacts and coils;
simulation functions and testing of the program by changing

the status of contacts and monitoring the outputs;
preparation of coil and contact list and their locations and

memory maps;
II
make system backup copies while the system is online;
upload and down load programs to the PLC on line;
carry out on line maintenance and fault finding on the PLC.
SCADA (Supervisory Control and Data Acquisition) / HMI

(Human Machine Interface)
a) General
The SCADA / HMI shall be suitable for day to day operation

by non-computer literate personnel in the monitoring and
control of entire WTP from the Control Room and few subprocess systems like Chemical Dosing Systems, Centrifuge
systems etc. shall be monitored and controlled through Local
Control Panel (LCP) provided with standalone PLC with
Panel Mounted HMI.
b) SCADA / HMI
PAGE 81 of 88
1656 of 2461
MMRDA
SCADA / HMI in a dual- redundant configuration shall be

provided at each Control Room of RWPS, CWPS, WTP and
each MBR.
The SCADA / HMI system shall provide efficient and safe

operation of the process plant by detecting alarm and error
conditions, alerting the operator to these conditions both
visually and audibly, monitoring all important system
parameters and providing facilities for plant optimisation. The
system will allow operators, technicians and engineers to
issue commands to change system parameters, start and
stop equipment, provide configuration tools and operate
diagnostic facilities from Operator Workstations (OWSs) and
Engineers workstation (EWS), after successful log-on by
security password.
The System shall perform all the necessary functions for the
optimum monitoring, control and operation of the entire
system.
The SCADA / HMI shall be constructed to a high standard to

provide a high profile feature and focal point for visitors to the
respective Control Room of Clear Water Pumping Station
(CWPS), Raw Water Pumping Station (RWPS), MMRDA
Office, Water Treatment Plant (WTP) and each MBR.
SCADA/HMI
system
should
be
housed
in
an
air-
conditioned environment.
Note: - In addition to redundant SCADA / HMI OWSs, one

number of Standalone Historian OWS shall be installed,
Tested and commissioned at WTP Control Room. For this,
the contractor has to make ensure that make of the Historian
OWS should be similar to the make of SCADA / HMI.
PAGE 82 of 88
1657 of 2461
5.9
MMRDA
The power for Programmable Logic Controllers (PLC) and Supervisory

Control and Data Acquisition (SCADA/HMI) shall be derived from separate
UPS.
The UPS provided shall be sized to provide sufficient power to maintain

system functioning for a period of minimum 1 hour, in case of power failure.
Note: - One Number of UPS shall be applicable in each Control Room of

RWPS, CWPS, WTP and each MBR location.
The above feature should be demonstrated during Factory Acceptance Test

(FAT) & Site Acceptance Test (SAT).
5.10
Submissions by Contractor
a)
General
The Contractor shall make submissions to the Engineer of all design

drawings, schedules and complete documentation on spare parts
relating to instrumentation and control equipment and systems
provided under this Contract.
These submissions shall include, where relevant, the following:
b)
Functional Design Specification
The Contractor shall submit a complete functional design specification

(FDS) for approval by the Engineer within three (3) months of the
award of the Contract. The Contractor should take note of the
importance of this obligation. This document shall serve as the primary
mechanism by which the Engineer may confirm that the Contractor
possesses an accurate understanding of the system and its control
requirements. The Contractor is encouraged to obtain clarifications and
PAGE 83 of 88
1658 of 2461
MMRDA
to suggest refinements to the control descriptions contained in this

Specification.
The FDS shall comprise an overall description of the plant, its

functioning and control, and a detailed description of each section of
the control system covering modes of operation, manual overrides, setpoint and parameter selection and adjustment. The detailed description
shall include a step-by-step control description which defines the
function of each piece of equipment and each control action and
interlock, including details of the program in each programmable item.
Proposed SCADA screens shall be an integral part of FDS

Submissions.
The format of the program details may be chosen by the Contractor,

however it is suggested that this format be chosen to satisfy the
requirements of the software design documentation, if applicable, as
described elsewhere.
The FDS shall describe the fail-safe features incorporated into the
design for the event of failure of a plant item or system, or loss of an
input signal affecting a control loop or process sequence.
The FDS shall describe control actions taken and monitoring functions
which remain available during a power failure, and any automatic
controls or sequencing which take place during system start-up and
shut-down.
The FDS shall be presented in a clear and precise manner and shall
include figures or drawings where appropriate.
The Contractor shall submit and obtain approval of the FDS from the
Engineer before beginning the detailed control system design. The
contractor should take note of the importance of this obligation.
PAGE 84 of 88
1659 of 2461
c)
MMRDA
Drawings and Schedules
i)
Process and instrumentation diagram which shall comply with

BS 1646 and BS 1553
ii)
General arrangement drawings of field-mounted instruments

showing installation details
iii)
General arrangement drawings of instrument and control panels,

fully dimensioned in
plan and elevation views, showing
foundation and fixing details, access doors, clearances, cableentry positions, weight and lifting arrangement
iv)
Layout drawings of panel fascias showing instruments, controls

and details of all labels
v)
Layout drawings of panel interior showing equipment, terminal

blocks and cable ways
vi)
Annunciator arrangement and engraving details
vii)
Internal circuit and wiring diagrams for instrument and control

panels
viii)
Schematic control diagrams
ix)
Instrument loop diagrams
x)
Instrument wiring and piping diagrams
xi)
Interconnection wiring diagrams
xii)
Cable block diagrams, drawings and schedules
xiii)
Instrument system and panel power distribution diagrams
PAGE 85 of 88
1660 of 2461
xiv)
MMRDA
Programmable-device functional design specifications which

shall include hardware details, logic flow charts, ladder diagrams
and program listings
xv)
Schedules of inputs to and outputs from programmable

controllers and telemetry outstations
xvi)
Labelling schedules
xvii)
Comprehensive testing schedules for all off-site, on-site, precommissioning and commissioning tests and take-over tests
All other drawings necessary for the provision of ducts, openings,

trenches, fixing holes for panels and the like and for the complete
understanding of the operation, maintenance and extension of the
system including any required for the Purchaser to dismantle,
repair, maintain, modify or extend the Plant.
d)
Data and Calculations
i)
Manufacturers
catalogues
and
data
sheets
for
entire
Instrumentation, Control & Automation (ICA) equipment
ii)
Calculations to support control system design
iii)
Specification for protective coatings and painting
iv)
Load calculation and Battery Sizing Details for UPS
e) Certtificates
i)
Manufacturers works tests
ii)
Pre-installation checks
PAGE 86 of 88
1661 of 2461
MMRDA
iii)
Pressure-testing schedules
iv)
Instrument loop test check sheets
v)
Installed instrument performance tests
vi)
System tests
vii)
Statutory certificates of compliance (such as hazardous area

equipment)
viii)
f)
Wet calibration certificated for each Flowmeter
Operation and maintenance instructions
i)
Composite manual describing the functional and operation of

each piece of equipment
ii)
Composite manual for testing and servicing every system and

individual item
g)
Design Basic Features
Instrumentation, Control, Automation and SCADA & HMI system shall

be designed, manufactured and installed to achieve the following basic
requirements:
to maintain the highest standards of availability, reliability and

accuracy and to give clear warnings of any deterioration in
performance;
to suit the abilities of the staff who will:

use the systems;
PAGE 87 of 88
1662 of 2461
MMRDA
service the systems;
to measure, indicate, process, store and control the relevant

parameters, as specified;
to give clear warnings of dangerous and other abnormal

conditions and to initiate plant safety procedures, shutdowns
and corrective measures as specified to assure the safety of
operations and maintenance personnel and plant and to store
and collate the data, as required;
to derive, present and utilize, as required, such additional data

as required to facilitate:
the most efficient operation of the plant;
the routine maintenance of the plant
PAGE 88 of 88
1663 of 2461
SUB-SECTION 6B.6
WATER TREATMENT PLANT
1664 of 2461
MMRDA
Table of Contents
SUB-SECTION 6B.6: WATER TREATMENT PLANT............................................. 1
6.1
Mixers and Flocculators ................................................................................................. 1
6.1.1
General ............................................................................................................................ 1
6.1.2
Static Mixers.................................................................................................................... 1
6.1.3
Flocculators ..................................................................................................................... 3
6.2
Clarifiers ....................................................................................................................... 4
6.2.1
General ............................................................................................................................ 4
6.2.2
Lamella clarifier ............................................................................................................... 5
6.2.3
Lamella Clarifier channels ............................................................................................... 6
6.2.4
Sludge Scrapers ............................................................................................................... 6
6.2.5
Clarified Water Removal ................................................................................................. 9
6.2.6
Clarifier Access ................................................................................................................ 9
6.3
Filters ........................................................................................................................... 9
6.3.1
General ............................................................................................................................ 9
6.3.2
Filter media ................................................................................................................... 10
6.3.3
Sand............................................................................................................................... 10
6.3.4
Packing gravel ............................................................................................................... 10
6.3.5
Media source ................................................................................................................ 11
6.3.6
Spare media .................................................................................................................. 11
6.3.7
Media placing ................................................................................................................ 12
6.4
Filter Under-drain System ............................................................................................ 13
6.4.1
General .......................................................................................................................... 13
6.4.2
System description ........................................................................................................ 13
6.4.3
Materials ....................................................................................................................... 14
6.4.4
Design requirements ..................................................................................................... 14
6.4.5
Installation .................................................................................................................... 15
6.5
Air Scour Arrangements............................................................................................... 15
6.5.1
Air blowers .................................................................................................................... 15
6.5.2
Air Intake ....................................................................................................................... 17
6.5.3
Air Pipework .................................................................................................................. 17
1665 of 2461
6.6
MMRDA
Backwash Arrangements ............................................................................................. 18
6.6.1
Backwash Pumps........................................................................................................... 18
6.6.2
Pipework ....................................................................................................................... 18
6.6.3
Washwater Flow Control .............................................................................................. 19
6.7
Filter Valves and Motive Power Systems ...................................................................... 19
6.7.1
Valves ............................................................................................................................ 19
6.7.2
Motive Power Systems.................................................................................................. 20
6.7.3
Pneumatic Actuators on/off type .............................................................................. 20
6.7.4
Filter-internal and gallery pipework ............................................................................. 20
6.7.5
Location of Pipes and Channels .................................................................................... 21
6.7.6
Filter House Access ....................................................................................................... 22
6.7.7
Filter plant lifting equipment ........................................................................................ 22
6.8
Waste Treatment Facilities .......................................................................................... 23
6.8.1
6.9
Submersible mixers ....................................................................................................... 23
Thickeners and Scrapers .............................................................................................. 24
6.9.1
Thickeners ..................................................................................................................... 24
6.9.2
Sludge Scraper............................................................................................................... 25
6.9.3
Supernatant Removal ................................................................................................... 27
6.9.4
Sludge Pipework and Valves ......................................................................................... 28
6.10
Chemical Storage & Handling ....................................................................................... 28
6.10.1
General .......................................................................................................................... 28
6.10.2
Storage and Reception .................................................................................................. 29
6.10.3
Chemical Storage Safety ............................................................................................... 30
6.11
Chemical handling ....................................................................................................... 30
6.11.1
Pallet trucks................................................................................................................... 30
6.11.2
Pallets ............................................................................................................................ 31
6.12
Dosing Pumps - Reciprocating Type.............................................................................. 31
6.12.1
General .......................................................................................................................... 31
6.12.2
Pump Head .................................................................................................................... 32
6.12.3
Pump Stroke .................................................................................................................. 32
6.12.4
Pump Drive & Motor ..................................................................................................... 32
6.12.5
Pump Performance ....................................................................................................... 33
6.12.6
Transfer pumps ............................................................................................................. 33
6.13
Pipework for Chemicals ............................................................................................... 33
1666 of 2461
MMRDA
6.13.1
General .......................................................................................................................... 33
6.13.2
Pipework Materials ....................................................................................................... 36
6.13.3
General .......................................................................................................................... 37
6.13.4
System components ...................................................................................................... 37
6.13.5
uPVC valves ................................................................................................................... 38
6.13.6
Rubber lined valves ....................................................................................................... 38
6.13.7
Pressure Relief Valves ................................................................................................... 38
6.13.8
Loading Valves............................................................................................................... 39
6.13.9
Pulsation Dampeners .................................................................................................... 39
6.13.10
Injection fittings ........................................................................................................ 39
6.13.11
Dosing Pump Calibration Vessels .............................................................................. 40
6.14
Coagulant Plant ........................................................................................................... 40
6.14.1
General requirements ................................................................................................... 41
6.14.2
Storage tanks Capacity, design and fabrication ............................................................ 41
6.14.3
Saturators...................................................................................................................... 41
6.14.4
Dilution and Stock Tanks ............................................................................................... 42
6.14.5
Constant head tanks ..................................................................................................... 43
6.15
Chlorination Plant ....................................................................................................... 43
6.15.1
Drum handling systems................................................................................................. 43
6.15.2
Monorail Runway Beam ................................................................................................ 43
6.15.3
Electric Travelling Hoist ................................................................................................. 44
6.15.4
Suspended Weigher ...................................................................................................... 45
6.15.5
Safe working loads ........................................................................................................ 46
6.15.6
Liquid catchpots ............................................................................................................ 46
6.15.7
Gas Pipe work................................................................................................................ 46
6.15.8
Gas Isolating Valves....................................................................................................... 47
6.15.9
Drum Changeover System............................................................................................. 48
6.15.10
Vacuum Regulating Valves ........................................................................................ 49
6.15.11
Gas Control Units ...................................................................................................... 49
6.15.12
Ejectors...................................................................................................................... 50
6.15.13
Solution Pipe work .................................................................................................... 51
6.15.14
Solution Isolating Valves ........................................................................................... 51
6.15.15
Injection Fittings........................................................................................................ 51
6.15.16
Motive Water Supply ................................................................................................ 52
1667 of 2461
MMRDA
6.15.17
Layout and design considerations............................................................................. 53
6.15.18
Sample Points............................................................................................................ 55
6.15.19
Off-take Arrangement ............................................................................................... 56
6.15.20
Sampling Rate ........................................................................................................... 56
6.15.21
Sample Recovery and Disposal ................................................................................. 57
6.15.22
Sample Pumps ........................................................................................................... 57
6.15.23
Sample Pipework....................................................................................................... 57
6.15.24
uPVC pipework .......................................................................................................... 58
6.15.25
Stainless Steel Pipework ........................................................................................... 58
6.15.26
Polyethylene Pipework ............................................................................................. 58
6.15.27
Sample isolating valves ............................................................................................. 58
6.15.28
uPVC valves ............................................................................................................... 59
6.15.29
Stainless steel valves ................................................................................................. 59
6.15.30
Sample taps ............................................................................................................... 59
6.15.31
Sample sinks .............................................................................................................. 59
6.16
Safety Equipment ........................................................................................................ 60
6.16.1
Safety showers .............................................................................................................. 60
6.16.2
Eye baths ....................................................................................................................... 60
6.16.3
Protective clothing ........................................................................................................ 61
6.16.4
Helmets ......................................................................................................................... 61
6.16.5
Overalls (chemical resistant) ......................................................................................... 61
6.16.6
Gauntlets (chemical resistant) ...................................................................................... 61
6.16.7
Gloves............................................................................................................................ 62
6.16.8
Boots ............................................................................................................................. 62
6.16.9
Storage lockers .............................................................................................................. 62
6.16.10
Self contained breathing apparatus .......................................................................... 62
6.16.11
Cartridge type respirators ......................................................................................... 63
6.16.12
Face masks ................................................................................................................ 63
6.16.13
Eye protection ........................................................................................................... 63
6.16.14
Ear protection ........................................................................................................... 63
6.16.15
First aid kits ............................................................................................................... 64
6.16.16
Fire blankets .............................................................................................................. 64
6.16.17
Ventilatory resuscitators ........................................................................................... 64
6.16.18
Safety signs................................................................................................................ 65
1668 of 2461
6.17
MMRDA
Laboratory Equipment................................................................................................. 65
6.17.1
Equipment ..................................................................................................................... 65
6.17.2
Flooring ......................................................................................................................... 65
6.17.3
Laboratory benches ...................................................................................................... 65
6.17.3.1
Sectional units ....................................................................................................... 65
6.17.3.2
Bench tops ............................................................................................................. 66
6.17.3.3
Fume extraction .................................................................................................... 67
6.17.3.4
Laboratory services ............................................................................................... 67
6.17.3.5
Electrical fittings.................................................................................................... 68
6.17.3.6
Furniture ................................................................................................................ 68
APPENDIX .................................................................................................... 69
1669 of 2461
MMRDA
SUB-SECTION 6B.6: WATER TREATMENT PLANT

6.1
Mixers and Flocculators
6.1.1 General
Chemical mixing shall use mechanical energy and shall provide uniform mixing
of the chemical in the main flow of water at all times over the entire range of
chemical doses applied and flows through the works. A high degree of local
turbulence is considered necessary for satisfactory mixing. The electrical power
or headloss requirements to achieve efficient mixing shall be optimized to
ensure minimum energy consumption at each mixing location.
Mixing energy shall be defined either by the mean velocity gradient, G, in the
3
expression water power (W) per unit flow (m /s) is equal to the product of the
viscosity (Pa-s), mean residence time (s) and square of the velocity gradient
-1
(s ) or any other method approved by the Engineer.
6.1.2 Static Mixers
Static mixers shall be inline mixers where dosed chemicals are mixed by
energy of water flow alone, employing stationary mixing elements which forces
water and chemicals to mix through a progression of divisions, expansion and
redistribution of the flow. They shall have no moving parts and have minimal
maintenance requirements.
The mixer shall comprise fixed elements installed in a housing of diameter

same as the pipe diameter and shall be provided with raised face P16 flanged
end connections to BS EN 1092 part 1 or BS EN 1515 part 1, unless otherwise
specified. The chemical injection pipes shall form an integral part of the mixer
unit. Any section of empty pipe between the outlet of the mixer and the
sampling point shall not be considered as part of the mixer.
SECTION 66B5: WTP
PAGE 1 of 69
1670 of 2461
MMRDA
The mixer housing shall be designed and tested in accordance with ANSI
B31.3 and constructed of carbon steel to BS 4360 Grade 43A. The internals of
the mixer shall be protected with a fusion bonded epoxy coating to a minimum
thickness of 300 microns.
Mixing elements shall be compatible with the chemicals to be dosed at the

maximum concentrations likely to be in contact with the mixer and shall be of
carbon steel to BS EN 10028 Grade 154 - 360 protected with a fusion bonded
epoxy coating system or stainless steel 316S14 or 304S14 to BS 3605.
The supply and location of the chemical injection point shall be the
responsibility of the static mixer supplier. Each static mixer shall be provided
with two injection points (one duty, one standby) for each chemical. Injection
points shall be fitted with 25mm stainless steel injection boss for each injection
point. Injection tubes shall be of the withdrawable under pressure type. The
material of construction of the injection tubes shall be compatible with the
chemical dosed at its maximum dosing solution concentration and shall be
stainless steel or hastealloy C276 or fibre reinforced plastic and shall be
adequately supported and designed to withstand the flow velocity at the point of
application and any flow or turbulence induced vibrations. The injection tubes
shall be supplied complete with cooperation cocks and non-return and isolating
valves.
Each mixer unit shall have a flow direction arrow and lifting lugs.
The mixer shall be designed to achieve a 95% minimum degree of mixing or to

give a coefficient of variation (Cov) not greater than 0.05 for the mixer over the
range of water flows in the pipe at a head loss less than the head loss specified.
Sampling point shall be located three pipe diameters downstream of the outlet
end of the mixer. Facilities shall be provided for taking representative samples
of the water from the pipe cross section for testing purposes. The tests shall
demonstrate that 95% of all concentration measurements taken from the pipe
shall be within plus or minus 10% of the mean concentration over the specified
SECTION 66B5: WTP
PAGE 2 of 69
1671 of 2461
MMRDA
flow range in the pipe and the specified dose range.
6.1.3 Flocculators
Flocculators shall be slow speed vertical shaft top entry type with proven paddle
arrangement subject to the approval of the Engineer.
The degree of agitation shall be defined by the `mean velocity gradient', G

-1
(sec ) in the expression water power (W) per unit flow (m /s) is equal to the
product of viscosity (Pa.s), mean residence time (s) and square of the velocity
-1
gradient (s ). The flocculation condition shall be defined by the product of

velocity gradient and mean residence time (=volume of tank flow).
The drive unit shall be suitable for 24 hour a day continuous operation. The
drive unit shall consist of an electric motor and gear reduction unit with a flexible
coupling provided between the motor and the gear reduction unit. When
specified, the motor shall be provided with a variable speed control system to
allow control of the rotational speed of the flocculator over the operating range.
The speed adjustment shall be by manual operation of a `knob' or `lever' with a
pointer moving against a scale calibrated in the flocculator speed units.
Lifting lugs shall be provided to permit lifting the complete drive unit. The motors
shall be readily separated from the gear reduction unit. All gearing shall be
helical or spiral bevel and shall be totally enclosed. Output shaft shall be
enclosed in a drywell which provides positive leak proof sealing. The flocculator
shaft shall be rigidly coupled to the output shaft.
The coupling to the flocculator shaft shall be readily accessible so that the
gearbox may be easily removed and replaced without entry of personnel into
the mixing chamber or shutdown of the flow.
Gear reduction units and motor bearings shall be oil or grease lubricated. All
points where oil leakage may occur shall be suitably trapped to prevent oil
SECTION 66B5: WTP
PAGE 3 of 69
1672 of 2461
MMRDA
contamination of water. The bearings shall have a L-10 rating of 100,000 hours.
Each flocculator shall be mounted on structural steel beam or channel supports

with chequered plate access platform complete with handrailings. The opening
in the platform shall be large enough to permit removal of flocculator and the
shaft after the removal of the paddles.
The arrangement of the paddles, their dimensions and the tip speed shall be of
a design to provide efficient flocculation of the chemically treated water.
Flocculator paddles and paddle shaft shall be constructed of stainless steel

type 316..
Flocculators shall be suitable for installation in concrete tanks. The mean

residence time in the tanks and the velocity gradient shall be as specified in the
Particular Requirements. The flocculation tank shall consist of one, two or
three equal-size compartments in series depending on the downstream
process flocculation requirements. Tanks shall be provided with baffles
arranged in such a way to eliminate short-circuiting. If necessary an allowance
shall be made in the residence time for short-circuiting. The number of
flocculation tanks to be provided in parallel shall be dictated by the maximum
tank size acceptable to the Contractor. Where tanks are provided in parallel the
water flow shall be divided equally between the tanks by weirs and flocculated
water shall overflow out into a common outlet channel.
The flocculators and the tanks shall be designed to achieve uniform mixing of
chemically dosed water to produce flocs of characteristics suitable for the
downstream solid-liquid separation process.
6.2
Clarifiers
6.2.1 General
SECTION 66B5: WTP
PAGE 4 of 69
1673 of 2461
MMRDA
Clarifiers shall be of a single design for each works. and shall be of concrete
construction each with identical internal dimensions.
6.2.2 Lamella clarifier
Plates shall be partly submerged with plates laid to extend above the normal
water surface to enable settled water to flow out between individual plate
spacings. The space below the lamella plates shall not be less than 2.5 m for
sludge collection and to accommodate scrapers or hoppers.. The slope of the
plates shall be not less than 55 to the horizontal.
The plates shall be designed to slide down into position and it shall be possible
to remove the plates singly by two men working off duckboards. Plates shall
be supported on stainless steel supports. The supports shall be designed to
withstand the weight of the plates when the clarifiers are empty during draining,
in operation with possible additional loads due to sludge and other material
deposits and additional loads during maintenance.
The plates shall be constructed in stainless steel sheets at least 0.7 mm thick.
Minimum plate width shall be 1.25 m and the horizontal centre-to-centre plate
spacing shall be 80 mm. The plates shall be flat sheets; corrugated sheets will
not be acceptable. The plates shall be stiffened at the top and bottom as
recommended by the manufacturer. The plate efficiency shall be greater than
95%. Facilities shall be provided to allow easy and safe access into the lamella
thickener below the plates for maintenance of the sludge scrapers.
The Contractor shall demonstrate that the proposed lamella clarifier design has
been in satisfactory and successful operation in similar applications in at least
two countries outside the proposed manufacturers country of origin for a
minimum of 5 years and the proposed manufacturer has been engaged in the
design and manufacture of such systems for a minimum of 10 years.
Evidence of the relevant experience shall be submitted with the tender.
SECTION 66B5: WTP
PAGE 5 of 69
1674 of 2461
MMRDA
6.2.3 Lamella Clarifier channels
Flocculated water shall be distributed evenly to all the plates. The method of
distribution shall be by slotted openings in the side walls of channels running on
either side of the plates along the length of the tanks, which shall introduce the
flocculated water between each pair of plates near the bottom. The channels
and the openings shall be hydraulically designed to equally distribute the
influent to all of the plates.
The settled water shall be collected by submerged orifices, one between each
pair of plates, in decanting launders.
The flocculated water distribution and clarified water collection channels in

each lamella row and channel components shall be of concrete construction.
Alternative flocculated water distribution systems and settled water collection

systems proven in waterworks over a minimum period of five years will be
considered; design details and evidence of relevant experience shall be
submitted with the tender for approval.
6.2.4 Sludge Scrapers
Scraper assemblies shall each comprise a rotating radial arm[s] scraper

supported by a bridge, bridge mounted centre drive unit and all associated
equipment necessary to safely and efficiently remove sludge from the clarifier
tank floor without re-suspension so as to not influence the quality of the clarified
water. Consideration will be given to peripheral drive systems of proven design.
The sludge shall be scraped to a central hopper from which it shall be
evacuated by gravity under hydrostatic head in the clarifier. The plant shall be
rated for continuous operation and shall be suitable for operation in an outdoor
environment.
For systems adopting a centre mounted drive unit/system, the scraper
assembly shall comprise a central torque tube of adequate stiffness supported
from a bearing assembly mounted on the bridge, designed to carry the rake
SECTION 66B5: WTP
PAGE 6 of 69
1675 of 2461
MMRDA
and sub-assemblies. The bearing should carry the final gear drive ring to
engage with a pinion gear on the output shaft of the motor reducer, or the motor
reducer may be directly coupled to the torque tube.
The bridge and scraper assemblies shall be designed to accept without
distortion any normal torsional or bending/deflection loads which may occur
during erection, testing and operation Any structural movements of the
bridge/scraper radial arm[s], must be limited so as not to effect the efficiency of
both sludge removal and performance of the clarifier. Underwater bearings
particularly support and stuffing boxes will not be acceptable.
The scraper shall comprise either one radial arm or two diametrically opposite
radial arms spanning the clarifier and bearing a series of vertical blades
sweeping the settled sludge on the floor to a central hopper.
Alternatively it shall have two diametrically opposite long radial and two
diametrically opposite short radial arms each bearing a series vertical blades
sweeping the settled sludge on the floor to a central hopper. Scraper blades
shall be firmly secured to the bottom of truss members and shall include angle
stiffeners.
The scraper central shaft shall also be fitted with an additional single blade for
scraping sludge off the sides of the central hopper.
Scraper blades shall be manufactured in steel with an epoxy finish and shall be
fitted with renewable synthetic rubber wearing strips to maintain contact with
the floor surface, and to cope with possible minor undulations in the floor. The
renewable inserts shall be not less than 100 mm by 15 mm in cross-section and
supported within 40 mm of the contact edge by stainless steel 316 backing
plates using bolts, nuts and washers in stainless steel 316 bolts. Adequate
provision for vertical adjustment shall be made to suit the extent of wear
allowable before replacement and to ensure proper clearance above the tank
floor for efficient scraping and to allow for deflection of the bridge and assembly
tolerances.
The scraper shall be used by the Contractor to trowel the cement mortar screed
over the base of each clarifier. The scraper blades and squeegees shall be
removed and replaced by timber screeding boards for this operation. The
Contractor shall clean the mechanism and replace the scraper blades and
squeegees after this operation.
SECTION 66B5: WTP
PAGE 7 of 69
1676 of 2461
MMRDA
The drive unit shall comprise a variable or fixed speed electric motor as
specified with coupling and totally enclosed reduction gear, all mounted on
girders so that the shaft couplings are accessible, and the gear box easily
removed and readily replaced without entry into the tank. Working access to
all sides of the drive unit shall be possible.and to all items of equipment
requiring periodic adjustment, inspection and maintenance.
All points where oil leakage may occur shall be suitably trapped to prevent oil
contamination of water. Greasing points shall be extended as necessary to
readily accessible locations.
The drive shall be capable of producing free and uniform rotation without
binding, when operating with excessive accumulations of sludge on the tank
floor. It shall be designed to start from rest following a sit-down condition such
as start-up following restoration of power after a power failure. The drive unit
shall be designed with a minimum service factor of 2 to withstand the blade
loads and hydraulic drag on the scraper mechanism whilst operating under the
specified performance criteria and at the maximum rotational speed
recommended by the manufacturer.
Each drive unit shall be provided with a torque limiting coupling between the
geared motor and the gearbox suitable for manual adjustment of the breaking
torque. The coupling shall incorporate a limit switch to shut down the motor
during an overload condition. An alarm shall be annunciated at the motor
starter and also at any other location specified in the Particular requirements.
Additionally shear pin overload protection shall be provided in each drive unit
as a back-up to the torque limiting coupling device. The shear pin protection
shall be designed to fail at a torque 25% in excess of the torque limiting
coupling maximum setting and also at not more than 75% of the torque for
which the drive and scraper structure mechanism is designed. Shear pins
shall be placed in an accessible location and shall not be subjected to bending
stresses. All shear pins shall be full diameter type.
Drive unit motors shall be as specified in Section 4.13 of the Specification.
gear assemblies shall conform to American Gear Manufacturer's Association
(AGMA) standards and shall be designed with a service factor of not less than
1.5. Gears shall be supported on anti-friction bearings and shall be oil
lubricated. Oil fill, breather and level indication devices shall be provided.
SECTION 66B5: WTP
PAGE 8 of 69
1677 of 2461
MMRDA
All bearings on the drive unit shall be selected to give a minimum calculated B
10 design life of 100,000 hours.
For peripheral drive systems, the bridge shall be provided with wheels of
polyurethane construction running on the outer wall of the clarifier. A special
durable running surface such as brass shall be installed, true to line and level.
Also, all guide wheels and traction wheels shall be provided with bearings
adequate for the loads to be carried and for the conditions of operation.
Mechanical plant shall be designed so that it may easily be maintained and
removed from the tanks.
6.2.5 Clarified Water Removal
The clarified water in circular sedimentation tanks shall be removed in a peripheral

launder located outside the clarifier. The clarified water shall enter the launder by
submerged orifices.
6.2.6 Clarifier Access
Clarifiers shall be provided with access to the peripheral weir, scraper drive and
flocculator drives. Where necessary platforms shall be provided to carryout
maintenance work. Scraper bridge shall be provided with open mesh flooring.
Lamella clarifiers shall be provided with access to the flocculator drives and
scraper drive. Access shall also be provided between each clarifier and to
clarified water collection channels. The Contract shall ensure that the access
provided is adequate for the removal of plates for cleaning. Facilities shall be
provided for removing plates for cleaning.
All desludging valves shall be provided with access for maintenance. Access
shall also be provided into sludge galleries.
All access ways shall be provided complete with hand railings.
6.3
Filters
6.3.1 General
SECTION 66B5: WTP
PAGE 9 of 69
1678 of 2461
MMRDA
The filters shall be rapid gravity type of concrete construction, each identical in
internal dimensions and designed for washing by the simultaneous application
of air and water as specified. Filter washwater shall be disinfected filtered
water.
Filters shall operate on a constant head declining rate principle. The filter
inlet system shall be designed to ensure that the total inflow is divided equally
between filters in service at all works throughputs.
Backwash pumps, air blowers and other filter ancillary plant shall be located
within the filter block.
6.3.2 Filter media
Filtration shall be through suitable filter media appropriate for the duty and shall
be supported by a layer of suitably graded packing pebbles.
6.3.3 Sand
Filter sand size shall be defined by its effective size i.e. 100% passing 0.7 mm
and 100% retained on 0.5 mm mesh and a uniformity coefficient of 1.4.
Loss in weight on ignition at 350C for one hour, which is a measure of the
organic content, shall be less than 2% by weight. The filter sand shall have a
saturated-surface-dry specific gravity of not less than 2.40. The loss due to
attrition (friability) shall not exceed 1% by weight over 100 hours backwashing
on a laboratory test. Filter sand shall be substantially free of fine and coarse
material and shall be between the grading limits specified.
6.3.4 Packing gravel
Filter sand shall be supported by a layer of suitable graded packing gravel. The
packing layer shall be not less than 50mm depth and be such as to ensure
adequate and uniform distribution of washwater and air after leaving the
nozzles, with the minimum risk of mixing sand with the layers of packing media,
SECTION 66B5: WTP
PAGE 10 of 69
1679 of 2461
MMRDA
or of fines in the sand penetrating the nozzle apertures.

Filter gravel or pebbles shall be rounded or waterworn stones which, when
placed in layers in a filter above and around the nozzles, will distribute the
washwater effectively. The gravel shall be washed to remove all carbonaceous
matter, clay and silt, and loss on acid washing shall be less than 4% by weight.
Acid washing shall be of the water-washed and dried sample with 24 hours
contact in 10% by volume of hydrochloric acid.
6.3.5
Media source
The Contractor shall submit with his tender his detailed specification for the
media which he proposes to use for the Works (which shall be at least to the
requirements set out herein), and shall include details of his proposed methods
of test and quality control (including friability) and details of the source from
which he proposes to obtain his supplies. Following award of Contract, the
sources of media shall be subject to the consent of the Engineer. Upon
preliminary approval of sources and within two months of the award of Contract,
the Contractor shall submit to the Engineer a 10 kg representative sample of
each media for testing and consent.
Only when the Engineer has approved the samples, shall orders be placed.
The Contractor shall thereafter not alter his sources without the prior written
consent of the Engineer. All filter sand shall be obtained from an approved
single source and supplier and shall be washed, heat dried, graded and packed
in bags as approved by the Engineer for delivery to or storage at Site. Hessian
bags, and bags made of similar materials which may deteriorate during transit
or in open storage shall not be used.
6.3.6 Spare media
Spare media to replace that lost in the first 5 years of filter operation following
the issue of the Maintenance Certificate, shall be provided. Media for storage
shall be dried and subjected to the quality control procedures specified for
media to be placed in filters. The spare media shall be packed in bags suitable
SECTION 66B5: WTP
PAGE 11 of 69
1680 of 2461
MMRDA
for long storage. Bags shall be stacked on pallets of the close-boarded type as
specified elsewhere for chemical storage.
6.3.7 Media placing
Following installation and satisfactory testing of filter floors and when the
Engineer is satisfied that the installations are complete, the Contractor will be
given written permission to commence charging the filters, which shall be
carried out to the procedures set out in section 23 of the AWWA Standard for
Filtering Media (AWWA B100-80) with the exception that the wash rate may be
varied.
Filter media shall be carefully placed and not charged by dropping or dumping,
or any other method which, in the opinion of the Engineer, will be detrimental to
the media, nozzles, floors and sealants. Chutes may be employed only after
300mm of covering has been placed over the floor. After placing each layer of
media it shall be thoroughly back washed to clear debris, mud and other
impurities. This shall be followed by an air distribution test to check that
nozzles have not been damaged during the placing of the media.
Prior to setting the filters to work, the media in each filter shall be backwashed
in-situ and skimmed to remove fines so that, in the top 150mm of the media, the
proportion of fines does not exceed 5% any time up to the end of the Period of
Maintenance.
Fines are defined as the particles which pass through an
aperture 0.9 times the effective size of the media. The depth of material
removed in skimming shall be replaced by an equal depth of media to the
specified grading.
The Contractor shall supply and replace free of charge sand lost in the washing
of filters during the periods of setting to work, site tests and the Period of
Maintenance.
The Contractor shall not place the media in a filter until, in the opinion of the
Engineer, the construction work is reasonably complete, and that there is no
threat of extraneous construction debris contaminating the media.
Where
construction work in the filters is necessary after placing the media, the
Contractor shall use suitable heavy duty covers to protect the media from
SECTION 66B5: WTP
PAGE 12 of 69
1681 of 2461
MMRDA
contamination.
6.4
Filter Under-drain System
6.4.1 General
Filter under-drain system shall include all items and materials within the filter
cell, above base slab and below the gravel layer. Such items and material
within each filter cell shall include the means for collecting filtered water for
uniformly distributing air and backwash water, together or separately and for
retaining, supporting, and sealing the filter under-drain system; all as necessary
for a complete under-drain system.
Prior to commencing any work on the system, the Contractor shall submit
complete details of the design, construction and the operating characteristics of
the under-drain system to the Engineer for review and approval. Such
submissions shall include supporting calculations with up and downwards
loadings and their derivations, materials of construction, head loss data for
filtration and backwash, installation details, levelling tolerances, allowable
percentage of flow mal-distribution within a filter cell and any other information
which in the opinion of the Engineer is necessary to assess compliance with the
Specification.
The Contractor shall demonstrate that the proposed under-drain system has
been in satisfactory and successful operation in similar applications for a
minimum of 5 years and the proposed manufacturer has been engaged in the
design and manufacture of such systems for a minimum of 10 years.
6.4.2 System description
The system for the collection of filtrate and the distribution of air scour and
washwater shall be by means of nozzles set in a reinforced concrete floor (i.e.
plenum floor). The plenum floor shall be either constructed in-situ concrete or
from individual floor sections.
SECTION 66B5: WTP
PAGE 13 of 69
1682 of 2461
MMRDA
6.4.3 Materials
Under-drain system shall be of proven non-corrodible materials. All exposed

metals shall be type 316 stainless steel.
Other materials used in the
construction of the reinforced concrete floor including the sealants shall be as

recommended by the manufacturer subject to the approval of the Engineer.
Nozzles shall be made of polypropylene. Asbestos cement based items shall
not be used.
6.4.4 Design requirements
The under-drain system shall be designed to provide uniform draw-off of filtered

water and uniform distribution of air and water over the whole area of the filter
and shall comply with the following:
(i) The spacing of nozzles shall be such that local disturbance of the pebbles
and/or sand layers surrounding or above the under-drain does not affect the
performance of the filter.
(ii) Nozzles shall:Incorporate separate entrances for air and water.
Be capable of being adjusted to exactly the desired level.
Be capable of being replaced without damaging fixed sealing rings.
Be "sand tight" bearing in mind the media in question which is likely to reach the
nozzles.
Be capable of being capped watertight to allow pressure testing of the
under-drain system.
(iii) Nozzles shall be designed to provide efficient separate positive control of
the distribution of air or washwater.
The under-drain system shall be structurally designed to withstand the
following loadings:Net loading during backwash at the maximum back wash rates.
Net downward loading.
A safety factor to account for dynamic shock loadings which may occur during
the starting and termination of air and water backwash.
SECTION 66B5: WTP
PAGE 14 of 69
1683 of 2461
MMRDA
All loads incurred during shipment, handling and installation.

To prevent any excessive loadings due to blockages of the filter nozzles or
accidental introduction of high pressure water, the Contractor shall include a
pressure relief chimney, with free discharge, in the washwater pipe work
system. A pressure relief valve system shall not be acceptable. The overflow
from the system shall be arranged to discharge to the site overflow receptor
system or to the filter inlet channel.
Access to the plenum shall be by a 600mm diameter access manhole on the
side wall of the filter. Man holes or similar sealed removable covers shall not be
provided on the filter floor.
6.4.5 Installation
The Contractor shall install the filter under-drain systems in strict accordance
with approved drawings and procedures. The Contractor shall take all
necessary measures to ensure that the false floor containing nozzles and the
air and water conveying system of pipes or channels connected to the plenum
are free from any concrete, sand or other debris which could otherwise block or
partially block the nozzles.
The under-drain system shall be laid to level, within the tolerances stated in the
consented drawings and shall be confirmed by measurement following
installation. All apertures in the under drain system shall be plugged until the
nozzles are installed, to avoid the possibility of extraneous material entering the
under drain system during installation.
Media shall be placed in the filter only after all construction work in the proximity
of the filter has been completed and air distribution tests have been
successfully carried out. Where this is unavoidable the media shall be kept
under cover using heavy duty polythene sheeting to prevent contamination of
the media with construction debris.
6.5
Air Scour Arrangements
6.5.1 Air blowers

SECTION 66B5: WTP
PAGE 15 of 69
1684 of 2461
MMRDA
Air supply to the filters shall be provided by Rootes type positive displacement
rotary / Turbo air blowers supplying oil-free air. The blowers shall include at
least one duty and one standby unit. Automatic starting of the standby on failure
of the duty blower shall be required. The selection of the duty blower shall be
carried out at the motor starter. Blowers shall be sized to deliver directly the
necessary flow rate of air at the pressure required by the filter.
Blower speed shall be less than 2000 rpm. Bearings shall be rated for a
minimum B-10 life of 100,000 hours.
Each blower shall be driven via a Vee belt drive arrangement by a cage
induction motor. The blower and motor shall be mounted on a combination
baseplate with slide rails for belt tension adjustment. A sheet steel guard shall
be bolted to the baseplate and the baseplate shall be provided with heavy duty
anti-vibration mountings.
Each blower shall have an inlet air filter, inlet and discharge silencers, a
pressure safety valve, pressure gauge, check valve and isolating valve. Due
allowance shall be made for operating a pressure safety valve set at a higher
pressure without overloading the blower or its driver.
Where necessary to facilitate starting of the blower (eg. at reduced voltage), an
unloading arrangement shall be incorporated in the blower delivery system and
shall include a motorised valve operated via auxiliary contacts on the blower
motor starter. Under no circumstances shall a blower be selected to operate at
or above the continuous maximum temperature or discharge pressure
specified by the blower manufacturer. A clear safety margin shall be allowed,
preferably of at least 0.2 bar.
In process applications where the discharge pressure may approach the
maximum permitted, the machine shall be arranged to shutdown on high
discharge temperature and a suitable switch and thermometer shall be
provided.
The sealing arrangement between the timing gearbox and compression
chamber shall ensure that leakage of oil cannot take place during operation or
shutdown. Where necessary to facilitate starting of the blower (eg. at reduced
voltage), an unloading arrangement shall be incorporated in the blower delivery
SECTION 66B5: WTP
PAGE 16 of 69
1685 of 2461
MMRDA
system and shall include a motorised valve operated via auxiliary contacts on
the blower motor starter. Where appropriate, the blower and its accessories
may be preassembled on a steel frame.
The noise from the air blower shall be as set out in the Specifications. The
blowers shall be provided with acoustic enclosures and the blower room shall
be sound proofed.
6.5.2 Air Intake
Air intakes shall be positioned in a manner which avoids collection of

contaminants such as engine exhaust fumes and excessive dust and always
away from any air extractor fan discharge points. Air may be admitted to the
room which houses the blowers either through an external wall or, where this is
not possible, via an intake duct.
A louvered panel or panels shall be installed at the air inlet point together with
primary filters. The filters shall comprise removable panels with convoluted
elements mounted in frames. The elements shall be of the washable type and
a spare set shall be provided to facilitate substitution for this purpose.
Intake ducting shall be in galvanised steel and of adequate proportions to
minimise pressure drop and vibration. Where necessary to suppress low
frequency noise, a silencer of the multiple aerofoil or `beam splitter' type shall
be installed within the duct close to the inlet point. Where air is drawn from
outside the building, then heat from the machines must be dissipated effectively
at times of high ambient temperatures. The room shall be properly ventilated.
6.5.3 Air Pipework
The blowers shall be connected to the pipework by stainless steel braided

flanged flexible connectors not less than 250mm long. Valves and pipework
covering air shall be designed for air velocities not exceeding 30m/s. Care shall
be taken in the design of the filter inlet to handle high air velocities. Air scour
pipework shall be located at such an elevation and shall ensure that water
cannot siphon back to the blowers.
SECTION 66B5: WTP
PAGE 17 of 69
1686 of 2461
MMRDA
Provisions shall be made for the release of air from the system at the end of the
air scour before the rinse commences. The necessary valve/pipework shall be
provided as appropriate to the filter design proposed. Provisions shall be made
for the release of air from the system at the end of the air scour before the rinse
commences. The necessary valve/pipework shall be provided as appropriate
to the contactors design proposed.
6.6
Backwash Arrangements
6.6.1 Backwash Pumps
Washwater shall be delivered direct to the filter by pumps or drawn by gravity

from an elevated storage tank. The pumps shall be of the double entry split
casing or end suction centrifugal type and shall be admitted to the filters at flows
recommended by the Contractor.
A minimum of two identical washwater pumps shall be provided to serve as
duty and standby units. Automatic starting of a standby unit in the event of
failure of a duty unit is not required. Selection of the duty washwater pump
shall be carried out at the motor starter. The pumps shall be self-priming with
their drive motors mounted above flood-level and connected to the pump via
suitably supported intermediate drive shafts.
6.6.2 Pipework
Pipework shall be complete with all necessary stays, brackets, thrust collars
and rings to facilitate erection and to prevent movement. Washwater delivery
pipework shall be designed to cope with the maximum hydraulic loadings likely,
particularly with respect to supports and anchorages. The maximum velocity
through washwater pipework and the filter wash inlet valve shall not exceed
3.5m/s. Care shall be taken in the design of the pipework and underdrains to
handle any possible high velocities and to avoid surge, cavitation and uneven
pressure within the system.
A protection device shall be provided to safeguard washwater system from the
SECTION 66B5: WTP
PAGE 18 of 69
1687 of 2461
MMRDA
effects of water hammer.
6.6.3 Washwater Flow Control
The washwater supply pipework to the filters shall be provided with a flow meter
of the magnetic type. The rate of flow shall be indicated local to the control
valve. The rate of backwash flow to the filters shall be controlled by a butterfly
valve located within the filter block and downstream of the flow measuring
element.
Operation of the valve shall be manual by lockable handwheel. The valve
shall be provided with a position indicator. Backwash system designs which
require two wash rates, the different rates shall be achieved either by providing
a suitably sized bypass to the control valve or by the use of he control valve.
The maximum velocity through the control valve shall not exceed 5 m/s.
6.7
Filter Valves and Motive Power Systems
6.7.1 Valves
Butterfly valves shall be used for the filters in preference to penstocks or sluice
valves. The use of penstocks shall be limited to the filter inlet. Where valves are
required for flow control, butterfly valves shall be used. Valve operating
mechanism including any actuator shall be accessible for removal and
maintenance, and clear of any water surface.
Valves shall be sized by the Contractor to enable the filters to operate within the
hydraulic limits set down in the Specification but also so that the following upper
limits of velocity through valves or penstocks are not exceeded:
Filter inlet 1.0 m/s Filtered water outlet 1.5 m/s Washwater inlet 3.5 m/s Waste
washwater outlet 2.0 m/s Air inlet 30.0 m/s
Each filter shall be provided with means for draining the filter completely. The
drain valve shall be not less than 150 mm diameter and shall be operated by
hand wheel. Discharge pipework shall be provided to direct the water to a
suitable drainage system in the pipe galleries. If gravity drainage is not
SECTION 66B5: WTP
PAGE 19 of 69
1688 of 2461
MMRDA
possible, a pump sump with duty/standby submersible pumps complete with

level sensing system shall be provided.
All butterfly valves shall be made by the same manufacturer, and shall be
rubber seated and double flanged. Wafer type U-section through-bolted
flangeless valves for insertion and clamping between flanges shall not be used.
Where filter inlet isolation other than by valve or penstock is proposed, a
manually operated gate shall be provided to isolate the flow and permit
maintenance of the device.
6.7.2 Motive Power Systems
Filter valves which require to be operated as part of the washing cycle shall be
power operated as specified.
The time taken to open or close any
valve/penstock shall be less than 60 seconds. In the event of motive power

failure, filter valves, including outlet control valves, shall remain `held' in the
position they were in prior to power failure.
Valves and penstocks operated during the backwash sequence shall be fitted
with proximity switches; volt free contacts shall be provided for transmitting
signals for remote operation and/or state lamps and initiation of valve/penstock
failure alarms.
6.7.3 Pneumatic Actuators on/off type
Pneumatic actuators shall comply with the requirements of the Mechanical

Standard Specification for both modulating and non-modulating valves and
penstocks.
6.7.4 Filter-internal and gallery pipework
Flexible jointing shall be provided as necessary on all runs of pipework

particularly at main movement joints in structures. Pipework generally shall be
of steel or ductile iron and shall be adequately supported. Pipes to be built into
concrete shall have puddle or thrust flanges as appropriate. Access shall be
SECTION 66B5: WTP
PAGE 20 of 69
1689 of 2461
MMRDA
provided to the pipework and valves opposite each filter. In the case of a
continuous pipework gallery, access shall be provided by means of ladders and
platforms located at least at opposite ends or each gallery and if necessary in
the middle of the gallery. In the case of non-continuous gallery, access shall be
provided to each section (pit) of the gallery by means of ladders fixed to the wall
of the filtered water channel opposite each filter. Access to the filter base
sections (plenum floor) shall be achievable without dismantling the main filter
pipework. The clearance for access below the filter floor fittings and support
beams shall be at least 600 mm. Entrance manholes shall be provided to each
compartment within the filter base; 600 mm blank flanged spigots shall lead to
the floor voids (one to each filter void) and a similarly mounted but flush fitting
studded steel cover, 600 mm x 500 mm, shall lead down to any central lower
air/water distribution channel between the filter sections.
6.7.5 Location of Pipes and Channels
Clarified water shall be distributed to the filters in channels which run along the
end of each filter remote from the central pipe gallery. The filter washout
channels shall be located beneath the filter inlet water channels. The
dimensions of the filter inlet pipes and channels shall be such that when all
filters are operating at the maximum filtration rate, the difference in level
between the highest and lowest water level in the inlet channel system shall not
exceed 100 mm.
Filtered water shall be delivered to a filtered water channel located centrally
within each pipe gallery.
The filtered water channel shall be hydraulically
isolated from the filter outlet/pipework. The outlet from each filter shall be taken
to a concrete weir box with side entry discharge into the filtered water channel.
The level of the weir shall be set at or above the top of the media level in the
filter.
The filtered water channel shall be designed to carry a flow equal to the
theoretical flow from all filters operating at the maximum filtration rate. The
highest water level at the remotest filter shall be 100 mm below the weir/trough
discharge level and the maximum velocity in the channel shall not exceed 1
SECTION 66B5: WTP
PAGE 21 of 69
1690 of 2461
MMRDA
m/s.
Filter gallery pipework and access platforms shall be designed to enable lifting
gear to be positioned for subsequent removal of pipes, valves and penstocks
for maintenance purposes. The access platforms shall also be arranged to give
easy access to pipework, valves and services located on filter front walls.
Filtered water channel drainage facilities shall be provided together with the
necessary isolation to facilitate future inspection and maintenance.
Filter
washwater inflow pipes may be located in the duct space between the filtered
water from the duct space to drain by gravity.
The common used filter washwater channel and the washwater outlet
valves/penstocks shall be sized to ensure that, at maximum discharge rates,
water does not pressurise the washout channel or back-up in the filter washout
bay. The minimum requirement is for conduits to be sized for a `dump' and for
washing of one filter simultaneously. A dump is defined as the discharge of the
contents of a filter via the washwater outlet valve.
6.7.6 Filter House Access
The top of the filters shall be provided with walkways around three sides of each
bank of filters excluding the sides common with the central gallery, and
between filters. Access from the top of the filters shall be connected to the
central covered upper filter gallery. The sides of the upper central gallery shall
be of glass panel construction above a height of 1000 mm to allow operators to
observe the washing of filters from the central gallery. The filter wash control
panels shall be located in the central gallery opposite each filter. Access to the
filters shall be provided from two opposite ends at least at one level. It shall also
be possible to access administration building and the filter plant rooms from the
filters. Stair access shall be provided from upper gallery to lower gallery from
the opposite ends.
6.7.7 Filter plant lifting equipment
An overhead hand-operated hoist shall be provided and installed in:SECTION 66B5: WTP
PAGE 22 of 69
1691 of 2461
MMRDA
The lower pipe galleries;

Washwater pump basement(s) where applicable;
Washwater pump motor room(s) where applicable;
Air blower room(s).
Each hoist shall have adequate capacity for handling the largest items of Plant
in the area commanded and shall be provided with lifting chains, hooks and
slings, runways and fixings. The hoist system in the lower galleries shall be
designed to aid the placing of pipework and valves and their removal for
maintenance if required.
The blower room(s) hoist shall be designed for
off-loading from vehicles.
6.8
Waste Treatment Facilities
6.8.1 Submersible mixers
Submersible mixers shall be of the axial flow type with shrouded propeller and
horizontal motor and propeller shafts. The design requirements of the mixer
shall be as follows:(a) Maintain solids in a uniform suspension throughout the tank without
shearing the flocculated material.
(b) Totally submerged operation to a depth 1.5 times the normal depth of
submergence.
(c) Operation in sludge of at least twice the specified solids content.
(d) Capable of starting from a "sit-down" condition without the need to raise the
mixer and then lower it after start-up.
(e) Suitable for continuous operation in the sludge of specified physical and
chemical characteristics without undue wear and tear.
(f) Motor rates shall be not less than 20% in excess of maximum absorbed
power rating.
(g) Capable of being operated at any depth and capable of angular positioning
both in the horizontal and vertical planes with location stops at no greater than
30.
SECTION 66B5: WTP
PAGE 23 of 69
1692 of 2461
MMRDA
Mixers shall be designed to be raised or lowered and shall be easily removed

from its working position without the need to enter the tank in which it operates.
Each mixer shall be provided with a guide rail and post with integral davit fixed
to the wall of the tank. Davit arms shall be at a height no greater than 2.25m
above local platform or hardstanding. The base of the guide rail shall be fixed
to the floor of the tank. The davit post shall be rotatable or pivoted and be
provided with means for lowering the mixer on to the walkway adjacent to the
tank when it is raised out of the tank. The davit shall be provided with all
necessary ropes, shackles and pulleys.
Pully block shall be suitable for
exterior applicable without corroding. The complete lifting unit shall be rated for
twice the maximum duty required.
Mixer motors shall have a built in cooling system which shall permit continuous
operation at rated output both when submerged and not submerged.
Motor cable terminations shall be provided with cable sleeve and strain relief.
The cabling to the motor shall be securely sheathed to prevent fouling with the
propeller. The cabling shall be of the correct length allowing only a minimum
of excess length.
Motor bearings shall be maintenance free.
The propeller and propeller shaft shall be in stainless steel to BS EN 10090. All
installation accessories including guide rail and wire rope shall also be in
stainless steel.
6.9
Thickeners and Scrapers
6.9.1 Thickeners
Thickeners shall be continuous flow type comprising a cylindrical tank of

reinforced concrete construction and a sludge scraper. The design of the
thickener shall be to TR 189, ' Sludge Treatment Plant for Waterworks', Water
Research Centre, UK, 1983 or any other design proven in waterworks
coagulant sludge thickening for at least five years; design details and evidence
of relevant experience shall be submitted with the tender for approval.
SECTION 66B5: WTP
PAGE 24 of 69
1693 of 2461
MMRDA
6.9.2 Sludge Scraper
Thickening tank scrapers shall be the rake type and shall comprise of a fixed
support bridge, a rotating rake spanning the full diameter carrying rake blades,
bridge mounted centre drive unit, and all associated equipment necessary to
safely and efficiently remove sludge from the thickener tank floor without
re-suspending. The sludge shall be scraped to a central hopper from which it
shall be evacuated by gravity or pumps as specified. Plant shall be rated for
continuous duty and shall be suitable for operation in an outdoor environment.
The rake assembly shall comprise a central torque tube of adequate stiffness,
supported from a bearing assembly mounted on a fixed bridge of steel
construction and carrying the rake and sub-assemblies. The bearing may
carry on the final gear drive ring to engage with a pinion gear on the output shaft
of the motor reducer, or the motor reducer may be directly coupled to the torque
tube.
The assembly shall be suitable for installation in tanks of specified side water
depths and floor slopes.
The rake assembly shall be fitted with two arms spanning the thickener and
bearing a series of vertical blades consisting of a central spiral blade and outer
blades set in echelon formation mounted at an angle to the arm, sweeping the
settled sludge on the floor. It shall also be fitted with an additional single blade
for scraping sludge off the sides of the central hopper.
Rake blades shall be manufactured in steel and shall be fitted with renewable
synthetic rubber wearing strips (squeegees) to maintain contact with the floor
surface, and to cope with possible minor undulations in the floor. The
renewable inserts shall be not less than 100mm by 15mm in cross-section and
supported within 40mm of the contact edge by stainless steel backing plates.
Adequate provision for vertical adjustment shall be made to suit the extent of
wear allowable before replacement.
The scraper shall be used by the Contractor to trowel the cement mortar screed
over the base of each thickener. The scraper blades and squeegees shall be
removed and replaced by timber screeding boards for this operation. The
Contractor shall clean the mechanism and replace the scraper blades and
SECTION 66B5: WTP
PAGE 25 of 69
1694 of 2461
MMRDA
squeegees after this operation.

The fixed bridge structures shall be supported on the tank walls and
constructed from rolled steel beam sections that span the tanks. One half of
the bridge shall be provided with galvanised mild steel walkway, handrailing
and toeboards. The fixed bridge structures shall be shot blasted and zinc
sprayed after manufacture and painted with an approved paint system. The
walkway shall comprise open mesh flooring, 750mm wide and not less than
20mm thick, of the specified pattern with individual panels weighing not more
than 50 kg. The panels shall be of adequate section to support a uniformly
2
distributed load of 5 kN/m . Walkway panels maximum deflection shall be 0.005

of the span or 5mm, whichever is the least.
Handrailing and flooring shall be provided between the point of access to the
bridge and extend to 1500mm beyond the drive unit. In the vicinity of the drive
unit it shall be widened to provide a minimum 750mm clear unobstructed
flooring around both sides. Handrailing and toeboards, 150mm high and 5mm
thick shall be fitted around all three sides of the walkway.
The bridge structures shall be designed to withstand self weight, weight of a
2
superimposed load of 5 kN/m over the complete walkway and a wind loading
of 40 m/s. Under the design loads the maximum deflection shall not exceed
1/360 of the span. Steps shall be provided as necessary for access to the
peripheral end of the bridge.
The drive unit shall comprise of a variable or fixed speed electric motor as
specified with coupling and totally enclosed reduction gear, arranged so that
the shaft couplings are accessible, and the gear box easily removed and readily
replaced without entry into the tank. Working access to all sides of the drive unit
shall be possible. The drive shall be capable of producing free and uniform
rotation without binding, when operating with excessive accumulations of
thickened sludge on the tank floor. It shall be designed to start from rest
following a sit-down condition such as start-up following restoration of power
after a power failure. The drive unit shall be designed with a minimum service
factor of 2 to withstand the blade loads and hydraulic drag on the scraper
mechanism whilst operating under the specified performance criteria and at the
maximum rotational speed recommended by the manufacturer.
SECTION 66B5: WTP
PAGE 26 of 69
1695 of 2461
MMRDA
Each drive unit shall be provided with a torque limiting coupling between the
geared motor and the gearbox suitable for manual adjustment of the breaking
torque. The coupling shall incorporate a limit switch to shut down the motor
during an overload condition. An alarm shall be annunciated at the motor
starter and also at any other location specified in the Particular requirements.
Additionally shear pin overload protection shall be provided in each drive unit
as a back-up to the torque limiting coupling device. The shear pin protection
shall be designed to fail at a torque 25% in excess of the torque limiting
coupling maximum setting and also at not more than 75% of the torque for
which the drive and scraper structure mechanism is designed. Shear pins
shall be placed in an accessible location and shall not be subjected to bending
stresses. All shear pins shall be full diameter type.
Drive unit motors shall be as specified and gear assemblies shall conform to
American Gear Manufacturer's Association (AGMA) standards and shall be
designed with a service factor of not less than 1.5. Gears shall be supported
on anti-friction bearings and shall be oil lubricated. Oil fill, breather and level
indication devices shall be provided.
The reduction gear shall incorporate an oil dam so that the oil contained is not
lost in the event of a seal failure.
All points where oil leakage may occur shall be suitably trapped to prevent oil
contamination of water. Greasing points shall be extended as necessary for
readily accessible locations.
All bearings on the drive unit shall be selected to give a minimum calculated
B10 design life of 100,000 hours.
6.9.3 Supernatant Removal
The supernatant shall be removed in a peripheral launder located outside the

thickener tank. The effluent shall enter the launder by overflowing a V-notch
weir which shall be provided for peripheral channels in sections with vertical
adjustment. The weir plates shall be constructed from stainless steel grade 316
or epoxy coated steel and shall have a minimum thickness of 6mm and shall be
supplied complete with stainless steel 316 anchor bolts and sealing strips.
SECTION 66B5: WTP
PAGE 27 of 69
1696 of 2461
MMRDA
Holes for anchor bolts shall be slotted to provide vertical adjustment of not less
than 30mm.
6.9.4 Sludge Pipework and Valves
All isolating valves on the sludge pipelines shall be resilient seated sluice type,
eccentric plug type or straight through diaphragm type. Sludge pump delivery
pipework shall be provided with pressure relief and non-return valves. Relief
valves shall be adjustable spring loaded type capable of passing the whole of
the output of the pump.
Valves shall be arranged to discharge the relief
individually back to the balance tank compartment in service and thickeners as

appropriate.
Small bore pipework shall not be used on the relief. The
discharge of the relief shall be visible.

Sludge pipework shall be designed to minimise sludge settlement and
blockages and shall be easy to flush and clean. Pipe tapers shall be of the flat
type and where possible branches from sludge lines shall be taken from the top
of the pipe.
Sludge pump suction and delivery pipework shall be provided with rodding
branches and flushing connections complete with isolating valves and
terminating in hose connectors.
6.10 Chemical Storage & Handling
6.10.1 General
The contractor shall design, supply and install the complete system for each
chemical to be handled including the chemical storage tanks, solution/slurry
preparation systems, water supply system, pumps and fittings, together with
the system of administering the chemicals to the points of application. Where
strainers are necessary, valves and fittings shall be provided to allow the
strainers to be removed for cleaning.
The system shall be complete with dust extraction and filter equipment,
chemical handling and weighing equipment, and all other accessories specified
SECTION 66B5: WTP
PAGE 28 of 69
1697 of 2461
MMRDA
and required to provide a comprehensive chemical plant in all respects. In the

layout of the plant adequate space shall be provided for access to carry out
operations and maintenance of equipment.
Particular attentions shall be paid to the layout of the chemical pipework, which
shall be functional and neat in appearance. Generally, where pipework is not
installed in main ducts, it shall be supported not less than 150 mm clear of the
floor. Where necessary, equipment and pipes shall be suitably protected from
the effects of cold weather. Protection of equipment and pipes may also be
required for other reasons such as local heating effects and/or condensation
problems.
6.10.2 Storage and Reception
Chemical building shall be designed to receive supplies of chemicals by road

transport and shall provide for unloading and transport to storage.
Lorry
hardstandings shall be provided for all chemical unloading areas. Facilities

shall be provided as specified for unloading chemicals delivered in individual or
palletised packages.
Storage areas for chemicals delivered in packages shall be sufficiently large to
provide space for storage, access corridors for personnel and mechanical
handling equipment. Following features shall be considered in the design and
layout of the storage areas:Good access for mechanical handling equipment such as pallet trucks, trolleys
etc. Adequate access corridors shall be provided and shall be sized for
manoeuvring pallet trucks into position making allowances for their turning
radius;
Packages shall be placed about 25 to 50 mm away from the walls, particularly if
condensation on walls is likely to occur.
Windows shall be avoided in the store.
Doors shall be draught proofed.
Good access to packages shall be provided to ensure good stock rotation.
Bags shall be stacked on pallets.
Adequate ventilation and where applicable dust filters and extractors shall be
SECTION 66B5: WTP
PAGE 29 of 69
1698 of 2461
MMRDA
provided.
6.10.3 Chemical Storage Safety
The Contractor shall design the plant to a high standard of safety and shall
comply with all local statutory requirements and where such local standards do
not exist, those of any other relevant bodies recognised or applied locally
The Contractor's design and installation shall
comply with the standards and codes of practice of his country of origin. The
chemical storage and handling shall conform to the relevant technical service
notes and literature published by the potential chemical suppliers and plant
manufacturers and any other guidelines published by reputable authorities.
The Contractor shall obtain the approval of the chemical supplier for the design
of the reception and storage facilities before proceeding with installation. In the
case of toxic or hazardous chemicals the Contractor shall afford the suppliers
the opportunity of offering advice on safety precautions to be taken on the
design layout, operation and maintenance of the facility.
Safety showers and eye baths shall be provided in the chemical solution
preparation and dosing areas. The contractor shall supply and install all
necessary warning and safety signs to BS 5499. Signs shall be manufactured
from durable, non-fading, and weather resistant materials. Materials shall be of
durable quality and chemical resistant for their intended environment, and
suitable for both indoor and outdoor sue.
Signs shall be in stove enamelled aluminium with rounded corners and drilled
fixing holes. A suitable backing board shall be provided for mounting suppliers
notices either on a clear wall just inside the access door or adjacent to plant as
appropriate.
Safety
signs
shall
use
local
or
internationally
recognised
pictorial
representations, such as those in BS 5378 and BS 5499.
6.11 Chemical handling
6.11.1 Pallet trucks

SECTION 66B5: WTP
PAGE 30 of 69
1699 of 2461
MMRDA
Pallet trucks shall be of the hand powered hydraulic type with wheels made of
polyurethane. When loaded to its maximum safe working load the full lift from
the lowered position shall not be less than 100 mm. The lowering speed shall
be infinitely variable by hand lever which shall be in the neutral position whilst
manoeuvring.
6.11.2 Pallets
Pallets for transport and storage of chemicals and other specified material shall
be of the close or open boarded and reversible or non-reversible types with
two-way or four-way entry, as specified. In open boarded pallets a maximum
spacing of 50 mm between deck boards (whether top or bottom) shall not be
exceeded.
Pallets dimensions shall be as specified and shall be fully
compatible with the pallet trucks supplied under the Contract.

Pallets shall be constructed in accordance with BS ISO 6780. Deck boards
shall have sectional dimensions not less than 25 x 125mm and shall be of
European redwood or approved equal. Blocks shall be 100mm cubes and
bearers shall have sectional dimensions 50 x 100mm. Blocks and bearers
shall be of European Oak or approval equal. Wood shall be fully treated
against fungal, insect and animal attack. The Employers name shall be burnt
into pallets.
6.12 Dosing Pumps - Reciprocating Type
6.12.1 General
Dosing pumps shall be mounted in a bund separate from the storage tanks and
shall be fully accessible for operating and maintenance purposes without
personnel having to enter the bund itself. Where appropriate, the pump bund
shall be interconnected with the tank bund at an intermediate level. The pumps
shall be of the reciprocating mechanically actuated diaphragm type driven by
electric motors. The pump, motor and drive arrangement shall be mounted on
SECTION 66B5: WTP
PAGE 31 of 69
1700 of 2461
MMRDA
a robust combination base plate. Unless otherwise specified, only one liquid
end shall be driven by any motor.
Pumps shall comply with API standard 675, Positive Displacement Pumps Controlled Volume.
6.12.2 Pump Head
Pump heads and diaphragms shall be manufactured from thermoplastic

materials suitable for the duty conditions.
6.12.3 Pump Stroke
Variable stroke mechanisms shall be incorporated in the drive arrangement to

allow infinitely variable adjustment of pump output by means of a micrometer,
hand wheel or similar mechanical device whilst the pump is running.
Where the pump is part of an automatic coagulation control or other process
control loop, the stroke mechanism shall be fitted with a three phase
bi-directional motor with torque limiter and automatic stops at both extremes of
travel. A position feedback potentiometer shall be provided to facilitate control
and remote indication of position. The operational range of stroke adjustment
shall be not less than 6:1.
6.12.4 Pump Drive & Motor
The pump head shall be driven through a totally enclosed speed reduction
gearbox with integral reciprocating drive device of the adjustable crank or
mechanical lost motion type. The gearbox and reciprocating drive shall be oil
bath lubricated. The unit shall incorporate filling and drain plugs for oil and an
oil level indicator.
Drive motors shall be of the three phase cage induction type whether for fixed
speed or variable speed operation. Where variable speed operation is
specified, the speed turn-down ratio shall be not less than
SECTION 66B5: WTP
PAGE 32 of 69
1701 of 2461
MMRDA
6.12.5 Pump Performance
The performance characteristics of the dosing pumps shall be adequate in terms of

linearity, accuracy and reproducibility as defined in API standard 675 to achieve the
stated plant performance guarantee. The deviation from flow linearity of the pump
shall not exceed 3% of the rated capacity. The steady state accuracy shall not
exceed 1% of the mean delivered flow under fixed system conditions over the entire
turndown range. The flow rate repeatability expressed as a percent of the rated
capacity of the pump shall not exceed 3% of the rated capacity.
6.12.6 Transfer pumps
End suction centrifugal pumps of the back pull-out type shall be used for
chemical transfer duties. The pumps shall be fitted with an external PTFE
bellows seal with a ceramic seat or alternatively may be of the glandless
magnetic drive type. All pumps shall be protected against dry running. Pumps
shall be constructed in suitable plastic materials such as glass filled epoxy resin
or high density polyethylene with external metal armouring or stainless steel or
steel depending on the chemical used.
Transfer pumps shall be located in bunded areas and shall be fully accessible
for operating and maintenance purposes without personnel having to enter the
bund itself.
6.13 Pipework for Chemicals
6.13.1 General
Pipework materials for chemicals shall be selected with due regard to chemical
compatibility, location, environmental conditions and operating regimes.
Specific material requirements are set out for the filling pipes of storage tanks.
In the case of pipework located outdoors, particular consideration shall be
given to the effects of ultra-violet rays, temperature and impact by wind-blown
objects. Thermoplastic materials shall not be painted as a means of protection
SECTION 66B5: WTP
PAGE 33 of 69
1702 of 2461
MMRDA
but shall be shielded from direct sunlight and adequately guarded against
mechanical damage.
Where
pressure
and
temperature
de-rating
precludes
the
use
of
thermoplastics, suitably lined reinforced plastics, rubber lined carbon steel or

stainless steel shall be used. Stainless steels shall not be used for chemicals
containing chlorides. All external chemical pipework shall be laid in trenches
provided with removable covers.
All pipework and hoses shall be adequately supported throughout their run.
Pipes shall be fixed to walls or mounted on channel sections fixed to walls or on
cantilevered supports off walls. Hanger type supports shall not be acceptable
nor shall pipes be underslung from roofs or cantilevered supports or supported
on the underside of pipe supports. Pipework laid on the floor shall be supported
on channel sections or similar off the floor.
Supports shall be spaced and shall be at centres not exceeding those
recommended by the pipe manufacturer. Pipe supports shall be designed and
installed to allow free axial movement of the pipe through the support during the
process of expansion and contraction. Supports shall not be positioned in close
proximity to fittings which would interfere with the natural movement of the
pipes. Supports shall be sufficiently wide to offer adequate bearing surface and
shall be installed so as to offer lateral restraint without restricting axial
movement of the pipe. Heavier fittings shall be supported independently of the
pipe.
Measures shall be taken in the design of pipework system to ensure that
expansion arising from temperature fluctuations can be accommodated without
damaging the system. Fixings of pipes shall by clips (cobra type) or clamps.
Where clamps are used on plastic pipes, pipe cushioning shall be used and the
pipe shall be mounted on channel sections with a plastic strip in between.
All pipe supports shall be hot dipped galvanised. Hoses carrying chemical
solutions shall be laid on horizontally mounted trays. Hoses shall be securely
fixed to trays by clips or similar. Hoses and pipes shall be laid in such a way that
individual pipe/hoses can
pipes/hoses.
be
removed without
dismantling adjacent
An allowance shall be made in the layout for any trace
heating/lagging of pipework.
The racks or trays used to carry chemical pipes/hoses and water service pipes
SECTION 66B5: WTP
PAGE 34 of 69
1703 of 2461
MMRDA
shall not be used for conveying electrical/instrument cable.
Where
electric/instrument cables are laid in the same duct with chemical/water pipes
the electric/instrument cables shall be laid on uppermost trays. Particular
attention shall be paid to the layout of the chemical pipework, which shall be
functional and neat in appearance.
All pipework above access ways shall be at not less than 2.5m above floor
level. Pipes laid at or near floor level across access ways shall be suitable
protected from damage. Joints in pipelines and fittings shall be sited away
from access ways and working areas; where this is unavoidable anti-splash
guards over the joints shall be provided.
Pipework at pumps shall be rigid and well supported so that strain is not placed
on pumps. Suction pipes shall, where possible, be straight and short. Elbows
shall be avoided in pipework as far as possible and shall be replaced by 45
degree or long sweep 90 degree fittings. Chemical transfer pipework shall be
arranged for self draining either towards the dosing pumps or dosing point.
Provision shall be made for draining all pipe sections at low points and for
flushing same with clean water and facilities for safe disposal of the drainage.
Pipework shall be provided with flushing connections and drains to facilitate
cleaning of pipes/hoses, dosing pumps and other fittings. It shall be possible to
isolate sections of pipework and dosing pumps for flushing with minimum of
interruption to dosing. All dosing pipes/hoses and associated injection/diffuser
fittings shall be provided in duplicate (1 duty, 1 standby).
Chlorine solution lines shall not be laid inside buildings (not designated for
chlorine). Where chlorine solution lines are laid in dosing chambers and other
confined spaces which are accessible by personnel, then the Contractor shall
provide a permanently installed leak detector and mechanical ventilation
systems. In pipes carrying slurries, tees and crosses shall be used in place of
elbows in areas where mechanical cleaning might be required. Pipe reducers
on slurry lines shall have level inverts and branches from slurry pipes shall be
taken from top of pipe. Long vertical rises above the discharge valve of dosing
pumps shall be avoided.
Slurry pipework shall be designed and laid to
eliminate settlement of particles; a minimum velocity of 0.3m/s shall be

maintained at all points in the pipework over the entire range of operating
conditions.
SECTION 66B5: WTP
PAGE 35 of 69
1704 of 2461
MMRDA
All nuts, bolts, washers and screws shall be manufactured from stainless steel
as set out in the Specification.
6.13.2 Pipework Materials
Carbon steel pipework shall be specified by nominal diameters in accordance

with BS EN 10220 and shall be in seamless material to BS EN 10216 or BS EN
10217 grade 360 or 430.
Carbon steel fittings shall comply with BS EN 10253 Part 1. Welding of carbon
steel shall be carried out in accordance with BS2633 Class 1 arc welding. All
welders shall be tested by an independent testing authority and shall satisfy the
requirements of BS EN 287 Part 1. Carbon steel pipework shall be lined with
natural rubber 3mm in thickness or alternative material approved by the
Engineer. Where protective coatings are required they shall comply with the
Specification.
Unless otherwise specified, flanges for steel pipework shall be of the weld neck
type, Code 111 to BS EN 1092 or BS EN 1515 with the appropriate pressure
designation but not less than PN10.
Stainless steel pipework shall be type 316S13 to BS3605 and shall be flanged.
Fittings shall comply with BS1640 Part 4. All welding shall be carried out to BS
4677 and procedures shall be subject to approval in accordance with BS EN
288 Part 3. Welders shall be tested by an independent testing authority and
shall satisfy the requirements of BS EN 287 Part 1.
Welder test certificates shall be provided by the Contractor for examination by
the Engineer. All welds shall be dressed.
uPVC pipework shall be `hi-impact' type to BS EN 1452 or BS3506 Class E with
solvent welded joints and fittings complying with the relevant parts of BS EN
1452 . Where flanged joints are required, full face uPVC flanges and galvanised
steel backing rings shall be used.
Where reinforced plastics are used, these shall comply with BS6464 and shall
contain a uPVC liner as specified above for uPVC pipework. The pipework
shall be fabricated and assembled such that only the liner comes into contact
with the fluid.
The piping system shall be designed and constructed in
SECTION 66B5: WTP
PAGE 36 of 69
1705 of 2461
MMRDA
accordance with BS7159.

Alternative plastic materials such as polypropylene and polyvinylidene
difluoride (PVDF) may be used in certain circumstances subject to approval by
the Engineer. Flanges shall conform to BS EN 1092 or BS EN 1515 PN10
minimum. Joint rings for steel pipework shall be compressed asbestos fibre or
proprietary alternative approved by the Engineer. Joint rings for plastic
pipework shall be of Viton encapsulated in PTFE. Flexible hoses shall be
reinforced rubber or equal of similar performance and quality to reinforced
rubber.
Dilution systems
6.13.3 General
Certain chemicals shall be provided with dilution or carrier water systems as

specified to assist in the conveying of the chemical to point of application and/or
to improve mixing and shall be carried out downstream of the dosing pumps.
The dilution water system shall be designed such that it is impossible for
chemicals to contaminate the drinking water supply system by back-flow or
other means or to cross-contaminate other chemical dosing systems.
Non-return valves shall not be considered a sufficient method of back-flow
protection.
6.13.4 System components
The system shall incorporate all isolating valves for water and the chemical,
check valves and flowmeter on the water inlets. All isolating valves shall be
positioned with due regard to routine access for operational and maintenance
purposes. It shall not be necessary to enter any bunded facility to operate
isolating valves. Isolating valves shall be compatible generally with the
pipework systems in which they are installed. Manual isolating valves for
hydrated lime slurry shall be either ball valves of the full bore type or diaphragm
valves of the straight through type. Valve bodies shall be of cast iron whilst balls
SECTION 66B5: WTP
PAGE 37 of 69
1706 of 2461
MMRDA
shall be stainless steel. Flexible diaphragms shall be selected for maximum

resistance to abrasion. Assembly nuts and bolts shall be in stainless steel.
6.13.5 uPVC valves
Isolating valves shall be of the diaphragm type with uPVC bodies, glass filled
polypropylene topworks and PTFE diaphragms.
Assembly nuts and bolts
shall be stainless steel. End fittings may be plain sockets for solvent welding or
flanged as appropriate. Flanges shall be to BS EN 1092 or BS EN 1515 PN10
minimum.
These valves may not be used for isolating tank outlets and drains unless
otherwise approved by the Engineer.
6.13.6 Rubber lined valves
Isolating valves shall be of the diaphragm type to BS EN 13397 with weir

bodies in grey cast iron to BS EN 1561 grade 220 (or alternative grade allowed
by the design standard) having integral flanged ends, a natural rubber ebonite
lining, PTFE diaphragms and topworks in standard proprietary materials.
Assembly nuts and bolts shall be in stainless steel. The valves shall be flanged
to BS EN 1092 or BS EN 1515 PN10 minimum. Isolating valves for tank outlets
shall be of the sealed bonnet type. All valves shall be tested in accordance with
BS EN 12266.
6.13.7 Pressure Relief Valves
Pressure relief valves shall be fitted to the delivery side of all positive
displacement pumps. All materials of construction shall be fully compatible with
the chemical handled. The valves shall discharge in a safe manner to a gulley
or sump designed for this purpose. The discharge pipes shall not be
manifolded.
The valves for lime slurry applications shall be of a non-choking type free of
cavities and crevices likely to block with lime. A means shall be provided of
SECTION 66B5: WTP
PAGE 38 of 69
1707 of 2461
MMRDA
detecting that a relief valve is operating and of raising an alarm.
6.13.8 Loading Valves
Loading or back-pressure valves shall be fitted where necessary to the delivery

side of the dosing pumps. All materials of construction shall be fully compatible
with the chemical handled. The valves lime slurry applications shall be of the
tubular pinch type pressurised externally with compressed air or of an
alternative approved type.
6.13.9 Pulsation Dampeners
Pulsation dampeners shall be fitted where necessary to the suction or delivery

side of dosing pumps to attenuate peak pressure drops and to smooth the flow.
The dampeners shall be of the vertical air vessel type or approved alternative
type. An air supply shall be connected to the dampeners to facilitate periodic
re-charging.
The supply shall incorporate a filter, pressure regulator and
pressure gauge.
6.13.10 Injection fittings
Where chemical is to be dosed into an open channel, weir chamber or

downstream of a hydraulic jump, it shall be applied using a distributor as
specified. The submerged distributors shall be tubular with orifices drilled at
even intervals to ensure uniform distribution of the coagulant. The distributors
mounted above the water surface shall be pipe or channel type with orifices
drilled at intervals to ensure uniform distribution. The channel type shall be
used for slurries. Where chemical is to be dosed into flow in pipelines, it shall be
applied using a suitable arrangement of injection tubes designed for the
specified duty flow rate.
(a) Pipelines up to 600mm in diameter A single horizontal injection tube shall

be used extending one third of the pipeline diameter into the fluid stream.
SECTION 66B5: WTP
PAGE 39 of 69
1708 of 2461
MMRDA
(b) Pipelines up to 1000mm in diameter Two injection tubes shall be used

mutually located at 90 with their axes at 45 to the horizontal and extending
15% of the pipeline diameter into the fluid stream.
(c) Pipelines up to 2500mm in diameter Four injection tubes shall be used
mutually located at 90 with their axes at 45 to the horizontal and extending
15% of the pipeline diameter into the fluid stream.
The nozzle velocity shall exceed 0.75 m/s or one half of the large pipe velocity
whichever is greater. Distributors and injection tubes shall be of sturdy design
and adequately supported. They shall withstand the flow velocity at the point
of application and any flow or turbulence induced vibrations.
The materials of construction of the distributors and injection tubes shall be
resistant to erosion and chemical attack over the full range of operating
conditions. The distributors and injection fittings shall be supplied complete with
the necessary isolating valves and, where applicable, non-return valves. When
injecting chemicals into static mixers, the static mixer supplier provide the
injection device as an integral part of the mixer.
6.13.11
Dosing Pump Calibration Vessels
Calibration vessels shall be transparent tubes of material resistant to the

chemical and not discoloured by the chemical. The effective height of the
vessel shall not be less than 1.25m and the diameter shall be selected to
ensure that at the maximum pumping capacity the rate of fall of level in the
vessel shall not be greater than 1.0m/min. The height of the vessel shall be
such that when full the liquid level in the calibration vessel shall the same as
that in the stock tank. This may be achieved by providing the calibration
vessel with a vent pipe.
The calibration vessel shall be provided with a drain discharging to an

appropriate bunded area.
6.14 Coagulant Plant
SECTION 66B5: WTP
PAGE 40 of 69
1709 of 2461
MMRDA
6.14.1 General requirements
The coagulant plant shall be suitable for use with the chemical or selection of
chemicals specified. The Contractor shall obtain information on properties,
materials of construction for handling equipment and safety information and
verify availability of the form, grade and delivery lot size of the specified
coagulant(s) at time of tender.
6.14.2 Storage tanks Capacity, design and fabrication
The coagulant plant shall be suitable for use with the chemical or selection of
chemicals specified in the Particular Requirements.
6.14.3 Saturators
Saturators shall be designed for receipt of aluminium sulphate in block form and
dissolution of same to form a saturated solution. Saturators shall comprise
reinforced concrete tanks with an acid-resistant lining.
The lining shall
comprise an impermeable membrane further lined with acid-resistant brick

bonded with acid-resistant cement or an alternative lining system such as fibre
glass approved by the Engineer.
The tanks shall be enclosed within a building and shall be arranged for manual
charging.
The floor of the tank shall be further protected by pebbles approximately 1420
mm in size to a depth of at least 300 mm to absorb initial impact and to protect
the solution draw-off pipes. Areas of the tank walls subject to impact shall be
protected by hardwood facing which shall be secured with stainless steel
fixings.
3
The tanks shall be sized for the specified duty requirements assuming 1.4m of
solution will be generated from each tonne of solid aluminium sulphate. A
system of perforated pipes shall be mounted on the tank floor to effect uniform
draw-off of the saturated liquor across the whole area of the tank. The pipes
shall be of non-corrodible materials and secured by means of stainless steel
SECTION 66B5: WTP
PAGE 41 of 69
1710 of 2461
MMRDA
fixings.
The following pipe connections shall be provided as a minimum on each tank.
All puddle pipes and connections shall be in stainless steel type 316S13 to BS
3605:
1. Water inlet;
2. Solution outlet;
3. Re-circulation inlet; overflow;
4. Drain;
5. Level gauge.
The saturated solution shall be transferred to stock tanks for dilution tanks by
means of pumping. Provision shall be made for using the transfer system for
recirculation of solution from the saturator outlet to a high level inlet in order to
assist dissolution.
Two isolating valves shall be fitted to the tank outlet
together with a sampling valve and an in-line strainer. Each tank shall be
provided with a level gauge equipped with low and high level alarm switches
and any other switches required for operational purposes.
It shall be possible to back flush the gravel bed via the overflow to waste.
6.14.4 Dilution and Stock Tanks
Dilution and stock tanks shall be designed for diluting a saturated solution of
aluminium sulphate to a pre-determined concentration as specified or to store a
pre-diluted solution of aluminium sulphate. Such tanks shall operate on a
rotational batch basis with a cycle frequency as specified.
Tanks may be constructed from concrete or rubber lined mild steel or fibre
reinforced polyester or alternative material as specified. Each tank shall be
equipped with a turbine type mixer constructed of stainless steel to BS 970 Part
1 or BS 1449 Part 2 grade 316S11.
The following pipe connections shall be provided:
1. Water inlet;
2. Solution inlet;
3. Solution outlet;
4. Overflow;
SECTION 66B5: WTP
PAGE 42 of 69
1711 of 2461
MMRDA
5. Drain;
6. Level gauge.
Where applicable, suitable level switches or probes and level measuring
equipment shall be provided for operational and monitoring purposes.
6.14.5 Constant head tanks
Constant head tanks shall be designed to provide a constant operating head for
downstream feeders. The constant head shall be maintained by providing an
inflow greater than the outflow with the excess flow being returned to feed
(stock) tank.
The tanks shall be constructed in fibre reinforced polyester or alternative
material approved by the Engineer. The following pipe connections shall be
provided:
1. Solution inlet;
2. Solution return;
3. Overflow;
4. Drain;
5. Outlet.
6.
6.15 Chlorination Plant
6.15.1 Drum handling systems
Drum handling systems shall be designed to operate with chlorine drums, of

approximate chlorine capacity 1000kg
6.15.2 Monorail Runway Beam
Monorail runway beams (straight or U-type) shall conform to BS 2853 and shall
extend the length of the drum store and over the unloading area. U-section of a
monorail shall have a minimum radius of 2 m and the spacing between the two
SECTION 66B5: WTP
PAGE 43 of 69
1712 of 2461
MMRDA
rails forming the U-beam shall be not less than 2 x the minimum radius.
6.15.3 Electric Travelling Hoist
Electrically operated travelling hoists shall be complete with shackles, drum lifting
bar and, where specified, a suspended weighing device. Travel and hoist motions
shall be electrically driven. Hoist functions shall be controlled from a single fully
insulated heavy duty pendant suspended by a non-metallic cord. The pendant
shall operate at a low voltage not exceeding 50 volts A.C. and shall incorporate a
key-operated switch to prevent unauthorised operation. Push button controls shall
be provided for dual speed and fine control of both travel and hoisting operations
with separate motors for each function. An interlock shall prevent simultaneous
travel and hoisting and an emergency stop shall be fitted.
Linear operating
speeds shall approximate the following criteria.

1. High speed Low speed
2. Raise/lower 5m/min 0.5m/min
3. Travel 10m/min
5m/min
Limit switches shall be fitted to prevent over-hoisting and over-lowering and shall
be adjustable within the working range of the hook. The mechanism shall be
self-resetting. End stops shall be fitted to each end of the runway beam. The power
supply to the hoist shall be delivered by a 3 phase and earth festooned cable
system supported from a track mounted off the top flange of the runway beam.
Where possible, this shall terminate within the store clear of the main doors and the
supply continued to the hoist by means of an extensible flexible cable. The
necessary junction box between these cables shall also run in the track and shall
be engaged by the hoist unit on inward travel through the doorway and disengaged
on reaching a mechanical stop in the track prior to outward travel of the hoist unit
through the doorway. In situations where the festoon arrangement continues
through the doorway, the proposed sealing arrangement for the support track at
the doorway shall be subject to approval by the Engineer.
An isolating switch, lockable in the off position, shall be provided wall mounted
1400mm above floor level with the store room arranged to enable the hoist to be
isolated from all power supplies.
SECTION 66B5: WTP
PAGE 44 of 69
1713 of 2461
MMRDA
The hoist and trolley shall comply with the operating performance of BS 466. Hoists
shall be fitted with a right and left hand spiral groove cast iron drum with a wire rope
hoist arrangement with spring-loaded rope bands and guards to ensure accurate
guidance and location. Safety disc brakes shall be incorporated to hold the
suspended load instantly, securely and automatically in the event of the electricity
supply being cut-off for any reason.
Lifting hooks shall be safety hooks from grade 30 carbon steel to BS EN 1677 and
capable of swivelling through 360 degrees. Steel wire rope shall be of tensile grade
and conform to BS EN 12385. Bearings shall be ball or cylindrical roller type. Drum
lifting bars shall be made of structural steel to BS EN 10137 and BS EN 10029 and
shackles and hooks shall conform to BS 3551 as applicable.
A permanent fixed elevated platform shall be provided at one end of the monorail
beam to enable maintenance work to be carried on the hoist and trolley. The
platform decking shall be non-slip chequer plate and the platform shall be provided
with access ladder and hand railing. The complete drum handling system including
the suspended weigher shall be designed for a safe working load of 2800 kg and
shall be tested with a load of 3500 kg.
6.15.4 Suspended Weigher
Where specified, the lifting system shall incorporate a suspended weighing

device. This shall be suspended from the load hook of the hoist and shall itself
have a swivel hook with safety catch to engage the centre shackle of the drum
lifting bar. The device shall be of the hydrostatic load cell type with a circular
scale indicator calibrated in 50kg divisions with the zero at the top of the scale.
The capacity of the weigher shall not be less than 2000 kg. The pointer shall
incorporate tare adjustment of up to 20% of full scale. The dial shall be not
less than 300 mm in diameter.
Alternatively a digital indicator with the readout attached directly to the load cell
shall be provided. The display shall be by a bright four digit 50 mm high LED
display with 1 kg resolution. The display module shall be housed in an
enclosure protected to IP 67.
The weigher shall have an overall accuracy better than + or 0.5% of full scale
SECTION 66B5: WTP
PAGE 45 of 69
1714 of 2461
MMRDA
deflection with 25% over rated capacity safety factor and shall be unaffected by
temperature variation in the range -10 to +50C.
6.15.5 Safe working loads
All parts of the lifting system shall be stamped with the manufacturer's symbol
for identification, with the manufacturer's test certificate and the date of
manufacture. The system shall be certified for a safe working load of 3.20
tonnes and tested with a load of 4 tonnes.
6.15.6 Liquid catchpots
Where chlorine is withdrawn as a gas from containers, the container header

shall terminate at a purpose designed liquid catchpot comprising a carbon steel
pressure vessel not less than 300 mm in length and 140 mm in diameter, with
flanged inlet and outlet connections, flanged full way top plate, an internal dip
tube on the inlet side and a wall mounting bracket. The catchpot shall be
works tested hydrostatically to 52 bars g. Isolating valves shall be installed
upstream and downstream of the catchpot.
6.15.7 Gas Pipe work
Flexible tubes for connections to containers for gas withdrawal shall be copper
externally plated with silver or cadmium or alternatively shall be Monel. The
tubes shall be fitted with suitable screwed adaptors for making the connections
to the containers. All screwed pipework conveying chlorine under pressure
shall be constructed from solid drawn steel tube to BS 1387 with heavy fittings
in malleable iron to BS 143 screwed to BS 21. Threaded joints shall be made
with a jointing compound compatible with chlorine or sulphur dioxide as
appropriate. PTFE tape shall not be used.
All flanged pipework conveying chlorine gas under pressure shall be carbon
steel hot finished seamless, cold drawn seamless or electric resistance welded
to BS EN 10216 or BS EN 10217 grade 360 or 430. Flanges shall be raised
SECTION 66B5: WTP
PAGE 46 of 69
1715 of 2461
MMRDA
face drilled to BS 1560 Class 150, double fillet welded, stress relieved and
radiographed. Joint rings shall be made of chemical resistant elastomers such
as Hypalon (Chlorosulphonated Polyethylene) or Viton (Co- Polymer of
Vinylidene chloride and hexafluro propylene) or alternatives approved by the
Engineer and shall fit within the bolt circle. Prior to installation, the joint rings
shall be impregnated or smeared with graphite compound or similar compound
compatible with chlorine.
All pipework for chlorine gas under vacuum or venting directly to atmosphere
shall be rigid `hi-impact' uPVC to BS 3506 Class E or T with solvent welded
joints and fittings complying with the relevant parts of BS EN 1452. Venting
pipework shall be arranged to inhibit ingress of moisture and shall be fitted with
an insect screen. Venting pipework shall not be manifolded.
Pipework shall be adequately supported throughout its length. Sleeves shall be
used where pipework passes through walls. All apertures shall be properly
sealed with a chlorine and sulphur dioxide resistant compound.
Pipework
within buildings shall not be run in floor ducts unless otherwise approved by the
Engineer.
6.15.8 Gas Isolating Valves
Isolating valves in pipework conveying chlorine under pressure shall be

interchangeable and specifically designed for chlorine service. Valves shall be
provided at each end of flexible connecting tubes to containers and shall be
needle valves having 150lb class forged bodies in silver plated brass with
screwed end connections and shall be of glandless design with a nickel
diaphragm. The valve shall be operated by means of a handwheel.
All other isolating valves shall be sleeved plug valves having 150lb class forged
bodies in carbon steel with integral end connections, tapered plug in Monel with
pure PTFE sleeve and top seal arrangement with PTFE diaphragm and delta
seal ring, back up metal diaphragm, floating thrust collar, electrostatic
eliminator, four bolt cover and three point self-aligning plug adjustment. The
valve design shall ensure that excess pressure in the plug and body cavity of
the closed valve is relieved spontaneously towards the direction of high
SECTION 66B5: WTP
PAGE 47 of 69
1716 of 2461
MMRDA
pressure. The valve shall be operated by a forged steel wrench with padlocking
facility in the closed position or otherwise by power actuator as specified
elsewhere.
Flanged valves shall have raised face flanges drilled to BS 1560 Class 150. All
valves shall be supplied degreased and dried for chlorine service and
maintained in this condition for inclusion in the Works. All valves shall be tested
in accordance with BS 6755 Part 1 and II.
A works test certificate is required for each valve covering hydrostatic testing of
the shell and seat and air testing of the seat. The gauge pressure for the air test
shall be 10 bars.
6.15.9 Drum Changeover System
Drum changeover system shall automatically switch the source of chlorine from
a duty set of containers to a standby set upon the pressure in the duty set falling
to 1.0 bar g. The system may comprise an integral purpose-designed assembly
where applicable or separate components, in either case complete with a
locally wall mounted control panel.
The changeover activating device shall be a pressure switch. A 100 mm
diameter pressure gauge shall also be provided. Changeover shall be effected
by means of one or more electrically operated valves. The design shall ensure
that the expired duty chlorine supply is isolated before the standby supply is
brought on line.
The control panel shall incorporate the following features:
1. Isolating switch;
2. Indicator lamps for SUPPLY No. 1 ON and SUPPLY No. 2 ON and
volt-free contacts connected to the SCADA system;
3. Indicator lamp for NO RESERVE, volt-free contacts connected to the
SCADA system and RESET pushbutton;
4. Push button to indicate that RESERVE is available;
5. LAMP TEST pushbutton;
6. Manual over-ride switch.
Control circuit and valve actuator voltage shall be 110 V a.c. Unless otherwise
SECTION 66B5: WTP
PAGE 48 of 69
1717 of 2461
MMRDA
specified on power failure, the system shall stay put. The drum changeover
system shall have a manual isolation and bypass arrangement to facilitate
maintenance.
6.15.10
Vacuum Regulating Valves
Vacuum regulating valves shall be wall mounted on a suitable backing board in

the drum store, located as close as is practical downstream of the drum
changeover system. Vacuum regulating valves shall be spring loaded
diaphragm operated valves, designed to reduce varying gas pressure
upstream to a desired regulated vacuum downstream and to maintain this
vacuum within close limits. The diaphragm shall be made of PTFE.
The vacuum regulating valve shall be fail safe and shall close fully upon loss of
vacuum. The valve shall be provided with an isolating valve upstream and a
pressure relief valve downstream. The pressure relief valve shall discharge to
outside the building. Vent pipes from pressure relief valves shall not be
manifolded.
The regulated vacuum shall be indicated on a vacuum-pressure gauge which
may be integral with the vacuum regulating valve or mounted separately.
6.15.11
Gas Control Units
Chlorinators are referred to herein as gas control units. They are devices for
measuring and controlling the flow rate of chlorine gas under vacuum
conditions created by a water driven ejector. Gas control units shall be wall or
floor mounted as applicable otherwise and shall incorporate the following items
all assembled and tested at place of manufacture:
Variable area flow meter with linear scale calibrated in g/s or mg/s of chlorine as
applicable.
Gas flow control valve to provide precise setting of the gas flow rate over a 20:1
flow range with an accuracy of 4% of the indicated gas flow rate.
Vacuum differential regulating valve to maintain a constant vacuum difference
between the inlet and the outlet of the flow control valve over the operating
SECTION 66B5: WTP
PAGE 49 of 69
1718 of 2461
MMRDA
range of the gas control unit.

Vacuum relief valve, if applicable, which shall be connected by pipework to
outside the building and arranged in a similar manner to venting pipework.
Vacuum gauge to indicate the unregulated vacuum induced by the ejector and
calibrated in mbar.
Vacuum switches, which may be integral with the gauge. One switch shall
initiate a high vacuum alarm and the other shall initiate a low vacuum alarm.
Both switches shall have volt-free changeover contacts.
6.15.12
Ejectors
Ejectors shall be designed to induce the vacuum necessary to operate the

corresponding gas control units over their working range under all downstream
pressure conditions at the point of application when supplied with motive water
at or above the minimum pressure.
The design flow range of motive water shall take into account the dissolution
requirements of the chemical, control loop time considerations for automatic
control systems and effective hydraulic design. Ejectors shall be mounted in the
vertical. Noise shall be kept to an absolute minimum consistent with efficient
operation but shall in no event exceed the sound pressure level stated in the
Specification.
The ejector shall incorporate an integral diaphragm-operated non-return valve
to prevent ingress of water to the gas system. A separate non-return valve
shall also be installed in the gas line to the ejector as a security measure.
The nozzle and throat diameters shall be engraved on a plate fixed to the
ejector in a visible position. Where small clearances are involved on the water
side of the ejector, in-line strainers shall be installed in the motive water supply
pipework to protect the ejectors from blockage. A minimum recovery length of
1.0m straight pipe length shall be provided downstream of the ejectors.
Ejectors shall be mounted separately from the gas control units either within the
same room or in a remote location as specified elsewhere.
Fittings on the downstream side of the injector shall be selected to give the
lowest possible `K' factor. Thus, valves shall be of the straight through type,
SECTION 66B5: WTP
PAGE 50 of 69
1719 of 2461
MMRDA
tees shall not be used, and bends shall be swept and long radius.
6.15.13
Solution Pipe work
All pipe work for chlorine solutions within buildings and elsewhere unless
otherwise specified, shall be rigid `hi-impact' uPVC to BS 3506 Class E with
1452.
Where flanged joints are required, full face uPVC flanges and galvanised mild
steel backing rings shall be used. Joint rings shall be Hypalon or Viton.
Flanges shall be drilled to BS EN 1092 or BS EN 1515 PN10 minimum.
Pipework
shall
be
supported
in
accordance
with
manufacturer's
recommendations and adequate provision shall be made for thermal expansion

and contraction.
6.15.14
Solution Isolating Valves
Manual isolating valves for chlorine solutions shall be of the diaphragm type
with uPVC bodies, glass filled polypropylene topworks and PTFE diaphragms.
Assembly nuts and bolts shall be stainless steel. End fittings may be plain
sockets for solvent welding or flanged as appropriate.
6.15.15
Injection Fittings
Where chlorine is to be dosed into flow in an open channel, weir chamber,

contact tank or downstream of a hydraulic jump, it shall be applied using a
submerged chlorine solution distributor. The distributor shall be either a drilled
tube or a ceramic tubular diffuser, designed to ensure uniform distribution of
solution at the point of application. Where chlorine is to be dosed into flow in
pipelines, it shall be applied using an injection fitting/device designed for the
specified duty flowrate as follows:(a) Pipelines up to 600 mm in diameter. The injection tube shall extend
one-third of the pipeline diameter into the fluid stream. In this case a
SECTION 66B5: WTP
PAGE 51 of 69
1720 of 2461
MMRDA
withdrawable type injection fitting entering the pipe through a corporation cock
shall be used.
(b) Pipelines up to 1000 mm in diameter. The injection tube shall be perforated
and shall extend right across the pipe bore and be supported with ends located
in diametrically opposite flanged branches.
The tube shall be drilled at
predetermined centres to ensure uniform distribution across the flow profile.

(c) Pipelines up to 2500 mm in diameter. Two perforated injection tubes shall be
used, each generally as for (b) only installed mutually at right angles and with
their axes at 45 to the horizontal in a plane normal to the direction of flow within
the pipeline.
Alternatively, four injection nozzles, mutually located at 90 and extending 15%
of the pipe diameter shall be installed.
The nozzles shall be installed in
diametrically opposite flanged branches and in the same plane normal to the
direction of flow in the pipeline. The nozzle velocity shall exceed 0.75m/s or one
half the large pipe velocity whichever is greater.
When injecting chlorine into static mixers, the static mixer supplier provide the
injection device as an integral part of the mixer. Distributors and injection
fittings shall be of sturdy design and adequately supported and designed to
withstand the flow velocity at the point of application and any flow or turbulence
induced vibrations.
The materials of construction of the distributors, injectors and sealing shall be
compatible with up to 3500 mg/l chlorine at operational fluid temperatures up to
30C. Porous ceramic material where used shall be inert and non-toxic. uPVC
tube where used shall conform to BS 3506, Class E.
Chlorine solution distributors or injection fittings shall be supplied complete with
the necessary non-return and isolating valves.
6.15.16
Motive Water Supply
Pumps shall be of the multistage centrifugal type. Pumps shall be vertically

mounted complete with direct coupled motor face or flange mounted on top.
Suction and discharge chambers shall be in fine grained cast iron whilst
intermediate chambers shall be in the same material or stainless steel.
SECTION 66B5: WTP
PAGE 52 of 69
1721 of 2461
MMRDA
Impellers shall be stainless steel or bronze with stainless steel shroud. Pump
shafts shall be stainless steel and pump bearings shall be bronze or tungsten
carbide.
The shaft seals shall be of the mechanical type with polished
tungsten carbide surfaces mounted on bronze or stainless steel carrier

assemblies.
Facilities shall be provided for the removal of trapped air on priming and for
draining the pump. The speed of the pump shall not exceed 2900 rpm. Pipe
work and valves for water supply systems shall comply with the requirements
for chlorine solution pipe work.
Isolating valves at the off-take plant from the treated water mains shall be cast
iron gate valves to BS EN 1171. Where supplies are taken from high pressure
mains in excess of 10 bar or where significantly reduced pressures are required
by downstream equipment, pressure regulating and relief valves shall be
installed.
6.15.17
Layout and design considerations
The chlorination installation shall comprise a chlorine container store and

chlorinator room and where necessary annexes for housing motive water
pumps, ejectors and switchboard. The container store shall house full and
empty containers with a container unloading area at one end, containers
on-line, automatic changeover devices and vacuum regulators. Adequate
space shall be allowed in the store for duty and standby container on-line,
containers in storage and spaces for empty containers.
The chlorinators,
ejectors, motive water pumps and switch gear shall be housed in respective
rooms.
The chlorine container store, chlorinator room and ejector room shall be
provided with separate exit doors opening outwards and emergency exit doors
also opening outwards fitted with pushbar operated panic bolts. Adequate
exits shall be provided to ensure that the maximum distance of access route
from any point in the store to the nearest exist is less than 10 metres.
Interconnecting doors between any room in the chlorine building shall not be
provided.
SECTION 66B5: WTP
PAGE 53 of 69
1722 of 2461
MMRDA
The levels of ceilings shall be sufficiently high to allow handling of drums,

satisfactory maintenance and replacement of parts.
All doors shall be of
robust construction preferably faced with a single sheet of material to ensure

that they are reasonably gas tight, and rebated into the architrave on the sides
and top. Bottom gap shall be kept to a minimum. All rooms where chlorine
leaks can occur shall be of substantially gas tight construction.
Adequate angle iron or channel iron protection shall be provided at all
protruding corners and frames or openings to prevent damage to structures
during container handling. Fire resistant construction material shall be used
throughout.
No external windows shall be provided in the container store and chlorinator
room, artificial illumination being employed throughout.
To safeguard
personnel in the event of a chlorine leak, gas-tight wire armoured toughened

glass glazed panels shall be provided in internal walls so that all areas may be
observed from adjacent rooms. Individual lighting fixtures shall be provided
wherever feasible, with two/three-way switching to allow lights to be operated
from the viewing rooms.
Air conditioning shall not be provided in the chlorine building. The floor of the
chlorine building shall be placed at such an elevation above adjacent ground
level that ingress of storm water is prevented, but entrances shall not be higher
than 200m above finished ground levels.
Switchboards, motor control centres and any other panels and electrical or
electronic equipment shall not be housed in areas where there is a potential for
chlorine gas or solution leak. Any electrical equipment required to be located in
such areas such as leak detectors, changeover panels etc. shall have
enclosures protected to IP 65.
All equipment and plant used in the chlorine environment shall be made of
appropriate chlorine (wet/moist) resistant construction material.
Where
necessary they should be adequately protected against corrosion by painting or

otherwise. All pipework and cables to and from chlorine store and chlorinator
room shall be taken through the wall. All threader tubes carrying cables and
pipes respectively out of the chlorine store and chlorinator room shall be sealed
to prevent any chlorine leaks being transmitted to other areas. Arrangement
and layout of pipework shall comply with the specification for chemical
SECTION 66B5: WTP
PAGE 54 of 69
1723 of 2461
MMRDA
pipework.
Independent ventilation systems for each area of activity where there is a
potential for chlorine leak shall be provided. Air intakes shall be through louvred
grills at high level and extraction shall be at low level in the room with high level
discharge to outside. Each area of activity shall be provided with leak detectors
3
specific to the chlorine gas and capable of detecting levels down to 0.5 ml/m .
They shall be powered by UPS systems which shall be operable for up to 4
hours in the event of a power failure.
Chlorine container store and chlorinator room shall be used solely for of
chlorine facilities. The siting of other buildings with respect to the chlorine
building shall be such that their ventilation intakes are at least 25m from the
chlorine building.
Adequate number of breathing aids and protective clothing shall be supplied as
specified.
In the siting, layout and design of the plant the contractor comply with all local
statutory requirements and standards, foreign codes of practices and
guidelines applied and/or recognised in the country of installation and those of
the country of origin of equipment.
WATER SAMPLING EQUIPMENT
6.15.18
Sample Points
Sample points shall be provided as specified where recommended by the

Contractor to suit his design. Sample points shall be positioned in a manner
which ensures that the sample is properly representative of the fluid stream
from which it is taken in terms of physical, chemical and microbiological
parameters.
Special care shall be taken following chemical dosing to ensure that mixing has
taken place before the sample is withdrawn.
In pipelines up to 600 mm in diameter, the limiting position of the sample point
shall be where the ratios of minimum concentration to maximum concentration
of the dosed chemical across the horizontal and vertical diameters of the
SECTION 66B5: WTP
PAGE 55 of 69
1724 of 2461
MMRDA
pipeline are at least 0.95.

In pipelines larger than 600 mm in diameter, these ratios of concentrations shall
not be less than 0.90 or, where applicable, such higher value as may be
necessary to achieve the stated plant performance guarantee. Similar criteria
shall apply to flow in channels and rectangular ducts of all sizes except that the
concentrations shall be across the horizontal and vertical centre axes.
6.15.19
Off-take Arrangement
In no circumstances shall samples be withdrawn directly from the pipe or

channel wall. Sample withdrawal tubes shall project into the bulk fluid flow in a
manner which avoids vibration and the collection of entrained gas bubbles or
sediment. Sample tapping points shall not be less than 25mm, NB. Generally,
any reduction in pipe size shall take place after the first isolating valve.
The off take arrangement up to and including the first isolating valve shall be
designed for maximum mechanical strength in addition to hydraulic
considerations and the integrity of the main fluid stream shall not be prejudiced
by any failure in or damage to the sampling system itself.
6.15.20
Sampling Rate
The sampling rate shall be optimised for each sampling system with due regard
to the following:The purpose of sampling; Maintenance of sample quality; Effective monitoring
and control, where applicable; Hydraulic restraints; Minimisation of wastage.
The sample delivery rate to analysers shall be as recommended by the
instrument manufacturers and any necessary pressure or flow regulating
device to maintain this shall be provided.
The sample delivery rate to sample taps shall be limited to 2 litres per minute
per tap by means of suitable preset or flow limiting valves but not by use of
isolating valves.
Generally, samples shall be delivered at rates significantly in excess of those
required by analysers and sample taps to satisfy all relevant design criteria.
SECTION 66B5: WTP
PAGE 56 of 69
1725 of 2461
MMRDA
Sample pipework shall not be less than " NB under any circumstances and,
where hydraulic or water quality conditions dictate shall be larger.
6.15.21
Sample Recovery and Disposal
Unless otherwise specified, excess sample water shall be recovered for re-use
provided that there is no risk of contamination and that it can be returned to the
process at a suitable point and always prior to final disinfection. In this way,
wastage shall generally be limited to discharge of used samples from analysers
and from sample taps.
All necessary means shall be provided for collection and disposal of waste
sample water with due regard to any contaminants which may be introduced
within the sampling facility such as analytical reagents or cleaning compounds.
6.15.22
Sample Pumps
Unless otherwise specified or approved, sample pumps shall be of the

progressive cavity type or centrifugal type with flange mounted three phase
cage induction electric motors. The pumps shall have close grained cast iron
bodies, stainless steel impellers and mechanical shaft seals.
Sample pumps shall be installed above flood level wherever possible and shall
be readily accessible for maintenance purposes. Over-pressure protection
shall be provided either by means of an integral device or a separate pressure
relief valve.
6.15.23
Sample Pipework
Sample pipework shall be selected to suit the application and type of

measurement from either uPVC or stainless steel. In addition, medium density
polyethylene pipe may be used where appropriate only for sections run through
buried ducts or laid directly in the ground.
SECTION 66B5: WTP
PAGE 57 of 69
1726 of 2461
6.15.24
MMRDA
uPVC pipework
uPVC sample water pipework shall be the `hi-impact' type to BS EN 1452 with
1452. Screwed connections to metal components such as sample pumps shall
be made with proprietary iron to uPVC adaptor fittings. Pipework shall be
supported in accordance with manufacturers' recommendations and adequate
provision shall be made for thermal expansion and contraction. uPVC pipework
shall not be used where it may influence analytical measurements such as
dissolved oxygen concentration.
6.15.25
Stainless Steel Pipework
Stainless steel sample water pipework shall be type 316S11 or higher grade to
BS 3605 Part 1 with tolerances in outside diameter to Table 1 of BS EN ISO
8434 and tested in accordance with Category 2 requirements.
Pipe couplings shall be light series compression Type A to BS EN ISO 8434.
Pipework shall be supported directly on surfaces with proprietary clips or,
where several lines follow a parallel route, they may be clipped to trays
dedicated to this service.
6.15.26
Polyethylene Pipework
Polyethylene sample water pipework in accordance with BS EN 12201 may be

used for those sections which are run through buried ducts or laid directly in the
ground. Pipe couplings shall be of the electrofusion type as approved by British
Gas and shall incorporate pins which pop up to confirm that optimum melt
pressure has been achieved.
6.15.27 Sample isolating valves
The valves shall be compatible with the main sample pipework system, uPVC
or stainless steel.
SECTION 66B5: WTP
PAGE 58 of 69
1727 of 2461
MMRDA
6.15.28 uPVC valves
Isolating valves shall be of the diaphragm type with uPVC bodies, glass filled
polypropylene topworks and PTFE diaphragms.
Assembly nuts and bolts
shall be stainless steel.
6.15.29 Stainless steel valves
Isolating valves shall be of the diaphragm type to BS EN 13397 with weir bodies
in stainless steel 316C16 to BS 3100, PTFE diaphragms and topworks in
standard proprietary materials. Assembly nuts and bolts shall be stainless
steel. The valves shall be tested in accordance with BS 6755 Part 1 and II.
6.15.30 Sample taps
Sample taps shall be in chrome plated brass, " BSP size, with cross handle
and outlet nozzle suitable for sterilisation by flaming. The nozzles shall have
protective screw on caps which are attached by means of chain to the tap
spindle.
6.15.31 Sample sinks
Sample sinks shall be to BS 1206, nominally 455 mm wide by 255 mm deep

and length to suit the number of sample taps:
-up to 4 samples 610 mm
-5 samples 760 mm
-6 samples 915 mm
The sinks shall generally be supported from a wall on cantilever brackets but
where this is impracticable, they may be supported on stanchions from the
floor. The base of the sink shall be approximately 700 mm from the floor and
shall be fitted with a drain connected to an approved discharge point. Sample
sinks in laboratories shall be flush with the bench tops.
SECTION 66B5: WTP
PAGE 59 of 69
1728 of 2461
MMRDA
The sample tap nozzles shall be positioned at 100 mm centres at a distance of

170 mm from the rear of the sink and at a suitable height above the sink to allow
collection of samples in a glass bottle approximately 300 mm high.
6.16 Safety Equipment
6.16.1 Safety showers
Safety showers shall be purpose-designed proprietary units suitable for indoor

or outdoor use as specified.
The showers shall incorporate nozzles specially designed to create a deluge of
water overhead for rapid decontamination and an additional spray at
approximately waist height to direct water onto the lower body and legs. The
water supply valves shall be mechanically operated by means of a grab handle.
Where specified, the units shall be fitted with limit switches with volt-free
changeover contacts for initiation of a remote alarm when the shower is
operated.
Showers shall incorporate protection against frost and if necessary a water
heater to minimise the initial shock of the deluge when the shower is operated.
The heater controls shall include over-temperature protection which shall not
interrupt the water flow. The showers shall be connected to a secure water
supply to ensure highest possible availability.
A pressure gauge shall be
provided for the supply to each unit. The shower collecting tray shall be
connected to an approved discharge point.
The appropriate safe condition signs shall be fixed in conspicuous places.
6.16.2 Eye baths
Eye baths shall be either self-contained units or integrated with safety showers
as appropriate. They shall be of a purpose-designed proprietary type suitable
for indoor or outdoor use as specified. They shall incorporate fine mesh filters
and pressure regulators to ensure a safe flow of water for eye irrigation. The
water supply valve shall be mechanically operated by means of a tread bar.
SECTION 66B5: WTP
PAGE 60 of 69
1729 of 2461
MMRDA
Frost protection shall be provided.

The eye baths shall be connected to a secure water supply to ensure highest
possible availability. A pressure gauge shall be provided for the supply to
each unit.
The collecting basin drain shall be connected to an approved
discharge point. The appropriate safe condition signs shall be fixed in

conspicuous places.
6.16.3 Protective clothing
Protective clothing shall be supplied in sets in the quantities specified and shall
comprise those articles appropriate to routine operations and maintenance
work in the designated areas of the Works. Where articles are manufactured in
various sizes and are not readily adjustable, then each set shall include a range
of at least two fittings covering medium and large sizes unless otherwise
specified.
6.16.4 Helmets
Helmets shall be of the general purpose industrial safety type complying with
BS 5240 and incorporating an adjustable harness. The colour of the helmets
shall be yellow unless otherwise specified.
6.16.5 Overalls (chemical resistant)
Overalls for chemical handling shall be of the boiler suit pattern manufactured
from plasticised PVC or PVC proofed nylon with welded seams and integral
hood. Front fastening shall be by means of a zip with button-over protective
flap. The overalls shall be impervious and resistant to acids and alkalis at the
maximum concentrations used in the Works.
6.16.6 Gauntlets (chemical resistant)
Gauntlets for chemical handling shall be of the heavy duty pattern with an
SECTION 66B5: WTP
PAGE 61 of 69
1730 of 2461
MMRDA
overall length of at least 400 mm and manufactured from PVC. The external
finish shall be smooth.
6.16.7 Gloves
Gloves for general use including the handling of steel drums and cylinders shall
be of heavy duty leather and fabric construction complying with BS 1651.
6.16.8 Boots
Safety boots shall be in moulded polyvinyl chloride complying with BS EN 345

Part 1 .The boots shall have protective mid-soles and safety toe-caps.
6.16.9 Storage lockers
Storage lockers for protective clothing shall be of the floor standing single
compartment type constructed from 22 swg steel with concealed hinges and
key operated locks. Each locker shall have a hat shelf and double coat hook.
Lockers shall be located away from hazardous areas but within convenient
reach thereof. The lockers shall be suitably labelled as to purpose.
6.16.10 Self contained breathing apparatus
Self contained breathing apparatus shall provide complete respiratory

protection from the surrounding atmosphere for a period of 60 minutes at
normal breathing rate. The apparatus shall comply with BS 7004 and shall be
type approved by the Health and Safety Executive.
Each set of apparatus shall incorporate an air cylinder, pressure reducing
valve, pressure gauge, demand valve, panoramic vision face mask, bypass
valve and adjustable harness with waist strap. The apparatus shall include a
warning whistle to indicate approaching exhaustion of the cylinder. A spare
cylinder shall be supplied with each set.
All air cylinders shall be pre-charged with air meeting the requirements of BS
SECTION 66B5: WTP
PAGE 62 of 69
1731 of 2461
MMRDA
4275. Each set of apparatus shall be capable of accepting an additional face

mask complete with its own demand valve and supply hose. Each set shall be
accommodated in a purpose-designed wall-mounting cabinet of a non-locking
type with lift-off front cover. The cabinet shall be suitably labelled.
6.16.11 Cartridge type respirators
Cartridge (or canister) type respirators shall comply with BS 2091 and shall be
of the full facepiece type unless otherwise specified. Each respirator shall be
supplied with a pack of at least three spare cartridges or canisters.
Each set shall be accommodated in a purpose-designed wall mounting cabinet
of a non-locking type or, where specified, in a suitable hand carrying case.
Cabinets or cases shall be suitably labelled. The labels shall state the intended
use and maximum concentration of the contaminant and exposure time for
which the cartridge or canister is suitable.
6.16.12 Face masks
Face masks for protection against dust shall comply with BS EN 149 and shall
be fully disposable. Masks shall be supplied in packs of at least 20.
6.16.13 Eye protection
Eye protection against gas, liquids and dust shall comply with BS EN 166. The
protection shall be of the goggle type with polycarbonate front lens and
anti-mist acetate rear lens.
6.16.14 Ear protection
Ear protection shall be of the ear muff type complying with BS EN 352 and
tested in accordance with BS 5108.
Ear muffs shall be accommodated in purpose-designed wall mounting cabinets
of a non-locking type which shall be suitably labelled.
SECTION 66B5: WTP
Cabinets shall be
PAGE 63 of 69
1732 of 2461
MMRDA
located immediately outside areas where sound attenuation is required.
6.16.15 First aid kits
First aid kits shall be contained in wall mounting boxes designed to protect the
contents from dampness and dust and marked with a white cross on a green
background.
Unless otherwise specified, each box shall contain the following items:
1. First aid guidance card;
2. 20 individually wrapped sterile adhesive dressings of assorted sizes;
3. sterile eye pads with attachments;
4. 6 individually wrapped triangular bandages;
5. 6 safety pins;
6. 6 medium sized individually wrapped sterile unmedicated wound
dressings (approximately 100 x 80 mm); 2 large individually wrapped
sterile unmedicated wound dressings (approximately 130 x 90 mm);
7. 3 extra large individually wrapped sterile unmedicated wound dressings
(approximately 280 x 175 mm). Additionally, where eye wash bottle sets
are not provided separately in the immediate vicinity,
8. 3 No. 300 ml of sterile water or sterile normal saline solution (0.9%) in
sealed disposable containers. Additionally, where soap and water of
drinking quality are not available in the immediate vicinity,
9. individually wrapped moist cleansing wipes.
6.16.16 Fire blankets
Fire blankets shall be of the heavy duty industrial type complying with BS 7944
or BS EN 1869 and contained in wall mounting cabinets suitably labelled with
white lettering on a red background.
6.16.17 Ventilatory resuscitators
SECTION 66B5: WTP
PAGE 64 of 69
1733 of 2461
MMRDA
Ventilatory resuscitators shall comply with BS 6850 and shall be contained in a

carrying case suitably labelled with white lettering on a green background.
6.16.18 Safety signs
All labels and signs providing health and safety information or instructions shall
comply with BS 5378. Fire safety signs shall comply with BS 5499 Part 1. Signs
which are not integral parts of the safety equipment and which are fixed
separately to cabinets or to nearby surfaces shall be manufactured in
accordance with Part 3 of this Specification.
6.17
Laboratory Equipment
6.17.1 Equipment
Laboratory equipment shall generally consist of standard products. Catalogues

or commercial pamphlets describing each major item shall be provided by the
Contractor along with details of laboratory furnishings and services. Materials
used in the construction of laboratory furnishings and fittings shall be the best of
their respective kinds and shall be selected for their specific applications.
Methods of construction shall be of proven design.
6.17.2 Flooring
The laboratory floor shall be able to withstand heavy traffic as well as stationary loads.
The surface shall be non-slip, resistant to chemical attack and easy to clean.
6.17.3 Laboratory benches
6.17.3.1
Sectional units
Sectional units shall be designed and constructed to develop maximum
SECTION 66B5: WTP
PAGE 65 of 69
1734 of 2461
MMRDA
strength and rigidity. Each sectional unit shall be completely fabricated

ready for placement in the laboratory assembly and shall be a complete
integral rigid unit in itself to permit relocation at any subsequent time.
Under-bench components located on the laboratory floor shall be
equipped with levelling devices, easily adjustable from within the units,
to compensate for any unevenness in the laboratory floor. Above-bench
units shall include draining and equipment racking and shelving of
various kinds. Shelving shall be of a width essential for its purpose and
shall be restricted so that only single line capacity is available when used
for carrying chemical reagent bottles, glassware or items needing careful
handling, in the main laboratory rooms.
Sectional units shall be constructed of timber with either timber or metal
underframing. The use of metal shall be generally confined to bench
underframing, storage cupboards and shelving.
A specialised titration bench shall be provided in the main laboratory with
translucent illuminated work top and back plate, with three double spring
clips to accommodate six burettes mounted on the viewing back.
6.17.3.2
Bench tops
Materials for the construction of bench tops shall be appropriate for their
use.
Bench tops for supporting precision balances and sensitive
instruments shall be rigid and have a surface that is hard and stable and
easily cleaned. Where necessary, anti-vibration supports shall be
provided.
For the main laboratory, the bench tops shall be of seasoned hardwood,
such as teak or iroko, (the quality of timber and workmanship shall
comply with BS 1186)solid grade laminates,solid epoxy resinsor ceramic
earthenware.Seasoned hardwood bench tops shall be well oiled and
waxed prior to use, unless sealed with special coating such as epoxy
resin. Bench tops intended for applications where protection from heat is
necessary, shall be of a suitable fire-resistant material of low thermal
expansion.
SECTION 66B5: WTP
PAGE 66 of 69
1735 of 2461
6.17.3.3
MMRDA
Fume extraction
Fume cupboards shall be confined working benches spaces equipped

with services and provided with an efficient means of removing
objectionable fumes.
The fume cupboard shall be provided with an efficient forced extraction
system designed to give a face velocity of not less than 0.5m/s. The
framing shall be of hardwood protected by a good quality varnish or mild
steel painted with a suitable finish. Transparent panels shall be of
toughened glass, and opaque panels of highly compressed fibreboard,
mechanically strong and resistant to heat. The worktop shall be of black
toughened glass of minimum thickness 10mm or approved equivalent
material. The sash front window shall be constructed of 6mm toughened
safety glass, framed in hardwood or metal, counterbalanced by weights
supported by stainless steel sash cords.
Ducting for extraction systems shall be of suitable material such as
fibreboard cement, joined together by suitable joining material.
6.17.3.4
Laboratory services
Service pipework shall as far as possible be located behind the sectional

units and shall be readily identifiable for purposes of inspection and
repair. Pipework for plumbing, except drain fixtures and fittings, shall be
a red-brass composition containing at least 85% copper, with washers
and seats of maximum wear - resistant materials for the specific use.
Above-bench fittings and taps shall have a corrosion-resistant polythene
finish.
In the main laboratory area, sinks shall be of glazed fireclay, fitted
beneath the bench top the bench top being cut to overhang the sink and
throated on the underside to provide a water break.
Waste systems shall be supplied in "Vulcathene" or similar high density
polythene. All sinks shall be fitted with suitable anti-syphon bottle traps,
SECTION 66B5: WTP
PAGE 67 of 69
1736 of 2461
MMRDA
with removable bases.
6.17.3.5
Electrical fittings
Extraction fan motors shall be wound for single phase or three phase
50Hz AC, supplies. Within the laboratory area, all conduits and
distribution boards shall be able to provide a minimum of 10% additional
capacity. No socket outlet shall be placed on a bench or in a
fume-cupboard in such a position that a spill of liquid can constitute a
hazard.
6.17.3.6
Furniture
A suitable number of desks chairs, laboratory stools and adjustable

height laboratory chairs, shall be provided.
SECTION 66B5: WTP
PAGE 68 of 69
1737 of 2461
MMRDA
APPENDIX
Loss due to abrasion test
The apparatus shall contain a cylindrical perspex column of diameter not less than 50
mm or 50 times the hydraulic diameter of the sample being tested, whichever the
greater and height about 500 mm. The bottom of the column shall be fitted with a
perforated plate or similar to uniformly distribute water applied underneath over the
cross-sectional area of the column. A packing layer may be used to improve the
distribution and to retain the sample. A pipe terminating in a fine mesh air inlet shall be
connected to the column just above the packing layer. The pipe shall be connected to
an air supply and the bottom of the column shall be connected to a clean water supply.
Flowmeters shall be provided on both air and water supply. The overflow from the
column shall pass through a mesh to retain any sample carry over.
The sample of the filter material to be tested shall first be washed to remove dirt, then
dried and sieved. Fill a weighed quantity of dry sample to approximately 250 mm
depth. Upwash the sample for 100 hours so that the material just fluidises and the
grains are all in contact with each other. After 100 hours remove the material from the
column, dry and weigh. Any material collected in the mesh shall be inspected and any
complete grains shall be included in the column material. The percentage loss of
weight shall be calculated.
Also the column material shall be sieved and the effective size and uniformity
coefficient shall be determined and compared with those of the original sample; the
results shall not fall out of specification.
For designs where simultaneous application of air and water are specified the sample
shall be washed at air and water flow rates to be applied in service.
Reference: The specification for filtering materials for Rapid Gravity Filtration, BW : P.
18.96R, June 1996, British Water, 1 Queen Annes Gate, London SWIH 9BT.
SECTION 66B5: WTP
PAGE 69 of 69
1738 of 2461
SUB-SECTION 6B.7
TUNNELS
1739 of 2461
MMRDA
Table of Contents
SUB-SECTION 6B.7 - TUNNELS ...................................................................................................... 1
6.1
General ...................................................................................................................................... 1
6.1.1
Scope of Work ...................................................................................................................... 1
6.1.2
Methodology .......................................................................................................................... 2
6.1.3
Codes ..................................................................................................................................... 3
6.2
Geology of Site ....................................................................................................................... 4
6.2.1
Site Investigation .................................................................................................................. 4
6.3
Details of Method of Construction Proposed. ................................................................ 5
6.4
Setting out the Work.............................................................................................................. 8
6.5
Communication Facilities .................................................................................................... 9
6.6
Safety Measures ..................................................................................................................... 9
6.6.1
General .................................................................................................................................. 9
6.6.2
Specific Precautions ....................................................................................................... 12
6.6.3
Payment .............................................................................................................................. 13
6.7
Lighting ................................................................................................................................... 13
6.8
Ventilation .............................................................................................................................. 14
6.9
Drainage and Pumping ....................................................................................................... 18
6.10
Excavation Lines .................................................................................................................. 20
6.10.1
Mode of Measurement ....................................................................................................... 21
6.11
Excavation Lines in Weak Rock ....................................................................................... 21
6.12
Subsequent Increase in Dimensions .............................................................................. 21
6.13
Excavation of Shafts and Tunnels ................................................................................... 22
6.13.1
General ................................................................................................................................ 22
6.13.2
Excavation Technique ....................................................................................................... 23
6.13.3
Geological Inspection. ....................................................................................................... 23
6.13.4
In-situ Rock Tests ............................................................................................................... 23
6.13.5
Geological Mapping ........................................................................................................... 24
6.13.6
Drilling Test Holes .............................................................................................................. 24
6.13.7
Probe Holes and Pre-Grouting ......................................................................................... 25
6.13.8
Scaling and Mucking for Tunnels and Shafts ................................................................ 25
6.13.9
Rolling Stock and Track for Tunnelling Operations....................................................... 26
6.13.10
Disposal of Muck ............................................................................................................ 27
6.13.11
Payment ........................................................................................................................... 27
6.14
Supports in Tunnels and Shafts ...................................................................................... 28
6.14.1
General ................................................................................................................................ 28
6.14.2
Permanent Supports .......................................................................................................... 28
6.14.3
Temporary Supports .......................................................................................................... 30
6.15
Supporting by Bolts ............................................................................................................ 30
6.16
Cement Concrete Lining and Back Packing ................................................................. 31
6.16.1
General ................................................................................................................................ 31
1740 of 2461
MMRDA
6.16.2
Initial Cleaning .................................................................................................................... 33
6.16.3
Composition of Concrete ................................................................................................... 33
6.16.4
Temperature of Concrete .................................................................................................. 35
6.16.5
Programme of placing concrete ....................................................................................... 35
6.16.6
Construction Progress ....................................................................................................... 36
6.16.7
Bulkhead Joints .................................................................................................................. 36
6.16.8
Formwork ............................................................................................................................. 37
6.16.9
Placing ................................................................................................................................. 37
6.16.10
Hand Placement ............................................................................................................. 38
6.16.11
Pumping of Concrete ..................................................................................................... 38
6.16.12
Consolidation .................................................................................................................. 39
6.16.13
Curing ............................................................................................................................... 39
6.16.14
Reinforcement ................................................................................................................. 39
6.16.15
Leakage Acceptance ..................................................................................................... 39
6.16.16
Final Finishing ................................................................................................................. 40
6.16.17
Tolerances for Concrete Lining .................................................................................... 40
6.16.18
Measurement and Payment of Work ........................................................................... 41
6.17
Grouting .................................................................................................................................. 42
6.17.1
General ................................................................................................................................ 42
6.17.2
Pre-Injection ........................................................................................................................ 43
6.17.2.1
Water Seepage Ingress Requirements ....................................................................... 44
6.17.2.2
Equipment ....................................................................................................................... 44
6.17.2.3
Probing Ahead of the Face ........................................................................................... 45
6.17.2.4
Injection holes ................................................................................................................. 46
6.17.2.5
Control holes ................................................................................................................... 47
6.17.2.6
Injection Materials .......................................................................................................... 47
6.17.2.7
Supervision and injection records. ............................................................................... 48
6.17.2.8
Measurement and Payment for Pre-Injection ............................................................ 48
6.17.3
Post-Injection ...................................................................................................................... 49
6.17.3.1
Codes ............................................................................................................................... 50
6.17.3.2
Types of Post-Injection .................................................................................................. 50
6.17.3.3
Drilling Grout Holes ........................................................................................................ 51
6.17.3.4
Cleaning Holes ............................................................................................................... 51
6.17.3.5
Pipes and Fittings for Grouting ..................................................................................... 52
6.17.3.6
Pack Grouting ................................................................................................................. 53
6.17.3.7
Pressure Injection Grouting .......................................................................................... 57
6.17.3.8
Grouting Equipment ....................................................................................................... 60
6.17.3.9
Measurement and Payment for Pressure Grouting .................................................. 61
6.18
Shotcreting ............................................................................................................................ 62
6.18.1
General ................................................................................................................................ 62
6.18.2
Materials .............................................................................................................................. 62
6.18.3
Mix Proportion ..................................................................................................................... 64
6.18.4
Codes ................................................................................................................................... 64
6.18.5
Shotcreting Process ........................................................................................................... 65
1741 of 2461
MMRDA
6.18.6
Application of Shotcrete .................................................................................................... 65
6.18.7
Measurement and Payment.............................................................................................. 66
6.19
Pipelines and Steel Liners ................................................................................................. 66
6.19.1
Scope ................................................................................................................................... 67
6.19.2
Erection ................................................................................................................................ 67
6.19.3
In - situ welding ................................................................................................................... 68
6.19.4
Inspection of Welded Joints at Site ................................................................................. 69
6.19.5
In-situ Cement Mortar Lining ............................................................................................ 69
6.19.6
Support to Embedded Pipes & Specials in the Tunnel................................................. 70
6.19.7
Encasing and Painting ....................................................................................................... 70
1742 of 2461
MMRDA
SUB-SECTION 6B.7 - TUNNELS
6.1
General
6.1.1
Scope of Work
The Scope of work mainly comprises the following:

(a)
Construction of Inlet shaft and outlet shaft including disposal of

muck and pumping out seepage water.
(b)
Excavation for tail tunnel and TBM assembly area, at bottom of

the shaft and TBM removal area at outlet and disposal of muck.
(c)
Boring of Tunnel from Inlet to Outlet shaft with upward gradient

1: 500 by TBM. Including communication facilities, safety
measures, lighting, ventilation, dewatering, wet/dry mucking and
its disposal, RCC lining of the tunnel to a finished diameter,
Providing steel liners as per IS: 2002 in addition to RCC lining
wherever necessary or steel liner over entire length of tunnel is
under water body.
(d)
Probe hole drilling, pre-grouting and post-grouting with cement

and/or chemical to control seepage of sub-soil water.
(e)
Dismantling of TBM and withdrawal of the same through shaft.
(f)
Concrete backpacking behind steel liner.
(g)
Supply, manufacture, laying, jointing and testing MS Pipelines

and specials along with inside and outside surface treatment
including allied civil, mechanical and electrical works.
(h)
Providing, supplying and erecting B/F valves along with DMJ,
SECTION 6B7: TUNNEL
PAGE 1 of 70
1743 of 2461
MMRDA
tapers and companian flange. Also providing, supplying and

erecting Kinetic Air valves.
(i)
Provide concrete encasement to pipes etc.
(j)
Cement mortar lining for internal surfaces of liners & pipelines.
(k)
Backfilling the shafts, assembly and the tail tunnel areas with
murum /earth / tunnel muck / plum concrete.
(l)
Demolition of existing structure & rebuilding.
(m)
Testing and Commissioning of the Tunnel including hydraulic

testing at pressure equal to 1.5 times maximum static head for
gravity main and for pumping main at pressure equal to sum of
working pressure and surge pressure.
6.1.2
1.
Methodology
The results of the alignment survey and topographic survey along the
main tunnel will be made available to the Contractor by the Employer.
However, it will be Contractors responsibility to verify the surveys and
conduct fresh surveys as necessary. The Contractor will carry out
detailed alignment survey of the tunnel.
An item of surveys is provided for in the Provisional Sum in the BOQ.
2.
The results of the boreholes taken along the alignment of the tunnel will
be made available to the Contractor by the Employer; however, it will
be Contractors responsibility to verify the results. Additional boreholes
may be taken along the alignment of tunnel to determine the exact rock
profile. An item for borehole is provided as the Provisional Sum in the
BOQ.
3.
Procure a TBM as per the MoU submitted with the bid and other
materials & equipment and transport to the site before completion of
tail tunnel.
SECTION 6B7: TUNNEL
PAGE 2 of 70
1744 of 2461
4.
MMRDA
Take up the excavation of inlet shaft. No blasting will allowed.

The required power and other utility facilities shall be installed so as to
start the lowering of TBM machines. The boring shall progress from
Inlet shaft to outlet shaft.
5.
On completion of tunnel boring, RCC lining of the tunnel shall start from
outlet shaft towards inlet shaft. The feeding of the concrete will be from
inlet shaft.
6.
Following activities are to be undertaken:
i)
Interconnections to the pipelines at inlet
ii)
Interconnection to the pipelines at outlet
iii)
Steel liners in the tunnel at Creek and other weak locations in the
tunnel, if required.
7.
Work has to continue during monsoon also.

8.
The final work will be that of slow charging the pipe lines to
shaft, in this case the pipeline and tunnel is to be charged till the
tunnel is gradually filled under laminar flow conditions.
9.
Commissioning of the tunnel as per the satisfaction of the

Employer.
10.
The contractor to submit a detailed methodology with detailed

Bar Chart and PERT/CPM chart plan using project management
software along with his bid so as to complete the entire work
within stipulated Contract Period.
6.1.3
Codes
The provisions of the latest revisions of the following I.S. codes shall
form a part of this specification to the extent they are relevant. Where
the I. S. code is in conflict with the stipulations of this specification, this
SECTION 6B7: TUNNEL
PAGE 3 of 70
1745 of 2461
MMRDA
specification supersedes the I.S- code. Where there is no I.S. codes of

practice laid down, relevant British and /or American standards shall be
followed.
IS 4138
- Safety code for working in compressed air.
IS 4167
- Glossary of terms relating to air pollution.
IS 4756
- Safety code for tunnelling work.
IS 4880
- Code of practice for design of tunnels conveying
water.
(Parts 1 to 7)
IS 5878
- Code of practice for construction of tunnels
conveying water.
(Parts 1 to 7)
- Indian Explosives Act 1
- Indian Explosives Rules
- Safety measures as per Indian Mines Regulations.
IS 456
- Plain and Reinforced Concrete Code of Practice
In addition, relevant safety provisions from Safety Manual of Central

Water
Commission (CWC) shall apply as appropriate.
6.2
Geology of Site
6.2.1
Site Investigation
It may be noted that the geological information and data to be provided
by the employer are only for the general guidance of the Tenderer and
the
Engineer
assumes
no
responsibility
for
any
deductions,
conclusions or interpretations that may be made by the Tenderer.
SECTION 6B7: TUNNEL
PAGE 4 of 70
1746 of 2461
MMRDA
Cores obtained from the bore holes have been logged and stored and
are available for inspection to the Tenderers with prior permission of
the Engineer.
6.3
Details of Method of Construction Proposed.

The Tenderer shall furnish with his bid complete information about the
method he proposes for sinking the wells, sinking the shafts within the
wells for shafts and tunnels where applicable, supporting system for
tunnels and procedure for dismantling TBMs inside the tunnel and for
withdrawing from respective end shafts. The Tenderer shall also give
details of mucking arrangement for the tunnels duly considering the
high rate of production of muck by TBMs and its final disposal
expeditiously. In this connection, the Tenderer shall note that due to
limited availability of area at the shafts head, intermediate dumping of
muck within the plots will not be permitted. The Tenderer shall further
furnish details of full circle shuttering to be used by him and the
arrangement for concrete hauling and placement of concrete for lining.
The tunnels shall be excavated using modern full face TBM suitable for
excavation of rock of all types. Outline details of the TBMs and mode of
transport to the sites shall be submitted by the Tenderer along with the
Tender.
The TBM shall include provision for forward probing at the face or on
the sides of the excavated tunnels to check rock quality and location of
likely places where water ingress could occur. They shall also include
provision for pre-grouting of rock in advance of excavating the tunnels
to seal water bearing fissures or to improve the strength of the rock
mass and provision for installing rock bolts or dowels within 10 m of the
excavated face or along the periphery of excavated tunnel. Tunnel
excavation without forward probing shall not be permitted to be carried
out.
The Contractor shall submit full details of the TBM, the backup train
and all ancillary equipment to the Engineer at least 6 weeks before the
same is ready for shipping. The Contractor shall be solely responsible
for ensuring that all equipment provided by him is suitable for the
SECTION 6B7: TUNNEL
PAGE 5 of 70
1747 of 2461
MMRDA
purpose of carrying out the said works. The TBM shall be capable of
excavating the tunnels of the required size to the line and levels shown
on the Specification Drawings at the rate of minimum 450 metres per
month. All the equipment shall be capable of dealing with poor ground
conditions over local areas and water inflow at the face.
In case the Contractor proposes to use TBM which has previously
been used on other projects, the same shall be refurbished before they
are transported to the Sites. If the refurbishing is carried out by an
organisation other than the original designer or manufacturer of the
TBMs, the Contractor shall arrange for certification by the refurbishing
agency/original designer/original manufacturer to confirm that all
refurbishing and adaptation can be accepted as being suitable for all
the conditions that could be expected at the tunnels. After this initial
refurbishing, the residual life of the TBM shall not be less than 1.5
times length of the tunnel to be excavated by TBM.
The Tenderer, in his bid, shall furnish in the Schedules complete
details of the
TBM, other construction equipment and constructional facilities that he
proposes to deploy for the Works along with their power requirements,
as listed below but not limited to:a.
TBMs, model to be used, with probing and pre-grouting

arrangements
b.
Muck and passenger hoisting arrangement
c.
Back-up system including battery operated electric locomotives,

mine cars and trolley track with crossings at a spacing of not more
than 1.0 km.
d.
Ventilation including silencers and acoustics
e.
Dewatering pumps, piping and flowmeters
f.
Rock bolting
g.
Mucking
SECTION 6B7: TUNNEL
PAGE 6 of 70
1748 of 2461
MMRDA
h.
Workshop facilities
i.
Shuttering
j.
Concrete placing arrangement - pumps, agitating cars, batching

plants and mixing etc.
k.
Shuttering
l.
Laser equipment with machine roll readout arrangement to steer

machines in correct alignment, distomat for surveying
m.
Lighting in shafts, tunnels and area around shafts at the surface
n.
Telephone communication
o.
Electrical installation
p.
Any other system
All the equipment and facilities listed above shall be in excellent

working condition and adequate stand-by shall be provided by the
Contractor.
The Contractor shall be responsible for design of cutter heads using
picks and/or discs so as to efficiently cut through the strata with range
of compressive strength from 40 MPa to 200 MPa. The Contractor shall
have to dismantle the cutter heads after boring the required length in
the tunnels and remove the same and the TBM from within the tunnel
through the end shafts without the need of an intermediate shaft. The
TBM shall have laser targets that can accommodate / compensate for
machine roll. The Contractor shall provide readouts of machine head
inclination to the TBM operators and shall arrange for fitting devices to
give visible and audible warning if inclinometer parameter settings arc
exceeded. The TBM and especially any electrical or electro-hydraulic
devices shall be designed to withstand humid and wet conditions.
The TBM operators shall have undergone training by the TBM
manufacturer and shall be certified as competent by the latter.
SECTION 6B7: TUNNEL
PAGE 7 of 70
1749 of 2461
6.4
MMRDA
Setting out the Work

The Contractor shall carry out detailed precision survey to establish the
length and bearing of the tunnel between shaft points, keeping the
alignment as close to the alignment proposed as per drawing and coordinates of the shaft points and other reference points. The Contractor
shall establish reduced ground levels along the alignment. The
Contractor shall establish permanent reference pillars and take all
precautions to see that the points fixed by the Engineer are not
disturbed by his work and shall make good the damage, if any, at his
own cost. All survey work shall be carried out by qualified and
experienced surveyor using precision instruments for fixing alignment
and transferring points through shafts to the tunnel.
The Contractor shall establish at suitable points permanent reference
marks on the centre line of shafts and tunnels as directed. The
permanent marks shall be inscribed on bronze pegs, set in substantial
concrete blocks where they will be free from any likelihood of
disturbance. Suitable permanent bench marks shall also be established
near the shafts. As the tunnelling work progresses, centre line marks
shall be made on pegs inserted into the roof of the tunnels, and other
hollow cuts at convenient intervals for checking alignment , grades,
levels etc. and also dimensions of maximum excavation lines. The
Contractor shall be responsible for the sufficiency and accuracy of all
such bench marks and reference points.
The Contractor shall excavate the tunnel true to alignment, grade and
levels and shall check the alignment over every 250 metres traverse as
the work progresses.
The Contractor shall check the alignment, grade and levels of the
tunnels every kilometre by a specialist surveying agency at his own
cost. Any discrepancy or error detected during the course of excavation
and /or at the end of the work and work beyond the permissible
tolerances shall be set right by the Contractor at his own cost in a
manner acceptable to the Engineer.
Also deviation in the vertical alignment of the tunnels shall not result in
SECTION 6B7: TUNNEL
PAGE 8 of 70
1750 of 2461
MMRDA
reversal of the longitudinal fall in any length of the tunnels. Sudden

deviations and corrections of the deviations from the alignment shall
not be permitted.
The Contractor shall provide suitable rigs and make all necessary
arrangements, to the satisfaction of the Engineer, for moving the rigs
along the alignment and grade of the tunnels to check the dimensions
of the minimum excavation lines and lining when required by the
Engineer. The cost of all the operations shall be considered as
included in the unit rates tendered for various items of work.
6.5
Communication Facilities
The Contractor shall install and maintain in good working order at all
times during the period of the work at or near working face of the
tunnels, a telephone connected with the of the shafts bottom and top,
office and all critical points so as to afford prompt communication over
each such telephone, throughout the full working hours every day, with
some responsible employee of the Contractor outside the tunnels
/shafts. The Contractor shall also install, maintain and operate such
other communication and signal facilities as may be necessary for safe
conveyance of men, materials and equipment through the shafts and
tunnels. All such facilities shall be subject to the approval of the
Engineer. The Engineer and persons authorised by him shall have free
use of such communication and signal facilities.
The entire cost of providing and maintaining such communication and
signal facilities shall be deemed to have been included in the unit rates
tendered.
6.6
Safety Measures
Following safety precautions shall be taken during excavation of the
tunnels and shafts.
6.6.1
General
a) All operations inside the tunnels or shafts shall be carried out under
the immediate charge of a properly qualified and competent safety
engineer.
SECTION 6B7: TUNNEL
PAGE 9 of 70
1751 of 2461
MMRDA
The Contractor shall also depute experienced safety supervisors in all

three shifts under the overall command of the safety engineer.
b) An effective and workable safety programme shall be planned in
advance in consultation with the Engineer and adhered to. Workmen
shall be thoroughly instructed in safety rules and shall be required to
follow them at all times. They shall be required to report immediately, to
the safety engineer, any unsafe conditions observed, who in turn will
bring the same to the notice of the Engineer and take necessary
immediate actions as required to ensure safety.
c) The safety engineer appointed to look after the tunnelling work may
also take guidance from geologists about the bad reaches expected to
be met in the tunnels so that necessary additional safety measures
could be adopted.
d) The occurrence of any accident involving injury to personnel or of
any dangerous incident, such as serious breakdown of or damage to
any apparatus / equipment and temporary works shall be reported to
the
Engineer and adequate precautions shall be taken by the Contractor to
prevent recurrence. An accurate record of such accidents shall be
properly
maintained.
Probable
reasons
of
accident
shall
be
investigated and precautionary measures taken to avoid further

recurrence.
e) All persons entering the tunnels or shafts shall be provided with
protective wear such as helmets, hand torches, and also safety belts if
required.
Gumboots or similar types of protective footwear shall also be
provided.
Ladies and children shall normally be not allowed entry in the
underground works, except in rare cases when they shall be
accompanied by responsible persons and escorted by the safety
engineer or a safety supervisor.
SECTION 6B7: TUNNEL
PAGE 10 of 70
1752 of 2461
MMRDA
f) Signboards 1 m x 1.5 m in size with the following wording shall be

erected at the access to the shafts "CONSTRUCTION AREA.
HELMETS REQUIRED BEYOND THIS POINT".
g) No loose garments or ragged clothing shall be worn by personnel
engaged in the tunnelling operations.
h) Effective artificial respiration arrangements shall be provided, with
trained men capable of providing artificia1 respiration.
i) First aid arrangements commensurate with the degree of hazard and
the number of workers employed shall be maintained in a readily
accessible place throughout the whole working hours of the tunnelling
job. At least one experienced first aid attendant shall be available on
each shift to take care of injured persons. Stretchers and other
equipment necessary to remove injured persons shall be provided at
shaft exits. The Contractor shall also make necessary arrangement to
remove the injured persons to the nearest qualified medical practitioner
/ hospital as required.
j) Only the materials required for work in progress shall be kept inside
the tunnels. All other materials shall be removed from inside the
tunnels and at least 1.5 M width of the .formation shall be as even as
possible and without any obstacles to enable the workers to get out of
the tunnels quickly in case there is any collapse or any other mishap
inside the tunnels.
k) All storage, handling and use of inflammable liquids shall be under
the supervision of qualified persons. All sources of ignition shall be
prohibited in areas where inflammable liquids / gases are stored,
handled and processed. Suitable warning and 'No Smoking' signs shall
be pasted at all such places. Receptacles containing inflammable
liquids / gases shall be stacked in such a manner as to permit free
passage of air. All combustible materials like rubbish shall be
continuously removed from such areas where inflammable liquids /
gases are stored, handled and processed. All spills of inflammable
liquids shall be cleared up immediately. Containers of inflammable
SECTION 6B7: TUNNEL
PAGE 11 of 70
1753 of 2461
MMRDA
liquids / gases shall be tightly capped.

l) Fire extinguishers and fire buckets appropriate to hazards should be
conveniently located and identified.
m) All cranes, winches, hoists, lifts etc. used for working in the shafts
shall be periodically (at least once a week) inspected by the safety
engineer jointly with the Engineer's Representative. Any deficiencies
noticed shall be immediately rectified by the Contractor so that the
equipment satisfies requirements of the respective codes.
6.6.2
Specific Precautions
Safety precautions for execution of tunnels, shafts and sundry
excavations:
a) Wet drilling shall be adopted to ensure dust free conditions in shafts.
b) The information on drilling pattern requires to be furnished to the
Engineer.
c) Strict safety measures shall be followed to ensure safe haulage of
men, materials and other equipment as per rules laid down in Indian
Mines Regulations.
d) Heavy duty pumps of adequate capacities shall be available at all
times at the Sites to control the seepage of water in the shafts and
tunnels.
e) Immediate arrangements shall be made for grouting the rock
(including chemical grouting) to control the seepage whenever
required.
f) The Contractor shall supply and erect head frames including hoists,
cables, pulleys, shackles and other accessories which shall be of steel
construction properly designed, with sufficient head room and safety
against possible overload and impact due to sudden drops.
g) Hoisting equipment shall be thoroughly inspected at least once a
week.
SECTION 6B7: TUNNEL
PAGE 12 of 70
1754 of 2461
MMRDA
Suitable stand-by power supply arrangement or alternate means of

working the hoists mechanically as specified in I.S. 807: Code of
practice for design, manufacture, erection and testing (structural
portions) of cranes and hoists, shall be provided. A limit switch or
automatic brake shall be provided on every hoist to control speed.
h) A masonry parapet wall of suitable height shall be constructed
around the well opening at ground level as well as around the shaft
openings to prevent entry of water or any other material falling into the
shafts.
j) Personnel shall be lowered in the shafts by passenger lifts from
ground level to the bottom of the shafts.
k) Reliable means of communication such as bells or whistles shall be
maintained at all times between the bottom of the shafts and the
surface and telephones used, whenever possible. Any code of signal
used shall be kept conspicuously pasted near work place and
entrance.
l) In case rail mounted equipment is deployed, the rail track shall be
properly earthed at suitable intervals.
6.6.3
Payment
The cost of all safety measures detailed as above and elsewhere in
this specification shall be considered as included in the unit rates
tendered.
6.7
Lighting
All the excavation works shall be adequately illuminated with electric
lights to the satisfaction of the Engineer. Points of intensive work shall
be properly and carefully illuminated to ensure safety during working. A
minimum of 100 lux shall be provided at the heading during drilling,
boring by machine, mucking and scaling.
When mucking is done by tipping wagons running on trolley track a
minimum of 50 lux shall be provided for efficient and safe working.
SECTION 6B7: TUNNEL
PAGE 13 of 70
1755 of 2461
MMRDA
Special lights shall be provided, if necessary, for checking alignment

etc. Proper illumination shall be provided also during non-working
hours as may be required at each location.
Steel forms and any other equipment shall be properly grounded to
prevent electrocution in tunnels due to damp or wet surroundings.
Switches shall be located on high ground and these shall be properly
grounded.
Whenever hand lamps are used for lighting they shall be:
a. Equipped with strong cover of glass or other transparent
material;
b. Dust and water proof;
c. Equipped with strong guard over the cover; and,
d. 24 volts as per safety code.
The cost of providing all lighting as specified above shall be considered
as included in the unit rates tendered.
6.8
Ventilation
All underground excavation work shall be properly and adequately
ventilated by a system of ducts and fans, to the satisfaction of the
Engineer to maintain healthy working conditions by keeping the air
fresh and respirable and by eliminating harmful and obnoxious dust,
dynamite fumes, and other gases.
The Contractor shall, before initiating the underground work, submit for
the approval of the Engineer, the complete layout, plan and
methodology of ventilation system, duly backed with detailed
calculations justifying the deployment of ventilation equipment and
accessories proposed by him, including the capacity of blowers, their
spacing, diameter of ducts, etc. If during execution of the work, the
Engineer finds that the capacity of ventilation system is inadequate for
the good health of workers and for speedy removal of obnoxious
gases, he shall direct the Contractor to install additional fans and take
all needed measures to achieve the specified results.
SECTION 6B7: TUNNEL
PAGE 14 of 70
1756 of 2461
MMRDA
The concentration of various gases in the atmosphere, by volume,

inside the tunnels shall reasonably conform to the following limits to
avoid any harmful effect on personnel working inside the tunnels:a) Oxygen - not less than 19.5 percent
b) Carbon monoxide - Not more than 0.005 percent
c) Carbon dioxide - Not more than 0.5 percent
d) Nitrogen fumes - Not more than 0.0003 percent
e) Methane - Not more than 0.5 percent at any place in the tunnel, e.g.,
a cavity in the roof
f) Hydrogen sulphide - Not more than 0.001 percent
g) Aldehydes - Not more than 0.0002 percent
The Contractor shall provide the following instruments /apparatus to
control and check the concentration of various gases in the tunnels:a) Six sets of self-contained oxygen breathing apparatus
b) Oxygen canisters and tools for adjustment of apparatus (the oxygen
cylinders being kept fully charged at all times during the course of
work)
c) One carbon monoxide tester
d) One explosimeter for the detection of combustible gases such as
methane, petroleum vapours etc.
e) One hydrogen sulphide detector
f) Two oxygen percentage indicators.
a) Tests shall be carried out by the Contractor in accordance with the
ASTM specifications as and when required by the Engineer. In
particular, the carbon monoxide content and percentage of oxygen in
the air shall be measured regularly.
SECTION 6B7: TUNNEL
PAGE 15 of 70
1757 of 2461
MMRDA
b) In case any of the gases mentioned above is detected to have

crossed the threshold value, the tests for that gas will be carried out
periodically till the percentage is brought down below the threshold
value by the Contractor by taking effective measures to improve the
ventilation inside the tunnel.
c) The Contractor shall be solely responsible for maintaining a good
ventilation system in the tunnels and keeping the concentration of
various gases within permissible limits. It may be noted that, if CO
content exceeds 0.005% (50 ppm) or the percentage of oxygen drops
below 19.5% at any place, the rates payable for the item of excavation
shall be reduced.
d) For the information of the Tenderers it may be mentioned that no
evidence of injurious gas was found during geotechnical investigations.
Only wet drilling shall be permitted inside the tunnels. Besides wet
drilling, there shall be adequate ventilation for dust control. The
Contractor shall do medical check-up of the workers working in the
tunnels periodically to check up their physical fitness. Such checks
shall be made at least once in three months and the results recorded in
the registers provided for the purpose.
The dust concentration in the atmosphere adjacent to the working face
shall be tested in accordance with ASTM specifications once in a
month and if concentration of dust particles of the size 0.5 to 5 microns
is more than 450 particles / cm3, ventilation shall be adequately
improved to bring the dust concentration to less than this limit.
Ventilation and exhaust system for tunnels and shafts excavation shall
be of sufficient capacity to maintain an adequate supply of
uncontaminated air at all points in tunnels and shafts. The ventilation
system shall be of such efficiency that the average air velocity in the
largest excavated profile is not less than 0.3 m/sec.
In case presence of methane gas is suspected or detected, this value
shall be increased to 0.5 m/sec.
For proper ventilation of tunnel, only battery operated electric
SECTION 6B7: TUNNEL
PAGE 16 of 70
1758 of 2461
MMRDA
locomotives will be permitted. On tunnel work, 4.25 m3 of air per

minute per man is usually considered the minimum requirement.
Where temperature is high, suitably augmented volume of air shall be
provided. Diesel or petrol driven engines shall not be used in the
tunnels. Reversible type centrifugal fans which could be adjusted to
required pressures shall be used for ventilation.
a) The following costs shall be deemed to have been included in the

unit rates tendered:i) The cost of furnishing, installing, maintaining and operating the
ventilation system; and,
ii) The cost of providing, installing and removing after completion of the
works equipment / apparatus as well as those considered necessary
for the purpose above.
b) No additional payment shall be made for mobilising additional
ventilation equipment, installing, maintaining and operating the same if
found necessary in order to maintain good ventilation in the tunnels.
c) The Contractor shall note that
i) if CO content is found on monitoring to be between 50 to 60 ppm,
then the excavation rates payable for the period of default will be
reduced by 5% ;
ii) if the Oxygen content is between 19.5-19.0%, the excavation rates
payable shall be reduced for the period of default by 5% ;
iii) if both CO and oxygen are found to be beyond above permissible
limits, the excavation rates payable shall be reduced for the period of
default by 10% ;
[Period of default will be reckoned from the time the objectionable limits
of concentration are noted till the time they are restored to normal limits
as indicated by monitor.]
SECTION 6B7: TUNNEL
PAGE 17 of 70
1759 of 2461
6.9
MMRDA
Drainage and Pumping

All water from the underground works shall have to be satisfactorily
drained away by pumping from the shafts into storm water drain / water
course in the vicinity of the Sites or as directed by the Engineer. Water
so pumped is expected to be contaminated with grit, silt, cement, oils
and greases and hence will not be allowed to be led to natural streams,
unless the same has been treated to confirm to Corporations
standards for potable raw water. Such treatment shall ensure removal
of oils and greases, settling of solids, and neutralization of acidity, if
any.
Rates for tunneling quoted by the Contractor shall be deemed to be
inclusive of the cost of all drainage from tunnel and treatment as may
be required. The Contractor must take all precautions essential to
prevent water from the surrounding grout open from flowing into the
shafts. In case any underground springs are met with, the water from
them shall be so led away as not to damage or endanger the work. The
Engineer may direct that water bearing seams or broken ground
encountered in excavations shall be grouted to reduce the flow of water
into the excavation.
The pumps used for dewatering shall be operated by electric motors /
compressed air. All pumps shall be procured new, where used ones
are to be deployed, their efficiencies shall be certified by a third party
acceptable to the Client. The use of internal combustion engine for
pumping is strictly prohibited.
The number of pumps used at site shall be adequate to meet the
requirements of total draining and the Contractor shall provide for at
least half the requirement as standby.
Maintenance of pumping equipment shall be carried out by first
providing substitute pumps. All work in the underground works shall be
stopped when adequate pumping equipment is not available for
dewatering. The dewatering pumps shall be manned at all times.
Drainage of the tunnels shall be by gravity but where such gravity
SECTION 6B7: TUNNEL
PAGE 18 of 70
1760 of 2461
MMRDA
drainage to shafts is not possible due to reverse grade or any other

reason, pumping shall be resorted to for leading the water to the shafts.
However, such pumping where necessary shall be the responsibility of
the Contractor and no separate payment shall be made for such
pumping from tunnels to shafts. The Contractor shall note that before
leading the water into any storm water drains or water course, the
same shall be led to a stilling tank so that grit and other such materials
shall be got removed. The grit and other materials so removed shall be
disposed off in the same manner as tunnel muck and the cost of such
disposal will not be paid for separately and shall be deemed to be
included in the item of excavation of tunnels/ shafts.
The Contractor shall take all care to see that disposal of pumped
seepage-water does not affect the work of other agencies, if any,
working in those areas. The
Contractor's pumping equipment as well as the complete scheme of
disposal of seepage water shall be approved by the Engineer.
The pumped-out seepage water shall be measured daily on 24 hours
pumping basis by suitable electromagnetic or ultrasonic flowmeters
fitted on individual discharge piping as per the manufacturer's
recommendations. The excess of pumped-out seepage water over and
above the limits specified above shall be paid for in terms of cubic
metres per day.
The unit rate tendered for pumping out in excess of above mentioned
quantities, as applicable, shall be deemed to include for the cost of all
pumps , pipework, excavation of sumps and niches for accommodating
pumps and drains for flow of water and refilling them with concrete
similar to that used in lining, works necessary to prevent inflow of water
from outside, cost of providing arrangements for separating grit etc. as
mentioned
above,
and
necessary
arrangements
to
prevent
inconvenience to public and movement of traffic.

In case of stoppage of work, the Contractor shall continue to dispose of
seepage water from the tunnels by pumping. The payment for this
SECTION 6B7: TUNNEL
PAGE 19 of 70
1761 of 2461
MMRDA
dewatering operation will be made in terms of cubic metres per day of

the entire quantity pumped out, actually during such stoppage period. It
shall however be noted that, this payment will be made only if it is
established that the Contractor is not responsible for stoppage of work.
6.10
Excavation Lines
The tunnels and shafts shall be excavated to the lines and grades
shown on the drawings.
The excavation or clearance lines indicated on the Specification
Drawings are minimum excavation lines within which no unexcavated
material of any kind, no timbering and no metallic or other supports
shall be allowed to remain. The payment lines in the drawings are the
outside limits upto which the Contractor will be paid regardless of the
fact whether the limits of actual excavation falls outside or inside these
lines except in the case of natural cleavages etc. in rock, as specifically
provided for herein below.
Any enlargement considered necessary by the Contractor for
convenience of his work may be done by him with the prior approval of
the Engineer. This shall be filled back with concrete of the same class
as specified for the lining. No payment shall be made for this extra
excavation or for backfilling it with concrete.
In case of overbreaks extending beyond the payment line due to
concealed joints, faults, or other structural defects in the rock and not
due to lack of reasonable care and skill in excavation on the part of the
Contractor, a new payment line will be established by the Engineer
provided the additional quantity of such overbreak beyond the original
payment line is not less than 5% of the total excavation quantity for the
shaft. The quantity of such additional excavation shall be measured
between the original payment line and the newly established line and
paid for at the rate tendered by the Contractor for excavation in that
particular portion of the work. In establishing the overbreak and
measuring the same, the
Engineer's decision shall be final and binding on the Contractor.
Overbreaks due to lack of reasonable care and skill in excavation on
the part of the Contractor shall not be paid for.
SECTION 6B7: TUNNEL
PAGE 20 of 70
1762 of 2461
MMRDA
The Contractor shall use all precautions to avoid excavation beyond

the payment lines marked on the Specification Drawings. Any trimming
required to the excavated surface to bring the excavation clear off the
excavation line or clearance line should be done carefully. No separate
payment shall be made for such trimming work. It shall be deemed to
have been included in the excavation rates.
6.10.1
Mode of Measurement
The Contractor shall provide arrangements to the satisfaction of the
Engineer to check the dimensions of the "minimum excavation line"
etc. as and when required by the Engineer. The cross-section for this
purpose shall be taken by establishing the centre line of the tunnel and
the springing level. The cross -section shall be recorded by taking
offsets correct to nearest centimetre at a regular interval of 30 cm
above and below the springing line. The cross-sections so recorded will
be plotted against the design section to indicate any undercuts,
overcuts etc. Such cross sections shall be recorded and plotted at an
interval of 50 m along the alignment or even at shorter intervals if the
Engineer so directs. For the portion of the tunnels excavated by
conventional method the cross - sections shall be plotted at intervals of
5 M.
6.11
Excavation Lines in Weak Rock

In some portions of work it may become necessary to support the rock
in continuous stretch by permanent supports and the excavation may
have to be increased to accommodate these supports. In such a case,
the increased excavation shall be accomplished by other means such
as pavement breaker, barring, wedging etc. and a new payment line
shall be established. This new payment line shall be taken radially and
normal to the centre-line of the tunnels and shafts 100 mm beyond the
outer face of the support.
The other conditions viz. overbreak due to concealed joints, natural
cleavages etc. and precautions to be taken. specified for excavation
lines in good rock hereinbefore, shall apply to this case also.
6.12
Subsequent Increase in Dimensions

If during the progress of excavation of the tunnels and allied works, it is
SECTION 6B7: TUNNEL
PAGE 21 of 70
1763 of 2461
MMRDA
required to increase the cross sectional dimensions of the excavated

area for any purpose, a new line will be established.
All excavation shall be so done that the rock around the periphery of
the excavated final section shall not be shattered, loosened or
otherwise weakened.
Large overbreaks shall be avoided by suitable means such as light
charges, ream holes or similar measures. The cost of those measures
shall be considered as included in the rates of excavation.
In special locations, where specifically indicated or ordered by the
Engineer, in writing, the use of explosives shall be discontinued and
the rock excavated by line drilling, barring, chiselling or wedging, etc.
as approved or directed by the Engineer. Only such excavations shall
be paid for at the rate accepted for excavation by line drilling, barring,
chiselling and wedging.
6.13
Excavation of Shafts and Tunnels
6.13.1
General
a) The lines and grades of shafts and tunnels are indicated on the
Specification Drawings. It may be noted that elevations shown in
various drawings with relevance to THD and not MSL.
b) Considering the scope of work under this contract and the time
available for completion of the same, TBMs are required to be used for
excavation of tunnels except for shaft sinking, tail tunnels and
assembly tunnels.
These portions will be required to be excavated using conventional
method of drilling except blasting.
c) Any excavation carried out over and above the minimum excavation
line in the tunnels for the facility of erection, dismantling of TBMs or for
any other facility required by the Contractor for construction work will
not be paid for separately and it is deemed that the extra cost towards
excavation, concrete backfilling with the same grade concrete as in
SECTION 6B7: TUNNEL
PAGE 22 of 70
1764 of 2461
MMRDA
lining and other related expenses are included in relevant items of

work.
d) On completion of boring of the tunnel by TBM, any local
enlargement of the cross section of the tunnel required for the purpose
of dismantling and taking out the cutter head shall be achieved by
excavating the rock by using pavement breakers or by line drilling,
barring, chiselling, etc. as approved or directed by the Engineer. No
separate payment will be made for this extra excavation, concrete back
filling with the same grade concrete as in lining upto minimum
excavation
line
and
any
rock
supports
necessitated
by this
enlargement. The extra cost shall be deemed to be included in relevant

items of work.
6.13.2
Excavation Technique
In the case of the TBMs bored tunnels, the Contractor shall take all
necessary steps to avoid damage to structures along and in the vicinity
of the alignment of the tunnels by any reasons arising out of the
tunnelling operations. It shall be the sole responsibility of the
Contractor to ensure this.
6.13.3
Geological Inspection.
a) The Engineer will carry out geological inspection at various locations
during the course of the work. The Contractor shall provide access and
all required assistance as required by the Engineer for the purpose of
carrying out such inspection. The cost of providing access and other
services as required herein shall be included in the unit prices tendered
for the relevant excavation item.
b) The Contractor shall wash down exposed rock surfaces in the shafts
and tunnels as directed by the Engineer and as required for geological
inspection. No separate payment will be made for this purpose.
6.13.4
In-situ Rock Tests

The Contractor will be required to conduct in-situ rock tests at various
SECTION 6B7: TUNNEL
PAGE 23 of 70
1765 of 2461
MMRDA
locations as directed by the Engineer during the course of the work to

determine the properties of rock surrounding the underground
excavations The Contractor shall engage a specialist agency, which
will be approved by the Engineer. A provisional sum for this work has
been allotted.
6.13.5
Geological Mapping
Geological mapping shall be carried out on on-going basis by the
Contractor's Consulting Geologist along with geological inspection of
surfaces washed. Interim reports after excavation of every kilometre of
the tunnels shall be submitted to the Engineer and this shall include all
visually distinguishable geological features, rock condition, rock type,
rate of progress of boring, seepage aspects and remarks of the
Geologist together with recommendations on any action to be taken by
the Contractor. On completion of boring, a consolidated geological map
and report shall be submitted to the Engineer in a bound form for future
reference.
The Contractor shall have a resident qualified geologist at least for the
duration of excavation of shafts and tunnels and till completion of
geological mapping.
This item of work will be paid on lump sum basis. However, the breakup of lump sum cost for interim payments will be finalised by the
Engineer.
6.13.6
Drilling Test Holes

a) Drilling shall be carried out in accordance with IS 4081 and IS 5878.
b) All equipment shall be kept in good working order. Safe handling
and proper lifting methods shall be used.
c) Only wet drilling shall be permitted.
d) Jumbos or other drill platforms shall be carefully designed, built and
maintained to provide safe working conditions.
SECTION 6B7: TUNNEL
PAGE 24 of 70
1766 of 2461
MMRDA
e) Where required by the Engineer, the Contractor shall drill test holes
in the rock surrounding the underground excavation for the purpose of
monitoring temperature and other rock conditions. The location and
depth of each hole will be specified by the Engineer. Payment for this
item will be made at the unit rate tendered for the item of drilling holes
for grouting.
6.13.7
Probe Holes and Pre-Grouting

Seepages may be expected during tunnel boring activity. It is therefore
imperative to carry out forward probing continuously, ahead of boring,
for assessment of seepage flows and changes in geological conditions.
For this purpose, probe holes not less than 50 mm nominal diameter
shall be drilled on the tunnel face at locations and in the directions as
directed by the Engineer for a length of up to 50 metres in one stretch.
When seepages are encountered, the Contractor shall resort to pregrouting of rock, before further boring. The Contractor shall submit his
grouting pattern to effectively arrest or reduce seepages, for the
Engineer's approval. When these holes are drilled, other operations
shall be suspended or modified as may be necessary to permit such
drilling and the Contractor shall not be entitled to any additional
compensation or extension of time on account of meeting such
requirement. Depth of drilling hole for pre-grouting is not expected to
exceed 20 meters. Drilling and grouting will be paid for separately
under relevant items of work in the Bill of Quantities.
6.13.8
Scaling and Mucking for Tunnels and Shafts

Scaling shall be performed only by experienced crews under the direct
supervision of a competent supervisor. Later, if any loose or loosened
rock is noticed anywhere in the excavation it shall be removed
expeditiously.
The cost of such scaling and removal of loose or loosened rock shall
be considered as included in the rate for excavation. Careful and
frequent inspection of tunnels side walls and floor, shall be done in the
SECTION 6B7: TUNNEL
PAGE 25 of 70
1767 of 2461
MMRDA
unsupported region of the tunnels, from a travelling scaling platform.

Isolated supported sections shall also be inspected regularly to make
sure that the weakness of the formation has not spread beyond the
supported section.
Loosened rock shall be removed forthwith. All supports shall be
checked occasionally to make sure that there is no member under
distress. Scaling platform shall be equipped with safety ladders.
The mucking zone shall be well lighted and workmen shall be kept
away from the vicinity of the cars being loaded to prevent injury due to
rock falling off the cars. Loading of muck into the cars shall be done
evenly and muck shall not be piled up dangerously high above the
sides.
6.13.9
Rolling Stock and Track for Tunnelling Operations

a) The trolley track shall be properly laid with points, crossings and
junctions and adequately maintained. Deadman switches or other
installations necessary shall be provided to check accidents occurring
due to runaway muck cars. Trolleys shall be operated with care and at
a speed under control of the operator at all times. If the locomotive is
pushing a string of cars, a man shall ride in the front with a whistle and
a flash light for warning men along the track and for signalling the
locomotive operator.
b) Every locomotive shall have a headlight on each end. It shall be
equipped with a whistle or horn with a tone of sufficient volume to be
heard by me along the track when air drills are working. The crew
working with tip wagons on trolley track shall be given whistles so that
they can announce the movement of tip wagons by blowing the
whistles. A shovel where used shall never be left unattended with
engine running and brakes not on.
When it is necessary to park it on a sloping ground, it shall be securely
blocked.
c) Cars carrying pipes, rails and materials shall be properly loaded for
SECTION 6B7: TUNNEL
PAGE 26 of 70
1768 of 2461
MMRDA
safe passage through the tunnels. The load shall be kept within the
side limits for the car. Loads projecting over the sides are dangerous to
men working in the tunnels and hence whenever wide loads are
transported, special care shall be ensured in the operations of the train
with ample warning to the workmen along the track to ensure a safe
journey.
d) The Contractor shall make proper arrangement for haulage of
workers and staff to the work sites inside the tunnels through well
designed passenger cars/trolleys. No person shall be allowed to ride
on front steps of a loader or on a coupling. None other than trainmen
shall ride the dump cars while going to and from work at change of shift
or any other time.
6.13.10
Disposal of Muck
Materials removed from the underground excavation shall be disposed
off at sites as decided by the Contractor with prior approval of the
Engineer and spread and levelled as directed by the Engineer to
facilitate re-use of the excavated good rock. The unit rates tendered for
excavation shall include transport of muck within the tunnels and shafts
and all leads from the center of shaft at ground level to locations of
disposal and other relevant work involved in such disposal. Prior to
commencement of work, the Engineer will inform the Contractor the
site to be used for muck disposal. From time to time, the
Contractor shall keep the Engineer informed of the status of filling at
the site currently in use. Shifting of site for muck disposal shall be
made only with prior approval of the Engineer.
6.13.11
Payment
The items of excavation of shafts and tunnels shall be inclusive of all
survey specified, power requirement, fencing, boring, communication
facilities, all safety arrangements, lighting, ventilation, muck disposal,
dewatering upto limits and providing temporary supports. The unit for
measurement for excavation of tunnels shall be running metre of bored
SECTION 6B7: TUNNEL
PAGE 27 of 70
1769 of 2461
MMRDA
length, whereas excavation of shafts shall be measured in cubic

metres.
6.14
Supports in Tunnels and Shafts
6.14.1
General
If the rock is weak, poor or structurally defective, it shall be supported
suitably by providing either rock bolts, shotcrete or steel supports with
proper lagging and back filling with concrete. Some of these supports
may be temporary and some permanent. Suitable support, temporary
or permanent as hereinafter specified, shall be erected and maintained
by the Contractor. Repairs if any / replacements of supports due to the
Contractor's negligence shall be made at the expense of the
Contractor. The Contractor shall be solely responsible for the safety of
the excavations and design of supporting system and shall bear all
liability for injuries to or deaths of persons or damage to property.
6.14.2
Permanent Supports
a) For the purpose of this Specification, permanent supports in tunnels
are defined as the steel supports, which shall be left in place and be
embedded in the concrete lining. The work shall include the structural
steel supports, complete with all welding rivets, bolts, nuts, plates,
spikes, drift pins, dowels, wedges, tie rods, temporary timber
spreaders, wrenches and other accessories required for assembling
the supports, erecting and supporting them in place until the concrete
lining is placed; also included are all permanent concrete blocks,
lagging, dry rubble packing and sills for steel supports. All these
materials shall be furnished by the Contractor. The details of these
steel supports in all parts of the underground excavation shall be
subject to the approval of the Engineer.
b) As soon as after the acceptance of his tender, the Contractor shall
submit a full description and the design of the permanent supports he
proposes to use.
c) The Engineer shall approve the types proposed by the Contractor or
SECTION 6B7: TUNNEL
PAGE 28 of 70
1770 of 2461
MMRDA
order modifications thereto, which the Contractor shall carry out, or the
Engineer may propose a new design. The Contractor should obtain
approval of design and type or types of supports and method of
installing them well in advance of their being actually required on the
job. The details of the supports to be actually erected would depend on
the rock load, spacing of the supports etc.
d) The steel supports shall be installed in a workman-like manner, true
to lines and grades in proper condition and alignment until the concrete
packing is placed against them. Any supports placed improperly shall
be promptly adjusted by the Contractor. Temporary timber spreaders
shall be removed before concrete is placed.
c) In permanently supported sections, the use of timber, if at all, shall
be allowed with the permission of the Engineer only in the locations
wherefrom it can be removed before concreting.
f) In situations where there is a danger of yielding of rock, the area
shall be immediately and adequately supported. Concrete lagging
and/or concrete slabs used shall be of quality not inferior to lining
concrete; packing with pieces of sound rock may be used and fully
grouted later.
g) Payment for design, supply and installation of the permanent steel
supports, as specified hereinabove, shall be made on the quantity of
steel in structural sections used in the supports proper and the tie rods
only. The weights of the net lengths, as given in books of standard
sections shall only be paid. Weights of welds, and/or bolts, nuts, rivets,
plates, spikes, wedges and dowels used to fabricate and erect the
structural supports will not be included in calculating the weight of steel
to be paid and shall be considered included in the rates for steel
sections. No separate payment shall be made for the lagging,
supporting, blocking and grouting used, which shall be also considered
included in the item of steel supports.
Payment for the lining with concrete placed later will, however, be
SECTION 6B7: TUNNEL
PAGE 29 of 70
1771 of 2461
MMRDA
made upto the payment line for excavation, irrespective of whether or

not any supports fall within that line.
6.14.3
Temporary Supports
a) These shall be erected by the Contractor at locations where the
Engineer considers it. Consequences, if any, for his failure to do so in
good time, shall be the sole responsibility of the Contractor. The
methods, extent of supporting sizes and spacing of supports etc. shall
be approved by the Engineer. This shall also include temporary
supports or propping that may be needed before fixing supporting bolts
(specified hereinafter). These temporary supports shall be removed
before placing the concrete lining.
They will be allowed to be left in the place provided, they are of steel
and do not reduce the minimum thickness of concrete lining.
b) The cost of such temporary supports used shall be deemed to be
included in the rate of excavation. If however, any steel supports are
allowed to be left in as specified hereinabove, they will be paid for as
permanent supports instead of temporary supports. Such supports
shall not, however, be left in place without the specific direction of the
Engineer.
c) As a contingency provision the Contractor shall ensure that at least
ten fabricated supports shall be kept readily available for the purpose
of installation at all times during tunnelling operations. The cost of
these ten spare supports shall also be deemed to be included in the
rate of excavation and no separate payment will be made for the same
even if they remain unutilized. Unused supports shall be the property of
the
6.15
Supporting by Bolts
Where, in the opinion of the Engineer, blocks of rock are likely to get
loose and fall down, the Contractor shall furnish and install supporting
bolts. I.R.C. fabric netting or chain link netting shall be used in
SECTION 6B7: TUNNEL
PAGE 30 of 70
1772 of 2461
MMRDA
conjunction with bolts if found necessary. Such supporting bolts are

expected to be needed mostly in the roof only. It shall however, be the
sole responsibility of the Contractor to bring to the notice of the
Engineer in writing, the locations where the Contractor may consider it
necessary to provide supporting bolts.
Following three types of bolts shall be used:
a) Resin grouted bolts
b) Cement grouted bolts with thixotropic grout
c) Mechanical bolts such as Swellex, especially in wet locations
In case of very humid conditions, appropriate resin grout, instead of
cement grout, shall be used for grouting the bolts to the rock.
The bolt is installed by first drilling a suitable hole in the rock to a depth
of about 50 mm less than the bolt length. The wedge is placed in the
slot and the wedge slot end of the bolt rammed into the bolt hole by
hand, thereby securing an initial anchorage. The bolt is then driven
over the wedge by applying an impact hammer. If found necessary
I.R.C. fabric (or any standard wire netting conforming to IS 1566 No 6)
shall then be spread over the surface of the rock to be bolted. The
bearing plate, washer and nut are then placed on the threaded end and
the nut tightened with an impact wrench to a torque as specified by the
Engineer.
Any other type of bolt in use may also be installed with the approval of
the Engineer.
Payment for furnishing and installing supporting bolts shall be on the
basis of number of bolts installed at the unit price tendered for this
item.
6.16
Cement Concrete Lining and Back Packing
6.16.1
General
a) The tunnels and shafts are proposed to be lined with relevant grade
of concrete which shall conform to the specifications given.
SECTION 6B7: TUNNEL
PAGE 31 of 70
1773 of 2461
MMRDA
b) Concrete lining work for the tunnel is expected to proceed from

outlet shaft towards inlet shaft end.
The contractor must achieve a lining speed of at least 2 x 750m/month.
He may choose a suitable methodology for the lining of the tunnel to
achieve this speed. Use of telescopic formwork is suggested to
expedite the lining work.
c) The concrete lining work under this item covers all concreting to be
done for tunnels and shafts for-full circle lining as required including
that of back packing against steel liner where required. The concrete
shall be placed between formwork and excavated clean surface of
rock. Depending on the rock strata met with, concrete to be placed will
be reinforced or non-reinforced. Concrete will also be required to be
placed at portions where rock is supported by steel supports and in
some areas against rock protected by shotcrete. Shafts lining shall
start from bottom of shafts.
d) The specification for concrete lining shall also be applicable to items
like concrete plug for closing weaker strata, filling in pockets, etc. for
works in tunnels and shafts where specifically not otherwise provided.
Due to probable occurrence of very poor rock strata or inadequate
overburden to withstand pressure inside the tunnel steel lining with
back packing has been included Specifications.
e) Proper arrangements for dewatering during concreting shall be
made in the tunnel and the shafts and also at the place of concrete
placing.
f) The thickness of lining could vary at places depending upon the rock
conditions and as such, the Contractor shall have no claims for
compensation and the rates quoted shall remain firm for all variations
of thickness. The area of work, approaches and other areas for the
lining work shall be properly illuminated and ventilated as per
specifications in lighting and ventilation clause. All machinery used for
concrete lining shall be driven electrically or pneumatically to avoid
setting up of excessive draughts of air required for ventilation purposes
SECTION 6B7: TUNNEL
PAGE 32 of 70
1774 of 2461
MMRDA
if other types of machinery are used.

g) All underground works shall be satisfactorily drained either by gravity
or by resorting to pumping where necessary. Water shall be excluded
from the space to be filled with concrete lining by caulking, diverting by
pipes, pans or other satisfactory means until the concrete has set
sufficiently so as to remain unaffected by the action of water through
percolation, hydrostatic pressure etc.
h) Communication facilities shall be provided during the work of
concrete lining.
6.16.2
Initial Cleaning
The invert, sides and arch of the tunnels shall be cleared of all the
excavated materials, cracked and shattered rock and then thoroughly
cleaned. Before placing of concrete is undertaken, the rock surface
shall be thoroughly wetted. Placing of concrete in any section of
tunnels or shafts shall not commence until authorised by the Engineer.
6.16.3
Composition of Concrete
Concrete for lining shall conform to the grade given below :
Item
of Grade of
Slump
concrete
in mm
work
Specified
Maximum
Characteristic
aggregate
Compressive
strength
at
28
size
days
Tunnel
& M25
80 -125
25 N/mm2
20mm
Shafts
i) Minimum cement content shall be as per requirements of mix design

for specified strength and minimum slump necessary for pumped
concrete.
SECTION 6B7: TUNNEL
PAGE 33 of 70
1775 of 2461
MMRDA
Fly ash from approved sources and/or plasticizers from approved

manufacturers should be used. Fly ash/GGBS shall be upto 30% of
minimum cement content of 350kg/m3.
ii) It is proposed to use 53 Grade ordinary Portland cement conforming
to IS 12269 for lining. However, if the rock/seepage water indicates a
high sulphate content, sulphate resisting Portland cement conforming
to IS:
12330 may be used. The minimum cement content will be the same in
either case. The Engineer's decision shall be final in this regard.
iii) Maximum size of aggregate depends upon the type of placement of
concrete. In case concrete is placed through a pipe, maximum size of
aggregate shall be restricted to 20 mm.
iv) The concrete mix shall be designed to take into consideration long
travel time through mixer cars and pumpability. For this purpose,
contents of fines per cu. m of concrete shall not be less than 425 Kg.
where mixture of fines is cement, fly ash plus sand of size 0-0.25 mm.
v) For improving workability of pumped concrete, the Contractor shall
consider a combination of natural and manufactured sands and shall
get the proposed proportions approved by the Engineer.
Since the tunnels are a part of the potable water transporting system,
the concrete used for tunnel lining shall be properly designed to ensure
that during the placing there is no segregation of its ingredients which
could lead to seepage through lining. The Contractor shall therefore
provide a system which consists of agitator cars for transporting
concrete, concrete pump for placing concrete in position through
suitable windows in the shuttering and vibrated by internal/external
vibrators. The Contractor's proposed method of concrete placement
shall be subject to the approval of the Engineer.
Suitable admixtures like retarders, plastisizers, air entraining agents etc
shall be used with concrete for proper placement of a homogeneous
concrete. The cost of admixtures is deemed to have been included in
SECTION 6B7: TUNNEL
PAGE 34 of 70
1776 of 2461
MMRDA
the rate quoted for the concrete.

6.16.4
Temperature of Concrete
Depending upon the atmospheric temperature inside the tunnel,
temperature of concrete at the time of placement in lining may have to
be controlled to 27C to 30C.
In order to achieve this, following measures shall be taken:a) Cement shall not be stored outside and exposed to the sun.
b) For preventing excessive heating of coarse aggregate, stock piles
shall be protected from direct rays of sun. Water shall be sprayed on
the aggregate piles every 300 mm or 450unm height as the piles are
built up. The piles thereafter shall be kept cool by use of water sprays.
c) If necessary, the coarse aggregate shall be taken into the bins and
chilled water at temperature not more than 8C shall be sprayed on it
through perforated pipe and aggregate shall be cooled and allowed to
be drained through screen fixed at the bottom. Draining screen shall
remove excess water from the aggregate in order to provide coarse
aggregate with minimum and uniform moisture content. The capacity
and arrangements of the bins shall be such as to supply moisture-free
cooled aggregate to the top of the batching plant so that the continuous
supply of concrete shall be maintained. For use of aggregate for standby mixer, a day's quantity of aggregate shall be separated from the
main stock pile 24 hours before use and sprinkled with water every 300
mm to 450 mm layer during transfer and then maintained at the
temperature as low as possible.
d) Mixing water shall be cold or ice may be used as a part of mixing
water.
Care shall be taken to see that ice is completely melted by the time
mixing is completed.
6.16.5
Programme of placing concrete
SECTION 6B7: TUNNEL
PAGE 35 of 70
1777 of 2461
MMRDA
During the period of monsoon the Contractor shall make all necessary /
adequate arrangements at his own cost to properly protect / cover the
cement storage system, mixing and batching plants and transport
areas. The planning of concreting shall be done depending upon the
maximum possible stockpile of material for concrete. On such days
when the weather conditions are extremely poor as not to provide
access for proper placement of concrete, the concreting work shall be
suspended.
6.16.6
Construction Progress
The concrete lining of the full bore shall be placed in one operation
unless otherwise permitted or directed and no longitudinal construction
joints will be allowed. Concreting in tunnels shall be done with
appropriate type and length of formwork to achieve a progress as per
Construction Schedule with due consideration for the stripping period
specified. Formation of cold joints shall be strictly avoided.
6.16.7
Bulkhead Joints
Bulkhead joints are the circumferential construction joint:; necessitated
because of stopping of the concreting at the end of a concreting bay,
the joint being formed by using bulkheads of a satisfactory design. The
joints shall be finished in a vertical plane at right angles to the axes of
the tunnels. All laitance and loose stones shall be thoroughly and
carefully removed by wire brushing / hacking and surface washed. Just
before concreting is resumed, the roughened joint surface shall be
thoroughly cleaned and loose matter removed and then treated with a
thin layer of cement grout of proportion specified by the Engineer and
worked well into the surface. The new concrete shall be well worked
against the prepared face before the grout mortar sets. Special care
shall be taken to obtain thorough compaction and to avoid segregation
of the concrete along the joint plane.
The Contractor shall construct keys in the bulkhead joints as directed
by the
SECTION 6B7: TUNNEL
PAGE 36 of 70
1778 of 2461
MMRDA
Engineer and the cost of the same shall be taken as included in the
overall rate for concrete lining. Reinforcement, as directed by the
Engineer, if required, shall be provided at the joints. This will be paid
for at the rate quoted for reinforcement in the lining / backpacking.
6.16.8
Formwork
The formwork for concrete lining of tunnels shall, in general, consist of
an approved type of telescopic, collapsible, steel shuttering of robust
sections manufactured in suitable lengths. The Contractor shall clearly
specify the length of shutter and number of shutters he proposes to use
in order to achieve the stipulated rate of progress specified.
The formwork shall be capable of being removed and re-erected
without disturbing the concrete lining and other forms in place. The
forms used for tunnel lining should, where necessary, have on sides,
openings of suitable size at close intervals to facilitate pumping of
concrete and insertion of vibrators into the concrete as also for
inspection during concreting. These openings shall be provided with
suitable and strong shutters to prevent leakage of concrete and shall
be flush with the lining to produce uniform surface finish. The formwork
shall be such that the internal dimensions of the lining conform to those
specified on drawings. The formwork shall be arranged close together
at the joints so that the finished surface of the concrete is free from
excrescences so as to afford smooth surface for passage of water.
The forms shall be arranged true to line and grade and shall be fixed
firmly to prevent movement during or subsequent to the placing of
concrete. Stripping / lowering / collapsing of forms of concrete
placement have been foreseen to be made after 16-18 hours from
placing of last batch of concrete.
6.16.9
Placing
The methods used for transporting, placing and consolidation of
concrete shall be such that the placed concrete is homogeneous and is
placed before the initial set takes place and the surface finish is even
SECTION 6B7: TUNNEL
PAGE 37 of 70
1779 of 2461
MMRDA
and uniform without rough patches, air holes, etc. It is expected that all
concrete in tunnel lining shall be placed by pumping.
To achieve the above, it is envisaged that the Contractor uses a quick
and safe method of transporting concrete from batching plant to the
bottom of shafts and further transportation is done by agitator/transit
cars of adequate capacity in the tunnels reach.
6.16.10
Hand Placement
Hand placement of concrete may be permitted by the Engineer, only
when the quantity to be placed is small and in his opinion mechanised
methods are not warranted or not practicable.
When hand placing is resorted to, utmost care shall be taken to avoid
delay in placement and segregation of concrete.
6.16.11
Pumping of Concrete
Concrete shall be placed by using concrete pump of sufficient capacity
to ensure stipulated rate of progress. The discharge lines should be as
straight as the work would permit to minimise friction and clogging of
pipe.
The pump shall be continuously fed by uninterrupted flow of fresh,
plastic unseparated concrete of proper consistency to avoid a plugged
or clogged placer line and the consequent delay and detriment to the
work. Such delays, damages and wastages shall be at the Contractor's
risk and cost.
If considered necessary, the pipelines shall be wrapped with gunny
bags and sprinkled with water to keep it wet in order to prevent
excessive temperatures during very hot weather.
The pump and all other accessories shall be maintained in efficient
order throughout the placing operation. Leakage of water into the
concrete shall be avoided. During cleaning of the pipeline, waste water
shall not be permitted to fly into the forms, where concrete is placed. It
shall be ensured that the concrete does not segregate while placing
SECTION 6B7: TUNNEL
PAGE 38 of 70
1780 of 2461
MMRDA
and those pipelines are rigid and strong enough to withstand the
impact of placing. The placing should be as continuous as possible and
cold joints avoided.
6.16.12
Consolidation
The concrete shall be well worked between the rock surface or the
lagging, when used, and the forms, special care being taken to fill
concrete tightly at the crown and at all irregularities of the rock
excavation. Concrete shall be vibrated by form vibrators of a type
approved by the Engineer, to produce dense and impervious concrete
having a smooth surface against the forms. Immersion type vibrators
may also be used, where practicable for consolidation of the concrete.
6.16.13
Curing
Wet curing of the lining shall be carried out as detailed in the
Specifications or as directed by the Engineer. The curing shall be
carried out by sprinkling water at short intervals to maintain a wet
surface. Strong draft of wind through the tunnel shall be avoided to
reduce chances of sudden drying and consequent cracking of lining.
6.16.14
Reinforcement
Reinforcement for lining of tunnels shall be of fusion bonded Epoxy
Coated TMT Steel Bars. The coating specification shall conform to IS
13620. Coating thickness should be 175 + 50 microns. The contractor
shall produce test certificate from the supplier of the fusion bonded
epoxy coating that the quality of coating confirms to IS 13620 for each
lot as per frequency mentioned in IS 13620 code. Coated bar
represented by samples that do not meet the requirements of IS 13620
specification will be rejected.
For supply, storage, laps, bending, fixing etc. provisions in clause 2.5
shall be referred to.
6.16.15
Leakage Acceptance
SECTION 6B7: TUNNEL
PAGE 39 of 70
1781 of 2461
MMRDA
After completion of the concrete lining work, all the interiors shall be
checked for leakages, if any. The total leakage water pumped out at
each of the shafts and measured by suitable electromagnetic or
ultrasonic flow meters shall not exceed 5 litres per minute per 100
metres length of the tunnel. If this limit is exceeded, the Contractor
shall carry out pressure grouting as directed by the Engineer to bring
down the leakage below the acceptable limit.
6.16.16
Final Finishing
After completion of the work of concrete lining and grouting and before
final acceptance of the work, the Contractor shall clean the internal
surface of the concrete or embedded pipework of all encrustations of
cement, mortar, grout and other matter and shall remove all unsighty
stains to the satisfaction of the Engineer.
6.16.17
Tolerances for Concrete Lining

The intent of this clause is to establish tolerances that are consistent
with modern construction practices, and governed by the effect the
permissible deviations will have upon the structural action or
operational functions of the structures. Where tolerances are not stated
in the Specifications or drawings for any individual structure or feature
thereof, permissible deviations will be interpreted in conformity with the
provisions of this clause.
The Contractor shall construct all concrete structures to the exact lines,
grades and dimensions established. However, variations from the
established lines, grades and dimensions will be permitted to the extent
set forth herein, provided that the Engineer reserves the right to
diminish the tolerances set forth herein if suc tolerance impairs the
structural action or operational function of the structure. The notations
on the drawings of the specific maximum or minimum in connection
with any dimension shall be considered as supplemental to the
tolerance specified herein.
a) Tolerances for concrete lining in tunnel and shaft
SECTION 6B7: TUNNEL
PAGE 40 of 70
1782 of 2461
MMRDA
i) Departure from established alignment or from established grid - 25

mm
ii) Variation in thickness at - Negative tolerance any point not to exceed
50 mm
iii) Centre lines of all embedded pipes and specials (adjacent to shafts)
inside the tunnel shall be within 12 mm of correct centre line.
b) Tolerances for placing reinforcing steel
i) Variation for protective - 12 mm for 100 mm covering or effective
depth in clear cover bending
ii) Variation from indicated spacing - 25 mm
6.16.18
Measurement and Payment of Work

a) The item of concrete lining / back packing to tunnels and shafts
(covering all the operations concerned within the intent of the work) will
include plain and reinforced concrete placed between the rock surface
excavated and the formwork. The item shall also include the concrete
in plugs placed under the direction of the Engineer in tunnels sides or
roof and other locations.
i) Measurement for payment for the concrete in shafts and portion of
the tunnels excavated shall be made on the basis of the quantity of
concrete placed between the payment line for the excavation work and
the formwork.
ii) Measurement for payment for concrete and back packing in the
portion of the tunnels excavated by TBMs shall be made on the basis
of running length of tunnels in metres.
The payment will be made at the tendered rates for the grade of
concrete placed.
The rate shall include cost of all the formworks, finishing and other
operations mentioned herein. No separate payment will be made for
lighting, ventilation and communication facilities.
SECTION 6B7: TUNNEL
PAGE 41 of 70
1783 of 2461
MMRDA
b) In the case of back packing and lining in weak rock in shafts and
tunnels excavated by TBMs requiring permanent supports, the
payment shall be made on the basis of the quantity of concrete placed
between the payment line for the excavation work and the formwork,
excluding cost of formwork which shall be paid separately. This
concrete will be paid for on the basis of the number of cement bags
consumed in concreting the lining. No separate payment will be made
for lighting ventilation and communication facilities.
c) The reinforcement shall be paid separately on the basis of the actual
quantity in weight. No deduction will be made for the volume of
reinforcement from the concrete.
d) No deduction will be made from the total volume of concrete lining
for the volume of steel supports.
6.17
Grouting
6.17.1
General
Grouting shall be carried out to meet such requirements as preinjection at the tunnels face to seal water-bearing and unstable strata
and postinjection for filling up voids, cavities between concrete lining
and rock, strengthening the rock shattered around the bore and closing
up water bearing passages to prevent the flow of water into the shafts
or tunnel behind the excavation face. All patterns and procedures shall
be submitted by the Contractor for the Engineer's approval.
It is seen from the cores of the rock strata that seepages could be
anticipated in the shafts and also in certain stretches along the tunnels
alignment. The
Contractor shall be required to mobilize and keep available adequate
injection grouting equipment to meet such situations.
Two type of injection works are required as mentioned above. These
are reinjection works and post-injection works.
SECTION 6B7: TUNNEL
PAGE 42 of 70
1784 of 2461
MMRDA
Pre-injection is the systematic injection of grouting materials ahead of

the excavation face and shall be conducted where required ahead of
the tunnel excavation face. The requirement to grout, the injection
quantities, materials and pressures to be used shall be determined on
the basis of systematic and continuous probe drilling ahead of the
tunnel face. This is described in section
Post-injection includes; backfill grouting behind tunnel/steel linings,
contact grouting between rock and tunnel linings and pressure grouting
to stop excessive water inflows from rock joints and poor strata.
6.17.2
Pre-Injection
The purpose of systematic pre-injection is to limit the ingress of ground
water into the tunnel during the excavation to a specified limit. This will
limit the risk of water inundation into the tunnel which may cause;
excessive pumping requirements; delays to tunnelling due to water
damage to TBMs and backup equipment; reduce the risk of ground
instability and delays resulting from tunnel collapse; allow tunnel lining
to be completed in dry conditions to maintain concrete quality and
reduce the requirements for steel liners.
Pre-injection is conducted by means of systematic probe drilling ahead
of the excavation face to verify the ground condition ahead of the
tunnel face. This is carried out by reading the probe drilling advance
rates, drill cuttings and water takes to identify changes in rock
conditions/stability and zones of permeability.
A decision can then be made to pre-treat zones of instability and
permeability from a safe location in the tunnel and inject those
identified zones with cementitious grouts (OPC and microfine cements)
and mineral grouts (colloidal
silicas) instead of the difficult process of post treatments with
expensive fast reacting chemicals.
A comprehensive method statement specifically for pre-injection of
cementitious grouts, mineral grouts and other such proposed materials
SECTION 6B7: TUNNEL
PAGE 43 of 70
1785 of 2461
MMRDA
must be submitted to the Engineer detailing equipment, injection

materials, pumping pressures, packer systems, injection procedures
and stop criteria (method statement should be submitted along with the
bid).
This pre-injection specification should be read in conjunction with
Preinjection general arrangement drawing.
6.17.2.1
Water Seepage Ingress Requirements

The allowable water seepage in the tunnel shall not be more than 20
litres/min/100 m run of tunnel. On the basis of the information obtained
from the probe hole drilling, injection may be required ahead of the face
to keep total water seepages within the stipulated limits as above.
Suitable V Notch weirs shall be provided at the tunnel entrance and in
tunnel locations as directed by the Engineer, to measure the flow of
water from the tunnel throughout the excavation process.
6.17.2.2
Equipment
i) Probe/injection drilling The TBM shall be fitted with an appropriate
probe drilling system to allow probe holes and injection holes to be
drilled at any position i.e. 360 degrees around the circumference of the
tunnel and drilled ahead of the cutter head for a minimum of 30m. The
probe drill system shall be hydraulic top hammer system using R32
speed rods (> 1,.5m length) with 51mm destructive drill bits. A suitable
collaring system shall be provided on the TBM to ensure that drill holes
are collared quickly and efficiently. The drilling rig shall be designed by
the contractor and approved by the Engineer and available and
operational on the TBM before commencement of tunnel excavation
and shall be tested to the satisfaction of the Engineer.
ii) Injection grouting equipment Injection grouting Equipment shall
specifically consist for the purposes of pre-injection of a suitably design
injection system which shall be either mounted on the TBM system, or
mounted as a mobile unit that may be transported into the tunnel as
and when required. The injection grouting system for pre-injection shall
SECTION 6B7: TUNNEL
PAGE 44 of 70
1786 of 2461
MMRDA
specifically consist of mixing unit, agitator tank and pump. The mixing
unit for pre-injection grouting shall be specifically of suitable colloidal
type with minimum 1500rpm mixing speed.
Agitator for pre-injection shall be of appropriate size to store and
deliver the anticipated quantities of grout. The pump for pre-injection
shall be specifically hydraulically driven, double acting reciprocating
piston type and shall be capable of delivering a pressure of minimum
100bars.
iii) Packer systems for delivering grout into the drilled injection hole
shall be capable withstanding all pumping pressures. Packers shall be
capable of being placed up to 12m depth within the drilled hole.
Packers can be disposable or inflatable type similar to CODAN type
packers. Packer system shall be designed and tested prior to
commencement of the excavation and shall be approved by the
Engineer.
6.17.2.3
Probing Ahead of the Face

A minimum of one probe hole of not less than 50 mm nominal diameter
shall be drilled on the tunnel face at locations and directions as
directed by Engineer for a length of up to 50m in one stretch. The
contractor shall submit his grouting pattern to effectively arrest or
reduce seepages for the Engineers approval. If required, a second
probe hole may be drilled. When these holes are drilled, other
operations shall be suspended or modified as may be necessary to
permit such drilling and the Contractor shall not be entitled to any
additional compensation or extension of time on account of meeting
such requirement.
Drilled probe holes shall be logged during the drilling by competent
persons and measurements of water seepage flow rate, drill cutting
colour and minerology, drilling penetration rates, hole identification
number and chainage shall be made during the progress of the drilling.
Detailed drilling records shall be kept by the contractor and submitted
SECTION 6B7: TUNNEL
PAGE 45 of 70
1787 of 2461
MMRDA
to the Engineer 24 hours after completion of probe drilling. The design

of probe drilling records shall be proposed and approved prior to
commencement of excavation. A comprehensive long section of drilling
showing the anticipated rock conditions and identified zones of
permeability and instability expected ahead of the face shall be
identified on the long section. The long section shall be submitted to
the Engineer 24 hours after completion of drilling.
No part of the tunnel shall be left without probe hole data and
excavation shall be stopped by the Engineer if probing has not been
carried out ahead of the face. A minimum of one tunnel diameter cover
shall be kept as overlap between successive probe drilling rounds.
Under no circumstances shall the probe cover be less than one tunnel
diameter.
If the water seepage from any one probe whole exceeds 5 litres/min,
injection of injection materials shall be commenced to control possible
water ingress within the limits specified. The acceptable inflow from
any single probe hole may be changed by the Engineer if the total
seepage flow within the tunnel exceeds the limit specified.
Injection may also be commenced if the drilling information from probe
holes, as indicated by the Contractors Geologist or the Engineer,
identify changes in rock conditions that indicate zones of instability
ahead of the tunnel face may cause tunnel collapse.
Packers shall be available at all times during probe drilling and installed
in case of sudden inflows of water at high volumes and/or pressures.
6.17.2.4
Injection holes
If the probe holes and drilling information identify that injection should
be commenced, a full fan of injection holes (max 1.5 m spacing around
tunnel circumference) shall be drilled throughout the circumference of
the tunnel to minimum 15m ahead of the face or intersecting
impermeable and unstable zones and injection shall be commenced.
Packers shall be placed in the hole as close as possible to the zone of
SECTION 6B7: TUNNEL
PAGE 46 of 70
1788 of 2461
permeability and
MMRDA
instability to
ensure
injection
pressures
are
maintained. Each injection hole shall be logged similarly to probe holes

and records maintained and submitted to the engineer. Maximum
injection pressures and injection material quantities shall be agreed
and approved by the Engineer prior to commencement of excavation
and incorporated into the method statement for pre-injection.
6.17.2.5
Control holes
Control holes shall be drilled between injection holes to verify the
results of injection. If the water flow from any control hole exceeds the
specified limits, the control hole shall be injected and records kept.
Secondary control holes shall then be drilled to verify the effectiveness
of injection and the process repeated until the zone of permeability or
instability is treated sufficiently so that no secondary/tertiary etc. control
hole exceeds the limits.
6.17.2.6
Injection Materials
Materials shall be provided by suitable manufacturers having a proven
track record in pre-injection tunnel projects similar to this contract in
India and overseas. All materials used in pre-injection shall conform to
this specification and be approved by the Engineer. The manufacturer
shall be able to provide full technical assistance to the contractor in
applying the injection materials in
TBM tunnel pre-injection systems, and be able to provide full technical
training at site. Injection materials shall consist of cementitious
materials and/or colloidal mineral grouts such as OPCs, microfine
cements and colloidal silicas.
It is expected that pre-injection shall consists of successive stages of
OPC, microfine cement injection and colloidal silica gels. Grouts shall
be stable with minimum bleeding (<5%) and maximum penetrability. It
is expected that extensive use of microfine cement shall be required to
achieve the water tightness limits set in specification.
1) OPC grouts shall have the following properties:
SECTION 6B7: TUNNEL
PAGE 47 of 70
1789 of 2461
MMRDA
i. Bleeding <5%
ii. w/c ratio <1
iii. Marsh cone <40s
2) Mineral Grouts shall be inert, environmentally friendly, contain no
hazardous chemicals and be a stable nanometric sol with max particle
size of 0.015microns, viscosity< 5mPas and adjustable gelling time
from 5 mins to 30 mins. Minerals grouts shall have little or no shrinkage
with time. This type of material shall be used where appropriate as a
final tightening to achieve water seepage ingress requirements as
specified where microfine cement does not achieve the required
penetrability.
6.17.2.7
Supervision and injection records.

The contractor shall employ a suitably qualified Geologist and
necessary assistants to conduct probe drilling, take the required
injection grouting and drilling records and analyse the probing and
injection grouting data to determine the necessary actions for face
advance. Excavation shall not be recommenced without the approval of
the contractors Geologist. The Geologist shall be approved by the
Engineer prior to commencement of excavation. Suitable site
Engineers may be trained to undertake probe drilling and injection
records and shall be approved by the Engineer.
6.17.2.8
Measurement and Payment for Pre-Injection

Payment for drilling and cleaning the holes as specified hereinabove
shall be paid on the running metre basis. The Contractor shall provide,
maintain and operate adequate and suitable drilling and cleaning
equipment. The cost of these shall be deemed to have been included
in the rates tendered for drilling.
Payment shall be made for the actual drilling work done from the face
of the tunnel. In bad ground conditions, payment shall be made for the
use of casing pipes and oversize drill bits required for drilling into
SECTION 6B7: TUNNEL
PAGE 48 of 70
1790 of 2461
MMRDA
unstable strata to prevent the injection hole form collapsing during

injection and drilling as agreed by the Engineer.
Measurement for payment of OPC injection will be made on the basis
of the standard (50 kg.) bag of cement.
The unit rates quoted by the Contractor shall include also the cost of
providing and operating suitable injection grouting equipment including
cost of labour and supervision required for injection grouting and
testing, etc. for the complete operation. Whenever other materials such
as microfine cement or mineral grouts are used for injection grouting,
the same will be supplied by the Contractor and therefore the
Contractor shall take the cost of these materials into account while
quoting for injection grouting with the same. The Tenderer should also
include the cost of providing all the necessary equipment, including
piping and packers required for injecting such materials in the unit rate
quoted.
As the quantities of pre-injection materials are dependant on the
outcome of probe drilling information, the quantities of OPC, microfine
cement and mineral grout are provisional.
Minimum stocks of 20 Tonnes of OPC, 20 Tonnes of microcement and
5 tonnes of mineral grout shall be kept on site at all times during
excavation.
6.17.3
Post-Injection
Postinjection refers to backfill grouting behind tunnel/steel linings,
contact grouting between rock and tunnel linings and pressure injection
grouting to stop excessive water inflows from rock joints and poor
strata.
Where it is determined by the Engineer that grouting is necessary and
practicable, the Contractor shall perform drilling and grouting
operations as follows:
i) Drilling and pressure injection grouting into rock around shafts and
SECTION 6B7: TUNNEL
PAGE 49 of 70
1791 of 2461
MMRDA
tunnels as well as pack grouting the concrete behind the lining;

ii) Grouting rock bolts in surface and underground excavations;
iii) Any other location as directed by the Engineer.
As and when required by the Engineer, the Contractor shall drill holes
around the periphery of the excavation for draining the surrounding
rock. The location, direction, length and number of holes to be drilled
shall be as directed by the Engineer. Similar holes shall be drilled, if so
directed, after completion of the work, to serve as weep holes and / or
grout holes. These will be paid for at the unit rate accepted for drilling
all grout holes, except those for packgrouting which are deemed to be
included in the unit rate for concrete lining. When so directed by the
Engineer, such holes shall be used for grouting the surrounding rock to
tighten the joints and stop or reduce seepage of water.
6.17.3.1
Codes
Drilling and grouting operations for the tunnels and shafts shall
generally conform to the requirements of IS 5878 (Part 7).
6.17.3.2
Types of Post-Injection
Following types of injection grouting operations are anticipated in this
work:
a) Backfill grouting to fill the spaces left unfilled between concrete and
rock surface in the tunnels and contact grouting to fill gaps left due to
shrinkage of grout
b) Consolidation pressure grouting, to fill up the joints and
discontinuities in the roc upto the desired depth around the tunnels and
shafts.
c) Water ingress reduction grouting, to reduce water inflows in the
excavation by pressure injection with fast reacting chemicals such as
Polyurethanes
SECTION 6B7: TUNNEL
PAGE 50 of 70
1792 of 2461
MMRDA
Grouting operation involved in (a) is commonly referred to as pack

grouting, whereas that involved in (b) and (c) is referred to as pressure
injection grouting.
6.17.3.3
Drilling Grout Holes

Grout holes shall be drilled through rock directly or through concrete
lining at the locations specified. Where steel rib supports are used and
in reinforced sections of the lining, grout holes shall be drilled through
pipes' embedded in the concrete lining. Where holes are drilled in steel
lining, the holes shall be threaded for convenience in making grout
connections and plugging the holes when grouting has been
completed. The exact location, direction, order of drilling and depth of
each hole shall be proposed by the Contractor and approved by the
Engineer. The minimum diameter of the holes shall be 35-mm. The
holes shall be ordinarily drilled in a direction normal to the surface of
the underground excavation or lining as the case may be. In cases
where seams, if any, in the rock, have to be intersected, the holes shall
be drilled at inclinations as may be directed by the Engineer. While
driving these holes, utmost care shall be taken to ensure that the
reinforcement, if any, in the concrete lining, or rock bolts are not cut
through.
For pressure injection grouting of rock surrounding the shafts or
tunnels, the location, direction and order of drilling grout holes shall be
as approved by the Engineer. The depth is not, ordinarily expected to
exceed 5 (five) metres. Each hole shall be protected from getting
clogged or obstructed by a grout connection pipe fixed suitably into the
hole, and the holes shall be suitably capped or otherwise protected
until they are grouted. Any hole that becomes obstructed before being
grouted, shall, before grouting, be opened by and at the expense of the
Contractor and in a manner satisfactory to the Engineer.
6.17.3.4
Cleaning Holes
Before commencing actual grouting through the holes, the latter shall
be cleaned by alternate streams of air and water to the satisfaction of
SECTION 6B7: TUNNEL
PAGE 51 of 70
1793 of 2461
MMRDA
the Engineer.
All holes but three (or more as directed by the Engineer) at a time shall
temporarily be closed at the surface, the holes being consecutive or
otherwise as directed by the Engineer. Water and air shall be pumped
under pressure, as determined by the Engineer into two holes and
allowed to escape from the third until all possible loose material, sand,
mud, etc., has been washed out of communicating seams or other
passage ways, if any. Combination of three holes at a time shall thus
be cleaned, before applying any grout into the holes.
Suitable valves shall be used to permit alternate or continuous injection
of air and water and for quickly switching the flow from one hole to the
other so as to produce the turbulent action necessary to dislodge the
softer material, if any.
Water will be connected to one hole and air to the other which shall be
an adjoining hole. The water and air connection shall be interchanged
at frequent intervals to cause water to flow in every possible direction.
The operation should be continued till reasonably clear water emerges
out of the holes. In general, the pressure of water and of air shall be
such as to maintain the maximum possible velocity but sufficiently low
to prevent heaving and movement of rock. The normal maximum
pressure should be about 2.1 kg/sq.cm (30 psi). Higher pressures shall
be used where so specifically directed by the Engineer. The connected
holes shall be blown clear of any detritus that might have settled in the
seams therein. Washing shall be so timed as to immediately precede
the grouting. Before grouting of a hole is taken up, the adjoining holes
shall be kept clear so that they are ready for grouting in case they are
found connected to the holes under grouting. The cost of such washing
and cleaning, etc., shall be considered included in the unit rate of
drilling grout hole as specified.
The above procedure is applicable to all holes drilled into rock for the
purpose of pressure grouting.
6.17.3.5
Pipes and Fittings for Grouting
SECTION 6B7: TUNNEL
PAGE 52 of 70
1794 of 2461
MMRDA
Plastic/Nylon pipes for grout connection shall be set in the holes at

such points as may be directed by the Engineer. Pipes placed prior to
placing of concrete lining/back packing shall be capped or plugged with
suitable material to prevent entry of obstructing materials prior to
grouting. The pipes shall be fixed into the holes with suitable caulking
to the satisfaction of the Engineer so as not to allow the grout to flow
out at the mouth.
The grout pipe shall be strong enough to stand the grout pressure.
Pipes and fittings for the grout connections and the packing and
caulking materials required shall be furnished by the Contractor as part
of the item of grouting. The pipe shall be cut and fabricated as
approved by the Engineer.
6.17.3.6
Pack Grouting
Back-fill grouting between the rock and over concrete lining is required
to fill any voids, gaps or cavities left after the placement of final
concrete lining and gaps due to shrinkage of concrete. The concrete
lining is to be carried out through pumpcrete. The portion below
springing level gets filled up through gravity but there are chances of
gaps being left in the portion above the springing, especially near the
crown. Grouting of the portion above springing level has to be done to
ensure complete interaction between the concrete lining and the rock.
The contact grouting shall also improve the strength of the rock in the
arch portion to make it more competent to carry external loads.
a) Grouting
Embedment of Grout Nipples
Prior to concrete placement in the overt, 75 mm diameter nipples of
plastic/nylon pipes shall be provided and duly fixed according to the
designed pattern. These nipples are extended upto the rock face and
shall be embedded during concreting to facilitate further drilling in the
rock for pack grouting.
b) Pattern of Grout Holes
SECTION 6B7: TUNNEL
PAGE 53 of 70
1795 of 2461
MMRDA
The pattern of grout holes for providing nipples shall be at 5 and 35

above springing level on both sides, staggering alternatively at 3.0 m
intervals, with a crown hole for each set of holes, as indicated in
Specification Drawing. The pipe nipples extending to the rock shall be
cleaned thoroughly of all dirt, grease, grout and mortar and fitted with
plugs before the placement of concrete. The pipes shall be held firmly
in position and protected from damage during the process of
concreting.
c) Drilling Grout Holes
(i) After the concrete lining sets and attains sufficient strength, grout
holes of 35 mm diameter shall be drilled through 75 mm diameter black
steel pipe nipples, already embedded in the concrete, with percussion
type rock drills. The depth of holes into the rock shall be kept as 0.9 m
in normal reaches and 1.5 m in geologically classified poor reaches,
including the reaches associated with high overbreaks. Drilling into the
rock is necessary so as to expose the contact between the rock and
the concrete for effective grouting.
During drilling, it shall be ensured that there is no grease or oily
substance on the drilling rods.
(ii) The holes shall be drilled in a group of, preferably, 12 holes
covering a length of 9 metres of the tunnel. Alternate blocks of 9 m
length of the tunnel shall be taken up for drilling and grouting
operations, so that the grout of the previous grouted block does not get
distributed or washed, even partially, during drilling and washing of the
next block. Each hole after drilling shall be protected from getting
clogged or obstructed by capping
(iii) At locations where the pipe nipples are left out or omitted
inadvertently during concreting, holes as per prescribed pattern [refer
para (b) above] shall be drilled through concrete with percussion type
rock drills into the rock and taken up for grouting along with the other
holes of the group.
SECTION 6B7: TUNNEL
PAGE 54 of 70
1796 of 2461
MMRDA
d) Grout Mix
(i) The grout mix to be used shall be either cement slurry (cement +
water) or cement-sand-water grout with hydrated bentonite as an
additive to prevent bleeding. The latter is used when the grout intake
through the holes is excessive. Cement used shall be ordinary portland
cement conforming to IS 269. Clean sand of
such fineness shall be used that not more than 5% is retained on No.
16 sieve; not less than 10% nor more than 30% passed the
No.100 sieve; and not more than 5% passed the No.200 sieve. (ii) In
normal reaches the mix to be used shall, preferably, be cement slurry
only. Grouting shall be commenced with 1:4 cement water ratio,
gradually coming down to 1:3; i :2 and finally 1:1 mix for plugging the
holes.
(iii) In high over-break reaches, where the grout intake through initial
grouting operation is excessive and causes wear of the cylinder liner of
grout pump, its use shall be restricted to the situations of high grout
intake. The quantity of sand in the grout mix shall also be varied as
considered appropriate at site. As a guideline, grout mix comprising 1
bag cement (50 kg), 1 bag sand and 72 litres of water may be used.
The grout mix shall be neither too thick to cause pumping difficulty nor
too thin to cause the segregation of sand.
(iv) Admixtures such as set accelerator and/or expansive agents will
have to be added to the grout as approved by the Engineer.
e) Grouting Procedure and Sequence Flushing of Holes.
After all holes in one group of 9 m length (a group of holes in 6 m
length can also be taken up, if it is more convenient) are drilled, these
shall be flushed with water by open washing to remove the rock
cuttings and rock dust, if any, left in the holes. The holes shall then be
fitted with pipe nipples, reducing sockets and plug valves at the end.
Water Testing
SECTION 6B7: TUNNEL
PAGE 55 of 70
1797 of 2461
MMRDA
All holes, after open washing, shall be tested at a water pressure not
exceeding 2.1 kg/sq.cm to establish contact with other holes; to find out
leakage, if any, in the concrete lining or around the embedded pipe
nipples; and to determine the rate of water intake or individual holes in
a group. The required quantities of cement (and sand, if considered
necessary) shall be arranged after ascertaining broadly the extent of
water intake/loss so that the grouting operation of a particular group of
holes, when undertaken, would continue uninterrupted.
Grouting Operation
In each group of holes, the lowest holes on both sides of the tunnel
shall be filled with grout injections at a pressure not exceeding 2.1
kg/sq.cm or 3.5 kg/sq.cm through 75 mm diameter pipe nipples
extending through the lining.
Particulars
Normal Reaches
Poor/high over-break
* Reaches
Depth of holes in rock
0.5m
1.0m
Spacing
3.0m
3.0m
Grout Pressure
2.1 kg/sq.cm (30 psi)
3.5 * kg/sq.cm (50

psi)
The lowest holes, provided at 5, shall be grouted first in order that the
upper holes may serve as vents for the escape of air entrapped in the
void/cavity, water and the thin mix of the grout which emerges on
settlement of grout. The upper holes, provided at 35 on both sides,
shall be taken up next for grouting; while the holes at the crown shall
be grouted last of all, at the specified pressure. Each group of holes
shall be considered as completed for grouting when all the holes
SECTION 6B7: TUNNEL
PAGE 56 of 70
1798 of 2461
MMRDA
individually refuse to take any more grout. The holes even with nil rate
to intake of water (during water testing) shall also be tried and grouted
at specified pressure.
During grouting, if any leakage is observed from concrete cracks or
some other locations, the same shall be caulked with lead wool or
oakum and the grouting, carried out intermittently at a pressure which
the crack could withstand without any further leakage, but not
exceeding the. Prescribed limiting pressure, viz. 2.1 kg/sq.cm.
Each hole after completion of grouting at specified pressure shall be
closed by a plug valve, so that the injected grout is retained in the
hole/gap/cavity. Other fittings, after removal, are washed for installation
on the next holes to be grouted. The plug valves shall, however, be
removed after the grout has an initial set (normally within 24 hours),
and shall be cleaned before the grout has hard set, for further use on
other group of holes to be grouted.
An extra set of pistons with piston rods, water meters, and few
pressure gauges fitted with copper tube coils, shall always be kept
ready for replacement for uninterrupted grouting operations. To avoid
frequent choking of pressure gauges copper tube coils fitted with
MOBIL oil shall be fitted with pressure gauges to provide a cushion
between the grout and the pressure gauge.
6.17.3.7
Pressure Injection Grouting

As many of the drilled grout holes as may be approved by the Engineer
shall be grouted under pressure specified for the respective work in
general or as specifically directed by the Engineer, with grout
composed of cement and water or cement, sand or crushed stone dust
(or similar other filler material such as fly ash, etc. as may be directed)
or chemicals such as Polyurethanes and water in proportion to be
determined by the Engineer The sand or stone dust provided by the
Contractor shall be clean and of such fineness that it shall all pass
through
SECTION 6B7: TUNNEL
PAGE 57 of 70
1799 of 2461
MMRDA
15 mesh sieve of Indian Standard Specifications. Cement and water

shall be of the same quality as specified for concrete in concrete lining.
The Tenderer shall note that polyurathene based chemical grout with
high foam factors along with equipment may have to be imported for
dealing with high, if needed and if not locally available. The Engineer
shall render all assistance to the Contractor for facilitating the import by
way of a recommendatory letter.
Application of chemical grout and use of the equipment shall comply
with instructions of the supplier. The necessity of use of the chemical
grout at any location within the tunnel shall be decided by the Engineer.
Hence the item of injecting chemical grout is provisional.
If so directed, a solution of silica gel or other similar material shall be
forced into the holes prior to grouting, in order to render the breccias
and similar layers less absorbent of water in the grout. Similarly,
bentonite or similar other material or chemicals shall be added to the
grout mix in such proportions as the
Engineer may direct.
Cement grout shall be applied at low pressure (as may be specified by
the
Engineer) initially and gradually but within the time as may be specified
by the
Engineer, increased upto the maximum pressure specified at which it
shall be maintained for a period of about 10 minutes. Grout pressures
are a matter of conjecture and depend on the circumstances and
geology of the surrounding rock. As a starting point, a pressure of 0.4
kg/cm2 per metre of overburden subject to a maximum of 7.0 kg/cm2
may be adopted after obtaining approval from the Engineer.
Grouting pressures for polyurethane grouting for water ingress control
shall be as per the manufacturers recommendations and agreed by
the Engineer.
SECTION 6B7: TUNNEL
PAGE 58 of 70
1800 of 2461
MMRDA
Chemical grouts shall be one or two components and shall have

variable setting times and adjustable foam factors and be specifically
designed for use with high water inflows in tunnel environments similar
to this project. Chemical grouts shall have a proven track record in
India and in overseas.
No hole or grout connection shall be grouted except with the
permission of the
Engineer within the period of one month from the date that all concrete
required within a radius of 5 M (Five Metres) has been placed, has set
and has been properly cured. If during grouting of any hole, grout is
found to flow from adjacent grout holes or a construction joint in the
concrete lining, in such quantities as to seriously interfere with the
grouting operation or to cause appreciable loss of grout, such holes or
joints shall be capped over or caulked temporarily. When such capping
or caulking is not essential ungrouted holes shall be left open to
facilitate the escape of air and water from pockets in the surrounding
space.
Should, at the time when grouting has just been commenced in any
hole, it be found that the grout has been freely flowing too far from the
hole at low pressure, fine stone dust, or other suitable material as may
be approved by the
Engineer shall be immediately added in order to block the leakages at
sufficient distance from the hole and thus localising the area to be
grouted for any particular hole or set of holes. As a hole approaches
refusal, the grout shall be progressively thickened and grouting
operation continued to refusal at the specified maximum pressure and
maintained for a period of about 10 minutes.
Utmost care and precaution shall be taken to ensure that the concrete
lining does not get damaged during the grouting. Any damage caused
to the lining shall be made good by the Contractor at his own expense
and to the satisfaction of the Engineer.
SECTION 6B7: TUNNEL
PAGE 59 of 70
1801 of 2461
6.17.3.8
MMRDA
Grouting Equipment
The equipment for mixing and grouting shall be capable of effectively
mixing in correct and specified proportions, agitating the grout and
pumping it into the holes in an uninterrupted flow at the designed
pressure upto the maximum specified for each element of work. There
should be satisfactory arrangements for accurately measuring the
quantity of water, cement and other ingredients to be used. The
agitator shall have paddles of suitable design and shapes, to keep the
mix at the proper consistency till it is pumped into the holes. The pump
shall be driven pneumatically or electrically.
Grout pumps shall be variable pressure ram type continuous supply
pumps and shall be capable of continuous delivery of grouts upto the
maximum pressure required. Each pump shall be provided with two
mixing tanks of not less than 150 litres capacity, each tank having a
mechanical mixer and arranged so that the grout is mixed in the first
tank and delivered through a screen to the second tank. The suction of
the pump shall be connected only to delivery from the second tank.
Should it be necessary to incorporate sand, fly ash or any other inert
material filler in the grout in proportions greater than one part of filler
material to one part of cementing material the grout shall be mixed in a
high speed colloidal unit capable of producing a highly intimate mixture
of main and subsidiary ingredients.
Where clay, bentonite or .chemicals are incorporated in the grout,
separate mixing tanks shall be provided in which grout mix can be
prepared and kept agitated until required.
The mixing and conveying system shall be laid out to provide sufficient
capacity for a heavy flow of grout. In general, an uninterrupted flow of
grout shall be maintained and the grout conveyed from the pump to the
hole through a pipe.
The mixer shall be placed as near to the hole a- possible and long,
pipe lines avoided. A portable unit mounted on a truck or a trolley on
SECTION 6B7: TUNNEL
PAGE 60 of 70
1802 of 2461
MMRDA
pneumatic tyres of suitable design would be the best.

Properly tested and calibrated pressure gauges generally of the type
used in food process industry, shall be provided to measure the
pressure of the grout being pumped into the hole. They shall be
provided with diaphragm to prevent grout from getting into the gauges
or the stand pipes and clogging them. The gauges shall be calibrated
frequently to see that they indicate the true pressure. Any damage
caused to the concrete structure or to the steel lining due to excessive
pressures build during grouting but not clearly recorded on gauges due
to faulty operation of the gauges will be rectified by the Contractor at
his own cost and hence it is very essential that the gauges are properly
calibrated from time to time.
The circulating system shall be so provided that the grout shall be kept
circulating continuously at sufficient velocity to prevent undue
settlement of cement or clogging of pipe line and fittings. The pumps
and pipe line shall be flushed with clear water at frequent intervals to
keep them clear. Deposits of grouts in the pump, mixer, etc., not
removed by flushing shall be removed by scraping and chipping.
Proper arrangements shall also be provided with the equipment to
stock adequate quantity of cement, stone dust, chemicals, etc., likely to
be required for grouting.
After grouting operations are completed for the shift or the day, the
remaining unused grout mix shall be thrown away. Also a mix not used
up completely within one hour after mixing or that which in the opinion
of the Engineer has set, settled, or clogged , shall be thrown away.
If, in the opinion of the Engineer, which shall be final and binding, such
wastage is due to the negligence of the Contractor, no payment shall
be made for the cement or sand so wasted.
6.17.3.9
Measurement and Payment for Pressure Grouting

Payment for drilling and cleaning the holes as specified hereinabove
shall be paid on the running metre basis. The Contractor shall provide,
SECTION 6B7: TUNNEL
PAGE 61 of 70
1803 of 2461
MMRDA
maintain and operate adequate and suitable drilling and cleaning

equipment. The cost of these shall be deemed to have been included
in the rates tendered for drilling.
Payment shall be made for the actual drilling work done.
Measurement for payment for grouting will be made on the basis of the
standard (50 kg.) bag of cement and weight of sand or stone dust
counted and measured separately, actually forced into the holes at the
direction of the Engineer. The weight of stone dust or sand shall be
taken in its loose dry state before mixing.
The unit rates quoted by the Contractor shall include also the cost of
providing and operating suitable grouting equipment including cost of
labour and supervision required for grouting and testing, etc. for the
complete operation.
Whenever other materials such as Pulverized Fly Ash, chemicals or
chemical grouts are used for grouting, the same will be supplied by the
Contractor and therefore the Contractor shall take the cost of these
materials into account while quoting for grouting with the same. The
Tenderer should also include the cost of providing all the necessary
equipment, including piping required for injecting such materials in the
unit rate quoted.
6.18
Shotcreting
6.18.1
General
Shotcreting shall be carried out to meet such requirements as to fill
open, joints fissures, seams and irregularities in the rock surface.
Shotcreting shall also be carried out to prevent water seepage from
joints. The Contractor shall mobilise and keep a reserve adequate
equipment to meet such situations at places where he considers it
necessary after prior approval of the Engineer.
6.18.2
Materials
a) Cement
SECTION 6B7: TUNNEL
PAGE 62 of 70
1804 of 2461
MMRDA
Cement used for Shotcreting shall be any of the following with prior
approval of the Engineer.
i) 33 Grade ordinary Portland cement conforming to IS 269;
ii) Rapid hardening Portland cement conforming to IS 8041;
iii) Portland slag cement conforming to IS 455;
iv) High strength ordinary Portland cement conforming to IS 8112;
v) Portland pozzolona cement conforming to IS 1489 (Parts 1 & 2);
vi) Sulphate resisting cement conforming to IS 12330;
vii) Low heat Portland cement conforming to IS 12600.
Contractor shall quote his rate for use of ordinary Portland cement. If
situation demands use of any other variety of cement listed above, the
same shall be done with the approval of the Engineer. For this purpose
separate rates will be negotiated with the Contractor.
b) Sand
Sand for shotcrete shall comply with requirement given in IS 383 and
graded evenly from fine to course as per Zone II and Zone III grading
of IS 383. Sand failing to satisfy this grading may, however, be used if
pre construction testing gives good results.
c) Coarse Aggregate
Coarse aggregate when used, shall comply with the requirements of IS
383. It shall conform to the grading given below:
IS Sieve
Percentage, by mass, passing for aggregate of
Designation
nominal max. size
10mm
12.5 mm
SECTION 6B7: TUNNEL
20 mm
PAGE 63 of 70
1805 of 2461
MMRDA
25
100
20
100
90-100
12.5
100
90-100
10
85-100
40-70
20-55
4.75
10-30
0-15
0-10
2.36
0-10
0-5
0-5
1.18
0-5
All oversized pieces shall be rejected by screening.

d) Water: Water shall confirm to the requirements of IS 456.
e) Admixtures
Admixtures shall only be used when it is specified or directed by the
Engineer.
Admixtures, when used, shall comply with the requirements of IS 456
or IS 9103.
f) Reinforcement
Reinforcing bars, when used, shall conform to IS 432 Part I or IS 1786.
Welded wire fabric conforming to IS 1566 may be used when so
directed by the Engineer.
6.18.3
Mix Proportion
Cement and aggregate shall be mixed in the proportion 1:3. The
aggregate shall be a mixture of 80% sand and 20% coarse aggregate.
Minimum cement content shall be taken as 400 kg / cu. m of shotcrete.
6.18.4
Codes
SECTION 6B7: TUNNEL
PAGE 64 of 70
1806 of 2461
MMRDA
Shotcreting operation for tunnels and shafts shall generally conform to

the requirements of IS 9012.
6.18.5
Shotcreting Process
The two types of shotcreting processes, as directed by the Engineer,
shall be used in this work:
a) Dry Mix Process
A mixture of cement and moist sand shall be conveyed through the
delivery hose to a nozzle where most of the mixing water shall be
added.
b) Wet Mix Process
All the ingredients including water shall be mixed before they enter the
delivery hose.
6.18.6
Application of Shotcrete
a) Preparation of surface
All surfaces shall be cleaned of loose rock and particles by washing
down with water prior to shotcreting work. Shotcrete shall not be placed
on any surface which is soft, spongy or where there is free water. The
surface shall be kept damp before applying shotcrete.
b) Placing
Each layer of shotcrete shall be built up by making several passes of
the nozzle over the working area. This shall be done by moving the
nozzle over the working area rhythmically in a series of loops from side
to side and up and down. The shotcrete shall emerge from the nozzle
in a steady uninterrupted flow. The distance of the nozzle from the
work shall be such as to give best results for working conditions. The
nozzle shall be kept perpendicular to the surface of application.
c) Construction Joints
SECTION 6B7: TUNNEL
PAGE 65 of 70
1807 of 2461
MMRDA
Construction joints shall be tapered to a thin edge over a width of about

300 mm. The entire joints shall be thoroughly cleaned and wetted prior
to the application of additional shotcrete.
d) Preparation for succeeding layer
Where a layer of shotcrete is to be covered by a succeeding layer, it
shall first be allowed to take its initial set. Then all laitance, loose
material and rebound shall be removed by brooming.
e) Inspection
The shotcreting operation shall be continuously inspected by a
qualified supervisor from the Contractor who shall check materials,
reinforcement, delivery equipment, application of material and curing.
Each layer of shotcrete shall be hammer tested to check the dummy
areas. These bad areas of shotcrete and those which in the opinion of
the Engineer are defective, shall be removed as early as possible and
they shall be replaced by fresh shotcrete. Such removal and rework of
defective shotcrete shall be done at the Contractor's cost by fresh
shotcrete. Such removal and rework of defective shotcrete shall be
done at the Contractor's cost.
6.18.7
Measurement and Payment

a) The shotcrete work for the purpose of payment shall be measured in
terms of square metre of area shotcreted where the rock is bored by
TBM.
b) The rate for shortcreting shall include for grading and testing of
materials, preparation of the rock surface, applying shotcrete, providing
construction joints, preparation for the succeeding layer, and inspection
by a qualified supervisor of the Contractor and clearing up the area of
any loose material, rebound, etc.
6.19
Pipelines and Steel Liners
SECTION 6B7: TUNNEL
PAGE 66 of 70
1808 of 2461
6.19.1
MMRDA
Scope
This specification covers supply, fabrication, testing, delivery at site,
laying, erecting and jointing of steel liner in the tunnels, M.S buried
pipelines, vertical pipe work in the shafts.
6.19.2
Erection
Prior to commencement of any erection operations, the Contractor
shall submit to the Engineer for his approval, complete details of the
scheme proposed
for erection of liners in shafts and tunnel. Erection
work shall commence only after obtaining approval. The Contractor

shall equip himself, at his cost, with all necessary tools, equipment and
labour required for this purpose.
To facilitate erection work the Contractor shall lay in the tunnel all
necessary temporary railway tracks of gauge, type and construction as
approved by the
Engineer. In the shafts, where pipes are to be erected vertically,
temporary supports shall be provided by the Contractor as may be
necessary with prior approval of the Engineer. All such temporary
works shall be dismantled and removed by the Contractor on
completion of the works. The cost of providing, maintaining and
removing such works shall be deemed to be included in the unit rates
quoted for respective items of work.
The erection of pipes and specials in shafts and tunnels shall be true to
position, lines and grade as shown in the drawings or as modified by
the Engineer. The
Contractor shall provide at his cost necessary saddles, pads, spiders,
scaffolds, shoring, guides, any ether aids necessary for erection etc.,
all necessary instruments and other materials and labour required for
proper erection of pipes and specials in position and for the Engineer
while checking the correctness of the erection. The deviation out of
plumb for the vertical column of pipes in the shafts shall not exceed 25
mm.
SECTION 6B7: TUNNEL
PAGE 67 of 70
1809 of 2461
MMRDA
Alignment of sections at edges to be butt welded shall be such that the

maximum offset is not greater than the values given below:
Thickness 't'
offset in Girth joints

(mm)
6.19.3
Upto 12
0.25 t
12 to 20
0.25 t
20 to 40
5 mm
In - situ welding
Only qualified welders shall be employed for in-situ welding of the
pipes and liners. Qualification standard for welding procedures,
welders and welding operation shall conform to the requirements of IS
7307 and IS 7310. The Contractor shall be responsible for the quality
of welding done by his organisation and shall conduct tests of welding
procedure to determine its suitability to ensure that welds will meet the
requirements of tests and also of the welders to determine their ability
to apply the procedure properly.
In case the result of any of the tests on test pieces are found to be
unsatisfactory, the welder concerned shall not be permitted to weld any
more pipes.
All the field joints shall be welded. All welding shall conform to the
requirements of IS 816 and IS 4353. Upon receipt of order and prior to
start of field welding, procedure for the field welding shall be submitted
by the Contractor to the
Engineer for his approval.
All circumferential welds, involving plates of unequal thicknesses shall
be so kept that the inside surfaces of plates match to provide
streamlined joints without alteration in the internal diameter.
SECTION 6B7: TUNNEL
PAGE 68 of 70
1810 of 2461
MMRDA
The welding should be of the best workmanship free from flaws, burns,
etc. The
Contractor shall provide his own electrodes and equipment including
ovens to keep the electrodes at the desired temperature and in dry
condition.
The welded joints after welding should not become brittle or sensitive
to blows and there should be no loss of toughness due to welding or
heat treatment. The material after welding or heat treatment shall be
tougher than the base material and shall retain its original ductility. No
allowance will be made for thinning of weld and the weld shall at no
point be lesser than the nominal thickness of the plate.
All field girth joints in tunnel liners shall be single welded butt joints with
backing strips as shown in the drawing. These liners shall be supplied
with their edges prepared to take a single "V" butt weld inside.
Field circumferential joints in the portion of pipeline in shafts, shall be
single 'V butt welded from the outside without backing strip. These
pipes shall be supplied with their edges prepared to take a single ' V
butt weld outside.
In welding continuous pipe pieces, they shall be so placed that
adjacent longitudinal joints are positioned and staggered, as directed
by the Engineer.
6.19.4
Inspection of Welded Joints at Site

All field welded joints in the buried pipelines outside shafts, pipe within
the shafts and liner in tunnel shall be inspected by conducting tests as
mentioned herein below:
Pipes in shafts and pipes or specials proposed to be embedded in
tunnel -The field welded joints shall be 10% radiographed.
6.19.5
In-situ Cement Mortar Lining

This work shall be taken up after completion of all erection, laying of
SECTION 6B7: TUNNEL
PAGE 69 of 70
1811 of 2461
MMRDA
pipes and testing of field welded joints. All materials and application of
lining to the internal surface of the pipes shall be as specified.
6.19.6
Support to Embedded Pipes & Specials in the Tunnel

Pipes or specials shall be supported by the Contractor on studs, stools
or pads or in any other manner necessary and suitably held in place
before commencing field welding of circumferential joints. No timber
work shall be permitted for such support in any location. When
supported, the shells shall be perfectly in line and level and in shape.
The support shall be such as will not get disturbed, dislodged during
the process of site welding or daring backpacking with concrete. The
liner shall be suitably braced from the inside with spiders while backing
and grouting.
No separate payment will he made for such studs, stools, pads, etc.
used for erection.
6.19.7
Encasing and Painting

Pipes and specials in the tunnels shall be embedded in the concrete
lining. In the shafts, the vertical pipe work will be encased in concrete.
SECTION 6B7: TUNNEL
PAGE 70 of 70
1812 of 2461
MMRDA
Table of Contents
SUB-SECTION 6B.8 - GENERAL PAINTING AND PROTECTION REQUIREMENTS ........... 1
8.1
General ...................................................................................................................................... 1
8.2
Colour Coding and Labelling of Pipes and Equipment ............................................... 2
8.3
Cleaning and Preparing at Place of Manufacture .......................................................... 3
8.4
Painting and Finishing at Place of Manufacture ............................................................ 4
8.5
Painting at Site ...................................................................................................................... 10
8.6
Waterworks Finish ............................................................................................................... 14
8.6.1
Welding and flame cutting ............................................................................................. 14
8.6.2
Castings ........................................................................................................................... 14
8.6.3
Covers .............................................................................................................................. 15
8.6.4
Flanges and beadings ................................................................................................... 15
8.6.5
Items to be chromium plated ........................................................................................ 15
8.6.6
External screws, boltheads, nuts and washers ......................................................... 15
8.6.7
Gauges............................................................................................................................. 15
1813 of 2461
MMRDA
SUB-SECTION 6B.8 - GENERAL PAINTING AND PROTECTION

REQUIREMENTS
8.1
General
The preparation, application and conditions for work shall comply with
the recommendations of BS 5493 and BS 6150 or if the protection is of
a special nature, in accordance with the manufacturer's directions.
Paints, primers and undercoats shall be obtained from the same

manufacturer and except where a definite time is specified between
mixing and application, shall be ready mixed for use. They shall be
compatible with one another.
Paints
shall
be
delivered
in
sealed
containers
bearing
the
manufacturer's name, batch number, etc. and shall carry a label giving
details of quality and instructions for use.
No site painting shall be carried out unless the surface to be painted is

dry, the air temperature above 4oC and the relative humidity less than
85%. The Employers representative shall approve the methods for
removing all dirt, oil, grease, etc, before Site painting commences.
Test plates carrying finishes from the actual coating used may be
required by the Employers representative for inspection and test
purposes.
To facilitate inspection, no consecutive coats of paint shall be of the

same shade except in the case of white.
Priming to two mating surfaces shall be applied prior to assembly.
All items of Plant shall be delivered to Site with the shop paint finish
applied unless specified otherwise. A further coat of final finish paint
SECTION 6B8: GENERAL PAINTING & PROTECTION REQUIREMENTS
1814 of 2461
PAGE 1 of 15
MMRDA
shall be applied at Site, of sufficient thickness to produce a uniform

colour and appearance. Such painting shall be carried out within one
month of successful acceptance trials for the Plant.
All paint thicknesses shall be checked using an alkometer or equivalent

instrument, supplied by the Contractor, for each layer of paint, to the
reasonable satisfaction of the Employers representative.
8.2
Colour Coding and Labelling of Pipes and Equipment
All pipes and equipment shall be colour coded to a schedule to be

agreed with the Employers representative before any site painting
starts, or earlier if necessary to suit manufacturing procedures. Valves
and fittings shall be painted in the same colour as the pipe of which
they form a part. Where a pipe enters or leaves a piece of equipment
the pipe colour shall extend up to but not including the flange attached
to the equipment.
All pipelines shall be identified by stick-on 90 micron thick vinyl film

labels showing the name of the material to be carried by the pipeline
and an arrow indicating the direction of flow. Letters of titles shall be
pre-spaced on carrier tape and the complete title protected by one
piece removable liners. Titles shall be at intervals not less than 8 m,
but shall in any case be provided in every space through which the
pipe passes. Locations of labels shall be subject to prior approval by
the Employers representative. Lettering sizes shall be between 16 mm
and 75 mm in height depending on the size of the pipe.
Pipes smaller than 22 mm outside diameter shall be labelled by the use

of tags instead of labels. Tags shall be made of brass no smaller than
65 mm x 16 mm by 1.5 mm thick, with lettering etched and filled with
black enamel.
Titles shall also be provided on all equipment in locations and in sizes

to be approved by the Employers representative.
1815 of 2461
PAGE 2 of 15
8.3
MMRDA
Cleaning and Preparing at Place of Manufacture
The Contractor shall be responsible for the cleaning and preparation

for painting, priming or otherwise protecting as specified of all parts of
the Plant at the place of manufacture prior to packing.
(a)
Cleaning
Parts shall be cleaned prior to testing at
the manufacturer's
works. Parts subject to hydraulic test shall be tested before any

surface treatment. After test all surfaces shall be thoroughly
cleaned and dried out if necessary by washing with an approved
dewatering fluid prior to surface treatment.
(b)
Preparation
Bright parts:
Bright parts and bearing surfaces
shall be
thoroughly polished and protected from corrosion
by the
application of rust preventive lacquer or high melting-point

grease, as approved by the Employers representative, before
the parts are packed.
A sufficient quantity
of the
correct
solvent for removal of the protective compounds shall be

supplied and packed with each particular part.
Embedded
assembly
parts:
Embedded parts or those parts
which will be embedded in concrete
of
an
shall
be
thoroughly de-scaled and cleaned to the satisfaction of the

Employers representative and before being packed shall be
protected by a cement wash or other approved method. No
cast iron or steel work shall be bitumen or tar coated where
it is to be cast into the concrete and provision shall be made
for cleaning off any portions so coated.
Grit or shot blasted parts: Grit or shot blasting shall be carried

1816 of 2461
PAGE 3 of 15
MMRDA
out in accordance with B.S. 7079 to a standard between `First

Quality' and `Second Quality' given in Table 1 after which the
maximum amplitude of the surface shall not exceed 0.1 mm.
Cast Iron and Steel pipework: All ungalvanised steel pipework

including pump suspension mains, bearing spiders shall be
prepared internally and externally by grit or shot blasting as
specified above and the surfaces primed as specified within
four hours of blasting.
8.4
Painting and Finishing at Place of Manufacture
This Clause governs the methods for the protective coatings to be

applied to structural steel,
metalwork and
ironwork
as corrosion
protection systems. The systems designed as specified here shall be

applied as specified under Protective Coatings.
Protective coating
specified elsewhere for particular works such as pipes and cladding

shall firstly be designed in accordance with particular requirements
specified elsewhere
and
secondly in accordance
with
requirements herein which are not overridden elsewhere.
any
This
specification makes reference to the following standard:
B.S.5493 "code of practice for the protective coating of iron and steel
against corrosion".
The Contractor shall design each protective coating system and shall
submit details of each system to the Employers representative
approval.
Submissions
shall
for
where possible be in the format of
which examples are given at the end of this section with such
additional information and samples as the Contractor may provide or
the Employers representative may require to enable the system to be
assessed.
Protective coating shall be designed in accordance with B.S. 5493 to

have a long life, generally of at least 10 years to first maintenance.
1817 of 2461
PAGE 4 of 15
MMRDA
Protection systems shall be chosen to be easily maintained in the

future and to allow non-specialist on-site re-coating where necessary
using single part paints.
For
the purposes of system design
the
general environment shall
be as specified in B.S. 5493 Table 3 Part 2 Èxterior exposed polluted

inland. Bulkhead gates and stoplogs shall be assumed to be exposed
to a Table 3 Part 8 `Non-saline water environment unless otherwise
Interior spaces shall be considered to be dry in administration areas

open to continuous access and damp or immersed in other spaces.
The protective coating of components
continuously
or infrequently
or
structures which
are
immersed shall be designed for
the
more onerous of these two conditions relevant to
the protection
system used.
All exterior exposed items to be coated shall have a final coat of good
appearance of a colour and type as approved by the Employers
representative.
Protective coating systems shall generally fall into one of the following
basic systems;
galvanising;
galvanising plus painting;
multi-coat painting;
bitumen enamel;
others as proposed by the Contractor and approved by the

1818 of 2461
PAGE 5 of 15
MMRDA
The Contractor shall submit to the Employers representative details of

his proposals for the corrosion protection of each of the
requiring such protection, which
items
will generally fall into the above
categories as follows:
trash screens, flooring, ladders, access covers and frames, step

irons and other components which are inaccessible but subject to
abrasion/damage;
structural
steelwork (including crane
beams, monorails, crane
structures and chassis), bulkhead gates, stop logs, steel tanks and
other large items readily accessible for maintenance;
valves and other corrosion-susceptible items which may be buried

and are not covered by the provisions of other specifications :
other
components
not covered by
the
above
for which the
contractor may propose a system which he considers to be more

suitable for the duty;
Electrical switchgear, transformers, control panels etc.
All painting material shall be applied in strict accordance with the paint
manufacturer's instructions.
(a)
Plant supplied to site with final coating applied:
Cubicles, cabinets etc.
Before any steel work is painted the steel must be thoroughly

cleaned and an approved anti-rusting priming coat applied so
that the possibility of rusting or corrosion taking place is
negligible. All surfaces should have not less than two
undercoats and two top coats or air drying paint. The undercoats
shall be easily distinguishable in shade or colour form the
1819 of 2461
PAGE 6 of 15
MMRDA
priming and finishing coats. The two final coats shall be in a

colour and finish to be advised by the Employers representative.
The inside surfaces of any
condensation is liable
to
cubicles, cabinets etc. where
occur, shall be
coated with
an
approved anti-condensation composition. The Contractor shall

ensure that all component sections of a switch board wherever
manufactured shall have a finish of uniform texture and an exact
colour match.
Chromium
plated
parts:
Where
chromium
plating
is
specified or offered by the manufacturer it shall comply with

the requirements of BS 1224 including the following provisions.
No blistering of any surfaces will be tolerated. The finished
appearance shall be brought. Where the base metal is steel,
plating shall be applied in accordance with Table 2 of the above
code. Other base metals shall be plated in accordance with
Tables 3, 4, 5 as appropriate. For all base metals the service
condition number 2 (of the above code) shall be used.
Small bore pipes, valves and fittings etc., which are sited in
architecturally finished areas of the station and selected by the
Employers representative shall be chromium plated. Damage to
chromium plating shall be made good before taking over.
Galvanised parts: All materials to be galvanised shall be of the

full
dimensions
shown
on
the
approved drawings
or
specified and all punching, cutting, drilling, screw tapping and

the removal of burrs shall be completed before the galvanising
process begins. Parts to be galvanised shall be shot blasted
as specified above. Such parts shall be galvanised not more
than four hours after commencement of shot blasting.
All galvanising shall be done by the hot dip-process.
No
alternative process may be used without the approval of the

Employers representative. No components shall be galvanised
1820 of 2461
PAGE 7 of 15
MMRDA
which are likely to come into subsequent contact with oil.
The zinc coating shall be uniform, clean smooth and as free

from spangle as possible.
In the case of component parts the
zinc coating shall weigh not less than 610 g/sq.m of area
covered and shall not be less than 0.090 mm in thickness.
Bolts
and
nuts
shall
be
standardised.
The
Employers
representative may select for test as many components to be

weighed after pickling, and before and after galvanizing as he
may think fit.
All galvanised parts shall be protected from injury to the zinc

coating due to differential serration and abrasion during the
periods of transit, storage and erection.
Damaged areas of
the coating shall be touched up with an approved zinc-dust paint

or other approved flake metallic compound.
Cast iron and steel pipework: (Internal surfaces)
The internal surfaces shall have an approved coating.
Where a bitumen based coating is used, it shall be in

accordance with Type 2 of BS 4147.
Prior to lining, the pipe shall be grit blasted and primed with an
approved primer. The lining shall be in accordance with BS 534.
After installation, the internal lining shall be made good and
satisfactorily tested with a Holiday detector to 8 kV.
The coating shall be suitable for use in contact with drinking

water.
The type of coating shall be entered in Schedule
provided and the Employers representative reserves the right to

call for test plates of the paint.
The manufacturer shall at the
time of ordering carry out the `Taste and smell test' (Appendix E
of BS 4147) and Èffects on water test' (Appendix C of BS 3416)
1821 of 2461
PAGE 8 of 15
MMRDA
and forward 3 copies of the test results to the Employers

representative for approval.
Where pipe are to be welded after the protective coatings

have been applied the pipe surfaces shall be primed and all
other coating stopped 250 mm short of the weld preparation.
Collars and fillings shall be primed but no other coating applied.
The manufacturer shall supply a sufficient quantity of suitable

materials to repair damage occurring during delivery to site
and to provided a flush finished internal lining at welded
joints. He shall supply sufficient coating to fill in the recesses at
internal welds over the previously primed areas. The costs of
these materials shall be included in the unit rates for the supply
of the pipes and specials.
The
coating
shall
be
applied
in
accordance
with
the
manufacturer's instructions and with Appendices J and K of BS

3416.
Machinery- (Internal surfaces) e.g. pumps, valves, strainers,

rising and suspension mains of wet well pumps:
As for cast iron and steel pipe work (Internal surfaces)
Cast iron and steel parts (External surfaces) immersed in Water:
All ungalvanised metal parts which will be immersed in water

shall be cleaned by grit blasting and within four hours of blasting
given a approved coating.
Cast iron and steel (External surfaces) in manholes and areas of

high humidity.
Ungalvanised metal parts exposed in manholes or areas of high

1822 of 2461
PAGE 9 of 15
MMRDA
humidity shall be cleaned by grit blasting and given two coats of

a black bituminous solution.
(b)
Plant forwarded to site for final finishing.
Cast iron and steel parts (External surfaces) outside buildings:
All
ungalvanised metal parts which will be exposed
to the
outside atmosphere shall be cleaned by grit blasting and

provided with two coats of an approved primer.
Cast iron and steel parts inside buildings:
All
exposed metal surfaces which will not be
immersed in
water or exposed in areas described above shall be rubbed

down, cleaned by grit blasting and within four hours of blasting
given one coat of an approved primer before packing.
8.5
Painting at Site
Immediately on arrival at the site, all items of plant shall be examined

for damage to the paint coat applied at the manufacturers works, and
any damaged portions shall be cleaned down to the bare metal, all rust
removed, and the paint coat made good with similar paint.
Steel and cast iron parts received at site shall be provided with
adequate number of further coats of coal tar epoxy polyamine coating
or Polyurethane coating as specified & approved, to a total dry film
thickness of minimum 275 microns including the primer coats.
All
sharp edges, nuts, bolts and other items difficult to be painted shall
receive a brush coat of specified paint before application of each coat
of epoxy based coal tar paint giving a total dry film thickness of at least
275 microns. In the case of fabricated steelwork this work shall be
done after assembly.
1823 of 2461
PAGE 10 of 15
MMRDA
Before painting is commenced the Contractor shall submit for the

approval of the Employers representative, full details of the paints he
proposes to use together with colour charts for the gloss finishes.
After erection, such items which are not finish painted shall be finish
painted, items finish painted at the Manufacturers works shall be
touched up for any damaged paint work.
The painting work shall conform to the following requirements:
(a)
The surface preparation shall be carried out generally in

accordance with IS: 1477 Part I and IS: 6005
(b)
After surface preparation, two coats of primer-red oxide zinc

chromate with modified phenolic alkyd base conforming to IS:
2074 shall be applied. Dry film thickness of each coat shall be
25 microns.
(c)
For finish painting, after application of primer as in (b) above,

two coats of synthetic enamel conforming to IS: 2932 shall be
applied. Dry film thickness of each coat shall be 25 microns.
(d)
Colours shall be selected as per IS: 5
No painting shall be carried out unless the item has been inspected
and accepted by Employers representative at the Manufacturers works
The dry paint film thickness shall be measured by Electrometer or other

instruments approved by the Employer. In order to obtain the dry film
thickness DFT specified, the Contractor shall ensure that the coverage
rate given by the paint manufacturer will enable this thickness to be
obtained. Strength of adhesion shall be measured with an adhesion
tester and this value shall not be less than 10 kg/cm 2.
Painted
fabricated steel Work which is to be stored prior to erection shall be

kept clear of the ground and shall be laid out or stacked in an orderly
1824 of 2461
PAGE 11 of 15
MMRDA
manner that will ensure that no. poles of water or dirt can accumulate
on the surface. Suitable packings shall be laid between the stacked
Materials. Where cover is provided, it shall be ventilated.
The painting procedure shall be submitted in the following format for

approval:
(a)
Surface Preparation
(b)
Reference Standard
(c)
Conditions of Work
(d)
Type of Materials
(e)
Tests and inspection methods and sequence, thickness (DFT)
(f)
Colour in final coat
(g)
Total thickness of coats (DFT)
(h)
Other necessary data and information
The following items in the plant are required to be painted;
(a)
Outer surfaces of pumps, valves, pipes, fittings, motors etc., not

exposed to treated water
(b)
Steelwork exposed to weather, such as outer surface of surge

vessel, valves, pipes etc.
(c)
Internal Plant and pipework, cranes, exhaust fans, fire

extinguishers and miscellaneous steelwork not exposed to
weather
(d)
Steelwork exposed to weather, such as platforms, ladders, hand

railing, etc.
(e)
Steelwork exposed to humid weather and requiring hard

maintenance and repairs
(f)
Buried steelwork
1825 of 2461
PAGE 12 of 15
MMRDA
(g)
Buried pipes and fittings prior to application of wrapping
(h)
Other equipment, as per requirement of employer.
All buried steel pipes and fittings shall be coated and unwrapped with
hot or cold applied, self-adhesive, polyethylene in accordance with
AWWA C214 or equivalent Standard.
Cast iron or mild steel parts to be built into concrete shall remain
unpainted.
Immediately before it is cast in-situ, it shall be made
perfectly free from dirt, scale, loose rust, paint, oil limewash or any
other coating.
No blast cleaning or painting shall be applied to corrosion resistant

Materials such as stainless steels. Ni-resist cast iron, bronze and other
metals used for seals, bearings, lighting fitting etc.
Machined surfaces such as gear teeth shall be coated with a thick layer
of grease. Other mechanical surfaces such as shaft ends or other
bright parts shall be coated with two coats of an anti-rust solution which
can be removed easily when required. Permanently bolted mechanical
interfaces such as flanges shall be coated with a thin coat of anti-rust
compound before assembly.
All primers, under coats and finishes shall be applied by brush or

airless spray, except where otherwise specified.
Consecutive coats shall be in distinct but appropriate shades.
All
paints shall be supplied from the store to the painters, ready for
application, and addition of thinners or any other Material shall be
prohibited. Any instruction given by the paint manufacturer shall be
1826 of 2461
PAGE 13 of 15
MMRDA
strictly followed.
All painting shall be carried out by the painters under supervision.

Paint shall be applied to the dry surface which has been prepared in
compliance with the approved procedure.
Paint shall not be supplied when or relative humidity rises above 90%.
The Plant and equipment shall be inspected and reviewed at the

various stages of the coating application both at the manufacturers
Works and at the Site of the Works. Samples may be taken from the
paints as delivered and submitted to such tests as are deemed
necessary.
The completed paint systems shall be tested by
instruments to ensure that the protection is of adequate thickness and

is free from pinholes and the direct measurement of adhesion shall be
checked by the removal of a small section of the coating.
The
Contractor shall supply all instruments and apparatus required for

carrying out such tests required by the Employer.
8.6
Waterworks Finish
A high standard of finish, defined as Waterworks finish" is required for
all Plant as detailed below.
8.6.1
Welding and flame cutting
A smooth neat finish, by careful grinding if necessary is required on all

exterior welding and flame cutting.
All plates and bars used in
fabrication shall have smooth surfaces with no pitting or deep slag

inclusions
8.6.2
Castings
Casting surfaces shall be smooth and free from surface blowholes.

Stock castings shall be specially selected with this in mind. All castings
1827 of 2461
PAGE 14 of 15
MMRDA
shall be shot blasted before machining.
8.6.3
Covers
All covers shall be firmly fixed. Weldmesh shall sit square in its frame.
Where panels are placed next to each other the patterns shall line up.
8.6.4
Flanges and beadings
All bolt holes shall be spot faced parallel with the mating face for good
seating of nuts and bolt heads. Surplus jointing shall be removed from
mating faces and peripheries.
8.6.5
Items to be chromium plated
Name plates, instruction plates, rotation
arrows, indicators and
pointers, small bore pipework, tundish oil level gauges and fittings,
small valves (including air valves), plugs and grease nipples, which
are sited in architecturally finished areas of the station and as selected
by
the Employers representative, shall be
chromium
plated.
Damage to chromium plating shall be made good.
All
pipes
and
fittings etc., shall be
fitted
in
a straight,
neat
symmetrical manner so as to present a pleasing appearance.
8.6.6
External screws, boltheads, nuts and washers
These shall be chromium plated, sherardised or made in stainless

steel.
8.6.7
Gauges
All indicating gauges fitted to any machine assembly shall be of similar

appearance and grouped together to present a pleasing aspect. They
shall all have chromium plated cases, bezels, cocks and fittings.
1828 of 2461
PAGE 15 of 15
Table of Contents
9.0 GENERAL SPECIFICATION FOR CONCRETE ROADS. ........................................... 1
EARTHWORK FOR SUBGRADE ..................................................................................... 1
9.1
GENERAL .............................................................................................................. 1
9.2
MATERIALS ........................................................................................................... 1
9.3
SETTING OUT ........................................................................................................ 3
9.4
DEWATERING ....................................................................................................... 3
9.5
SPREADING AND COMPACTION ......................................................................... 4
9.6
FINISHING OPERATIONS ..................................................................................... 5
9.7
QUALITY CONTROL TESTD DURING CONSTRUCTION ..................................... 6
9.8
ROCK FILL CONSTRUCTION ................................................................................ 6
SECTION II: GRANULAR SUB BASE ............................................................................... 7

9.9
GENERAL .............................................................................................................. 7
9.10
MATERIALS ...................................................................................................... 7
9.11
CONSTRUCTION OPERATIONS ...................................................................... 8
9.12
SURFACE FINISH AND QUALITY CONTROL .................................................. 9
SECTION III: GENERAL SPECIFICATION FOR CONCRETE PAVEMENTS ................. 10

9.13
CEMENT ......................................................................................................... 10
9.14
AGGREGATES................................................................................................ 11
9.15
WATER ........................................................................................................... 13
9.16
ADMIXTURES ................................................................................................. 13
9.17
MILD STEEL BARS FOR DOWELS AND TIE BARS ....................................... 14
9.18
PREMOULDED JOINT FILLER ....................................................................... 14
9.19
JOINT SEALING COMPOUND ........................................................................ 14
9.20
SEPARATION LAYER ..................................................................................... 15
9.21
SIZE AND GRADING OF AGGREGATES ....................................................... 15
9.22
HANDLING AGGREGATES ............................................................................ 16
9.23
BATCHING AND MIXING OF CONCRETE ..................................................... 17
9.24
CONCRETE MIXERS ...................................................................................... 18
9.25
TIME ALLOWED FOR CONCRETING ............................................................ 19
9.26
WORK IN ADVERSE WEATHER .................................................................... 19
9.27
CURING LIQUID.............................................................................................. 20
SECTION IV: WATER BOUND MACADAM .................................................................... 21

SECTION V: PAVEMENT QUALITY CONCRETE .......................................................... 21
9.28
NOMINAL SLAB THICKNESS ......................................................................... 21
1829 of 2461
9.29
MATERIALS .................................................................................................... 21
9.30
MIXTURE DESIGN .......................................................................................... 21
9.31
TRIAL MIXTURES ........................................................................................... 23
9.32
TRIAL AREAS ................................................................................................. 24
9.33
PREPARATION OF UNDERLYING SURFACES ............................................. 25
9.34
REGULATION OF EXISTING SURFACES ...................................................... 26
9.35
FORMS ........................................................................................................... 27
9.36
PLACING SEPARATION LAYER .................................................................... 27
9.37
TRANSPORTING AND PLACING OF CONCRETE MIXTURES ..................... 28
9.38
ROUTINE TESTS ON CONCRETE MIXTURES THROUGHOUT PLANT
MIXING ........................................................................................................................ 28
9.39
SPREADING, COMPACTING AND FINISHING CONCRETE BY PAVING
TRAIN
........................................................................................................................ 30
9.40
SPREADING
COMPACTING
AND FINISHING
CONCRETE BY SEMI-
MECHANISED MEANS................................................................................................... 32
9.41
SPREADING, COMPACTING AND FINISHING CONCRETE BY SLIP-FORM
PAVER
........................................................................................................................ 33
9.42
METHODS OF FORMING JOINTS.................................................................. 35
9.43
EXPANSION JOINTS ...................................................................................... 35
9.44
SEALING OF EXPANSION JOINTS ................................................................ 36
9.45
CONTRACTION GROOVES............................................................................ 37
9.46
CONSTRUCTION JOINTS .............................................................................. 38
9.47
JOINTS BETWEEN NEW PQC AND EXISTING BITUMINOUS SURFACING . 40
9.48
ROUTINE TESTS ON CONCRETE AFTER LAYING (SURFACE ACCURACY) ..

........................................................................................................................ 41
9.49
TEXTURING OF SURFACE ............................................................................ 43
9.50
INITIAL CURING ............................................................................................. 44
9.51
FINAL CURING ............................................................................................... 45
9.52
ROUTINE TESTS ON CONCRETE AFTER LAYING (CORES) ....................... 45
9.53
ROUTINE TESTS ON CONCRETE AFTER LAYING (SURFACE TEXTURE) . 48
9.54
FILLING CORE HOLES ................................................................................... 49
9.55
TRAFFIC ON FINISHED CONCRETE ............................................................. 49
9.56
CUTTING OUT CONCRETE ........................................................................... 50
9.57
REPLACEMENT OF CONCRETE ................................................................... 50
9.58
SCORING AND GROOVING HARDENED CONCRETE ................................. 51
9.59
SAW CUTS ADJACENT TO AGL FITTINGS, MANHOLE COVERS, PIT
COVERS ETC. ................................................................................................................ 52
1830 of 2461
9.60
HIGH PERFORMANCE JOINT ........................................................................ 52
SECTION VI: TESTING .................................................................................................. 52

9.61
TEST RESULTS .............................................................................................. 52
9.62
TESTS FOR INITIAL APPROVAL OF MATERIALS ......................................... 52
9.63
ROUTINE TESTS ON BULK SUPPLIES THROUGHOUT PLANT MIXING ..... 53
9.64
ROUTINE TESTS ON PLANT THROUGHOUT PLANT MIXING ..................... 54
9.65
ROUTINE TESTS ON CONCRETE THROUGHOUT PLANT MIXING ............. 54
9.66
ROUTINE TESTS ON CONCRETE AFTER LAYING....................................... 55
9.67
CERTIFICATES THROUGHOUT THE WORK................................................. 55
1831 of 2461
9.0 GENERAL SPECIFICATION FOR CONCRETE ROADS.
EARTHWORK FOR SUBGRADE

9.1
GENERAL
This work shall consist of construction of earthwork for subgrade including
earthen shoulders and miscellaneous backfills with approved material obtained
from excavation, borrow pits or other sources.
The work shall be carried out in accordance to Clause 305 of Specification for
Road and Bridge Works (Fourth Revision August 2001), issued by the Ministry
of Road Transport & Highways, Government of India and published by the
Indian Roads Congress, henceforth called MORT&H Specifications.
9.2
MATERIALS
All material for embankment whether such material is brought from excavation
within
the
site
/borrow
areas,
will
subject
to
Engineers
approval.
Notwithstanding any approval given to the fill material proposed to be used,

Engineer/Employer reserves the right to reject such material which in his opinion
either does not meet the specification requirements or is unsuitable for the
purpose for which it is intended. If demanded by Engineer, Contractor shall have
to arrange trial pits of specified dimensions and numbers dug at location
specified, for Engineer to examine the nature & type of material likely to be
obtained for the embankment. Such materials shall be free of logs, stumps,
roots, rubbish or any other ingredient likely to deteriorate or affect the stability of
the embankment / subgrade.
The following types of material shall be considered unsuitable for embankment:
Materials from swamps, marshes and bogs;
Peat, log, stump and perishable material: any soil that classifies as OL, OI,
OH or PT in accordance with IS: 1498;
Materials susceptible to spontaneous combustion;
Clay having liquid limit exceeding 70 and plasticity index exceeding 45;
SECTION 6B9: CONCRETE ROAD
PAGE 1 of 55
1832 of 2461
Materials with sails resulting in leaching in the embankment;
Expansive clay with free swelling index exceeding 50 per cent when tested
as per IS: 2720 Part 40;
Any fill material with a soluble sulphate content exceeding 1.9 gm. of
sulphate per liter when tested in accordance to BS: 1377 Test 10; and
Materials with a total sulphate content exceeding 0.5 per cent by mass,
when tested in accordance to BS: 1377 Test 9.
The size of the coarse material in the mixture of earth shall ordinarily not exceed
75 mm in soil embankment and 100 mm in Rock fill embankment when being
placed in the embankment. However, the Engineer may use his discretion in the
selection of material if he is satisfied that the same will not present any difficulty
as regards the placement of fill material and its compaction to the requirements
of these specifications.
The materials satisfying the density requirements given in Table 300-1 of

MORT&H specifications and presented in Table below.
Density Requirements of Embankment & Subgrade Materials

Sr.
Type of Work
Maximum laboratory dry unit weight when
No.
1
tested as per IS: 2720 (Part 8)

Subgrade
and
earthen Not less than 17.5 kN/cum
shoulders / verges / backfill
The contractor shall obtain representative samples from each of the identified
borrow areas and have these tested at the site laboratory following a testing
program approved by the Engineer. It shall be ensured that the subgrade
material when compacted to the requirements as presented in Table below shall
yield the design CBR value of the subgrade.
Compaction Requirements of Embankment & Subgrade Materials
PAGE 2 of 55
1833 of 2461
Sr.
Type of Work
No.
Relative compaction as percentage of

max. laboratory dry density as per IS:
2720 (Part 8)
Subgrade
and
earthen Not less than 97
shoulders
9.3
SETTING OUT
The limits of embankment shall be set out true to lines, curves, slopes, grades
and sections as shown on the drawings or as directed by the Engineer. The
Contractor shall provide all labour, survey instruments and materials such as
strings, pegs, nails, bamboos, stones, lime, mortar, concrete, etc., required in
connection with the setting out of works and the establishment of bench marks.
The Contractor shall be responsible for the maintenance of bench marks and
other marks and stakes as long as in the opinion of the Engineer they are
required for the work.
The limits of embankment shall be marked by fixing batter pegs on both sides at
regular intervals as guides before commencing the earthwork. To ensure their
safety, it is desirable to fix the pegs about 500 mm back from the actual limits of
the fill and to paint them in a distinctive colour.
9.4
DEWATERING
If embankment is in an area with stagnant water, and in the opinion of the
Engineer it is feasible to remove it, the same shall be removed by bailing out or
pumping, as directed by the Engineer and the area of the embankment
foundation shall be kept dry. Care shall be taken to discharge the drained water
so as not to cause damage to the works, crops or any other property. Due to
any negligence on the part of the Contractor, if any such damage is caused, it
shall be the sole responsibility of the Contractor to repair/restore it to original
condition or compensate the damage at his own cost. Cost of dewatering and
removal of sludge including disposal of same within airport boundary is included
in the rate quoted by the agency.
If removal of slush is required to be done
PAGE 3 of 55
1834 of 2461
again during the execution of work as per instruction of Engineer in writing, the
same shall be done by contractor at no extra cost.
9.5
SPREADING AND COMPACTION

Filling shall be permitted after removing vegetation, trees, roots etc. Approved
soil fill consisting of ordinary soil, murmur, graded material of rock etc. shall be
deposited in layers not exceeding 200 mm compacted thickness where particle
size of soil being laid does not exceed 40mm for fill. When soil particle exceeds
more than 40mm, then compacted thickness of layer shall be accepted up to
300mm and unless otherwise stated, every layer shall be power rolled with 80100 KN vibro-rollers as directed by Engineer to achieve 97% of modified Proctor
density. The material shall be spread by a motor grader uniformly. The motor
grader blade shall have hydraulic control suitable for initial adjustments and
maintain the same so as to achieve the specified slope and grade.
Contractor should ensure that all clods of earth are broken down to a size not
larger than 75 mm and coarser material of rock not larger than 75 mm.
The moisture content to be used where proctor density or modified Proctor

density is used shall be strictly controlled to within 2% of the optimum moisture
determined in accordance with IS: 2720 Part II. Where the moisture is higher,
the soil shall be raked and moisture allowed evaporating before rolling is
commenced. Water shall always be sprayed and not poured. Ponding shall
never be allowed. In wet weather, the work may have to be suspended for which
no extra would be payable to the contractor. Care shall be taken to see that
moisture is uniformly spread throughout the layer and where necessary mixing
with harrows or rakes shall be done. The dry density of the compacted layers
shall be determined as per IS: 2720 Part XXVIII. The frequency of carrying out
tests for determining moisture content and density will be as directed by
Engineer.
If the fill material has to be compacted by use of rollers, Contractor shall ensure
necessary compaction by means of 80 to 100KN rollers smooth weeded, sheepSECTION 6B9: CONCRETE ROAD
PAGE 4 of 55
1835 of 2461
foot or vibro rollers. A smaller weight roller may be used only if permitted by
Engineer. As rolling proceeds water sprinkling shall be done to assist
consolidation. Engineer will determine the thickness of the layers in which fill has
to be consolidated depending on the fill material and equipment used. Rolling
shall commence from the outer and progress towards the centre and continue
until compaction is to the satisfaction of Engineer, but in no case less than 10
passes of the roller will be accepted for each layer. The compacted surface shall
be properly shaped, trimmed and consolidated to and even and uniform
gradient. All soft spots shall be excavated and filled and consolidated. At some
locations it may not be possible to use rollers because of space restrictions, etc.
Contractor shall then be permitted to use pneumatic tampers, rammers, etc. and
he shall ensure proper compaction.
To ensure that the fill has been compacted as specified, field & laboratory tests
shall be carried out by Contractor at his cost. Field compaction test shall be
carried out at different stages of filling and also after the fill to the entire height
has been completed.
Contractor shall protect the earth fill from being washed away by rain or
damaged in any other way. Should any slip occur, Contractor shall remove the
affected material and make good the slip at his cost.
9.6
FINISHING OPERATIONS
Finishing operations shall include the work of shaping and dressing the
shoulders/verge, runway bed and side slopes to conform to the alignment,
levels, cross-sections and dimensions shown on the drawings or as directed by
the Engineer subject to the surface tolerances described below. Both the upper
and lower ends of the side slopes shall be rounded off to improve appearance
and to merge the embankment with the adjacent terrain.
When earthwork operations have been substantially completed, the area shall
be cleared of all debris, and ugly scars in the construction area responsible for
objectionable appearance eliminated.
PAGE 5 of 55
1836 of 2461
9.7
QUALITY CONTROL TESTD DURING CONSTRUCTION

For ensuring the requisite quality of construction, the materials and works shall
be subjected to quality control tests in accordance with Section 900 of MORT&H
specifications.
9.8
ROCK FILL CONSTRUCTION

Where specifically permitted by the Engineer because of imperative economic or
technical reasons, construction of rock fill fillings shall be in accordance with the
lines, grades and cross-sections as shown in drawings or as directed by the
Engineer.
Rock fill shall not be used at least for a depth of 750 mm below the formation
level. The size of rock pieces used in rock fill fillings shall be such that they can
be deposited in layers so as to suit the conditions evaluated in the field
compaction trials or as directed by the Engineer. The rock fill shall consist of
hard, durable and inert material, preferably maximum size not exceeding 100
mm.
Argillaceous rocks (clay, shales etc.), un-burnt colliery stock and chalk shall not
be used in rock fill. The rock fragments and blinding material required for filling
the voids shall also satisfy the above requirements.
The material shall be tipped, spread and levelled in layers extending to the full
width of filling by a suitable dozer. Fragments of rock shall then be spread on the
top of layer to the required extent and layer compacted by minimum of 5 passes
of vibratory roller having static weight 80-100 KN. The compacted thickness of
each layer shall not exceed 300 mm. After compaction of each layer, the surface
voids shall be filled with broken fragments. Next layer, where required, shall be
placed in the same manner, above the earlier compacted layer.
The top layer of rock fill, on which normal earth fill will rest, shall be thoroughly
PAGE 6 of 55
1837 of 2461
blinded with suitable granular material to seal its surface.
SECTION II: GRANULAR SUB BASE

9.9
GENERAL
This work shall consist of laying and compacting well-graded material on
prepared subgrade in accordance with the requirements of these specifications.
The material shall be laid in one or more layers as sub-base according to lines,
grades and cross sections shown on the drawings or as directed by the
Engineer.
The work shall be carried out in accordance to Clause 401 of Specification for
Road and Bridge Works (Fourth Revision August 2001), issued by the Ministry
of Road Transport & Highways, Government of India and published by the
Indian Roads Congress, henceforth called MORT&H Specifications.
9.10
MATERIALS
The material to be used for the work shall be crushed stone. The material shall
be free from organic or other deleterious constituents and conform to the
Grading II given in Table 400-2 of Specification of Road & Bridge Works and
presented in Table below with the percentage passing 0.075mm size restricted
to 5%. The portion of the total aggregate passing 4.75 mm sieve shall have a
sand equivalent value of not less than 50 when tested in accordance with the
requirement of IS: 2720 (Part 37) and material passing 425 microns shall be
silica or lime stone and not clay.
Grading for Coarse Graded Granular Sub-Base

IS Sieve designation
Percent by weight passing the IS sieve
53.0mm
100
26.5 mm
50-80
9.50 mm
4.75 mm
15-35
2.36 mm
PAGE 7 of 55
1838 of 2461
IS Sieve designation
Percent by weight passing the IS sieve
0.425 mm
0.075 mm
<5
The material to be used in the sub-base course shall have a 4-day soaked CBR
value not less than 30 per cent. Besides the CBR (not less than 30), the typical
stipulations in regard to the physical characteristics of coarse fraction of subbase materials shall be as under:
LA value of the material shall not exceed 50 or AIV shall not be more
than 30 per cent.
Ten percent fines value of 50 KN or more (soaked condition) when tested

as per BS: 812 (Part-III).
Combined Flakiness and Elongation Indices (Total) not more than 30

percent.
The water absorption value shall not exceed 2 per cent, (as per IS: 236part-3).
Sodium sulphate soundness (5 cycles) shall be less than 15% (as per IS:
383).
The Contractor shall, at least 21 working days before the commencement of the
construction of the sub-base course, submit to the Engineer, the results for
approval of the laboratory testing on the physical properties defined above. The
construction of the sub-base course can be taken of only upon the Engineers
approval of the material.
9.11
CONSTRUCTION OPERATIONS
Immediately prior to the laying of sub-base, the subgrade shall be prepared in
accordance to Clause 301 and 305 of MORT&H specifications by removing all
vegetation and other extraneous matter, lightly sprinkled with water if
necessary and rolled with two passes of 80-100 KN smooth wheeled roller.
PAGE 8 of 55
1839 of 2461
The thickness of the loose layers shall be so regulated that the maximum
thickness of the layer after compaction does not exceed 150 mm. The sub base
material shall be spread on the prepared subgrade with the help of a motor
grader of adequate capacity.
Moisture content of the loose material shall be checked in accordance with IS:
2720 Part 2 and suitably adjusted by sprinkling additional water from a truck
mounted or trailer mounted water tank and suitable for applying water uniformly
and at controlled quantities to variable widths of surface or other means
approved by the Engineer so that, at the time of compaction, it is from 1% above
to 2% below the optimum moisture content corresponding to IS: 2720 Part 8.
Immediately thereafter, rolling shall start with the help of a vibratory roller of
minimum 80 to 100 KN static weights with plain drum or pad foot-drum / heavy
pneumatic tired roller of minimum 200 to 300 KN weight having a minimum tire
pressure of 7 kg/cm2 or equivalent capacity roller capable of achieving the
required compaction. Rolling shall commence at the lower edge and proceed
towards the upper edge longitudinally for portions having unidirectional cross fall
and super elevation and shall commence at the edges and proceed towards the
centre of portions having cross fall on both sides.
It is recommended to achieve the desired density of 98% of MDD as

recommended in IS: 2720 Part 8.
9.12
SURFACE FINISH AND QUALITY CONTROL

Horizontal alignment shall be reckoned with respect to the centre line of the
carriageway as shown on the drawings. The edges of the carriageway as
constructed shall be correct within a tolerance of 10 mm there from. The
corresponding tolerance for edges of the roadway and lower layers of pavement
shall be 25 mm.
PAGE 9 of 55
1840 of 2461
Tolerance in surface level of granular sub base shall be 20 mm for flexible

pavements and 6 mm for concrete pavements.
For ensuring the requisite quality of construction, the materials and works shall be
subjected to quality control tests in accordance with Section 900 of MORT&H
specifications.
SECTION III: GENERAL SPECIFICATION FOR CONCRETE PAVEMENTS
The contractor shall indicate to the Engineer the source of all materials to be used in
the concrete work with relevant test data sufficiently in advance, and the approval of
the Engineer for the same shall be obtained at least 45 days before the scheduled
commencement of the work. If the contractor later proposes to obtain materials from
a different source, he shall notify the Engineer for his approval, at least 45 days
before such materials are to be used with relevant test data.
9.13
CEMENT
The general term cement in this specification means Portland cement
complying with minimum following grades.
o
Ordinary Portland cement, 33 Grade. IS: 269,
Ordinary Portland cement, 43 Grade. IS: 8112,
Ordinary Portland cement, 53 Grade. IS: 12269.
If the soil around has soluble salts like sulphates in excess of 0.5 per cent, the
cement used shall be sulphate resistant and shall conform to IS:12330.
The characteristics of different types of cement grades proposed for

construction shall be as presented in Table below.
Characteristics of Cement Grades proposed for Construction

Characteristics
OPC 53
OPC 43
OPC 33
PAGE 10 of 55
1841 of 2461
Fineness Minimum specific surface (cm^2/gm.) 3000
3000
3000
Setting time (minutes)

Initial not less than
30
30
30
Final not more than
600
600
600
Le-Chatelier (mm)
10 (max)
10 (max)
10 (max)
Autoclave (%)
0.8 (max) 0.8 (max) 0.8 (max)
Soundness expansion by
Minimum compressive strength (kg/cm^2)

3 days
270
230
160
7 days
370
330
220
28 days
530
430
330
9.14
AGGREGATES
The Works Contractor shall inform the Project Engineer of the source and
aggregate properties of each aggregate and provide all technical information
as required this specification. Tests for the initial consent of aggregates shall
be carried out by the Works Contractor before mixing starts. Aggregates shall
consist of naturally occurring material. They shall not contain deleterious
material is such a form or in sufficient quantity to adversely affect the strength
at any age of the durability of the surfacing, including resistance to frost.
Examples of such deleterious materials include, clay, loam, chalk particularly
as an adherent coating; mica, shale and other laminated materials; coal and
other organic impurities, sulphates and chlorides or other reactive materials
liable to break down during drying or subsequent exposure to weather or
moisture. Weathered rock shall not be permitted. Fine aggregates shall be
approved sharp grained clean natural bank, river, dune, or pit sand, or
crushed rock, and shall be free from loosely bonded aggregations and other
foreign matter. When crushed rock is selected for a part or the whole of the
fine aggregate, the parent rock shall be tested for stripping. Sea-dredged
sand shall not be used. The physical requirements of coarse or fine aggregate
to be used for pavement concrete shall be as shown in Table below. Fine
aggregate from each supply source shall be tested for absorption as per IS:
2386 (P-3) and if absorption exceeds 2% that source shall be rejected.
PAGE 11 of 55
1842 of 2461
Physical Requirements of Aggregates for Pavement Concrete

Property
Strength
Situation
Test Method
Test Reference BC
Crushed
Los
Rock
Abrasion Value
Gravel
Aggregate
Angeles
IS: 2386: Part 4
Max30%
IS: 2386: Part 4
Max30%
Magnesium Sulphate IS: 2386: Part 5
Max15%
Sodium Sulphate
IS: 2386: Part 5
Max10%
Magnesium Sulphate IS: 2386: Part 5
Max18%
Sodium Sulphate
IS: 2386: Part 5
Max12%
Water Absorption
IS: 2386: Part 3
Max2%
Max0.06%
Max0.25%
Impact
Value
Durability
Fine
(Soundness)
Aggregate
Fine
Aggregate
Coarse
Aggregate
Coarse
Aggregate
Water
Absorption
Chemical
Content
All
All
Total
Chloride
content
Total
Sulphate
Content
Deleterious
substances
All
Clay lumps
IS:2386: Part 2
Max1%
All
Coal & lignite
IS:2386: Part 2
Max1%
IS:2386: Part 1
Max3%
All
Materials passing IS
sieve No. 75 micron
Aggregates shall also be tested for deleterious reactivity with alkalis in the
cement, which may cause excessive expansion of the concrete. Tests of
coarse and fine aggregate shall be made in accordance with ASTM C 1260. If
the expansion of the coarse or fine aggregate test specimens, tested in
accordance with ASTM C 1260, does not exceed 0.10 % at 16 days from
casting, the coarse or fine aggregates shall be accepted.
PAGE 12 of 55
1843 of 2461
If the expansion at 16 days is greater than 0.10%, tests of combined materials

shall be made in accordance with ASTM C 1260 or ASTM C 1567 using the
aggregates, cementitious materials, and/or specific reactivity reducing
chemicals in the proportions proposed for the mixture design. If the expansion
of the proposed combined materials tests specimens, tested in accordance
with ASTM C 1260 or ASTM C 1567, does not exceed 0.10 % at [30] days
from casting, the proposed combined materials will be accepted. If the
expansion of the proposed combined materials test specimens is greater than
0.10% at 30 days, the aggregates will not be accepted unless adjustments to
the combined materials mixture can reduce the expansion to less than 0.10 %
at 30 days, or new aggregates shall be evaluated and tested.
9.15
WATER
Water used for mixing and curing of concrete shall be clean and free from
injurious amount of oil, sail, acid, vegetable matter or other substances
harmful to the finished concrete. It shall meet the requirements stipulated in
IS: 456.
When water is not available from a Public Utility Undertaking or from the
Establishment, the Contractor is to arrange for tests in accordance with IS
456, and shall submit the resulting report to the Project Engineer for his
consent prior to commencement of trial areas.
9.16
ADMIXTURES
Wherever applicable, admixtures conforming to IS:6925 and IS:9103 shall be
permitted to improve workability of the concrete or extension of setting time,
on satisfactory evidence that they will not have any adverse effect on the
properties of concrete with respect to strength, volume change, durability and
have no deleterious effect on steel bars. The particulars of the admixture and
the quantity to be used must be furnished to the Engineer in advance to
obtain the approval before use. Satisfactory performance of the admixtures
PAGE 13 of 55
1844 of 2461
should be proved both on the laboratory concrete trial mixes and in trial
paving works.
9.17
MILD STEEL BARS FOR DOWELS AND TIE BARS

Wherever applicable, these shall conform to the requirements of IS: 432, IS:
1139 and IS: 1786 as relevant. The dowel bars shall conform to grade S 240
and tier bars to Grade 425 of IS.
9.18
PREMOULDED JOINT FILLER

Joint filler board for expansion joints shall be of 20-25 mm thickness within a
tolerance of 1.5 mm and of a firm compressible material and complying with
the requirements of IS: 1838, or BS specification clause no. 2630 or
specification for Highway Works, Volume: I Clause 1015. It shall be 25 mm
less in depth than the thickness of the slab within a tolerance of 3mm and
provided to the full width between the side forms. It shall be in suitable lengths
which shall not be less than one lane width. Holes to accommodate dowel
bars shall be accurately bored or punched out to give a sliding fit on the dowel
bars.
The Contractor shall obtain a copy of the manufacturer's technical description

of its composition and qualities for his records will provide a copy to the
Project Engineer on request.
9.19
JOINT SEALING COMPOUND

The joint sealing compound shall be of hot poured, elastomeric type or cold
polysulphide type having flexibility, resistance to age hardening and durability.
For hot application, an approved Type F1 compound complying with the

requirements of BS 2499- 1 shall be used as indicated. For cold application,
an approved compound Type FB, as shown on the drawings, complying with
the requirements of BS 5212-1 shall be used. Only sealing systems which
include separately applied primers shall be used and the primers shall be as
PAGE 14 of 55
1845 of 2461
recommended by the manufacturers of the sealing compounds. Compounds

shall maintain adhesion and concrete which has been cleaned, dried and
primed according to the manufacturers instructions.
9.20
SEPARATION LAYER
A waterproof membrane shall be provided, which shall be two coats of
bituminous spray. Where a bituminous spray has been used to cure the dry
lean and wet lean concrete then only those areas which have been damaged
shall be re-sprayed after making good. A further coat of bituminous spray
shall be applied over the whole area and allowed to cure prior to concreting. If
a satisfactory finish to the dry lean or wet lean concrete cannot be achieved a
125 microns thick impermeable polythene sheet shall be used.
9.21
SIZE AND GRADING OF AGGREGATES

The maximum nominal size of aggregate for PQC shall not exceed 25mm.
continuously graded or gap graded aggregates may be used depending on
grading of fine aggregates. The particle size distribution of the combined
aggregates when plotted shall give a smooth curve throughout the whole
range of the sieve sizes.
The proportioning of other sizes of coarse aggregates shall be as

recommended in Table 2 of IS: 383-1970 and presented in Table below.
Proportioning of Course Aggregates for Pavement Concrete

Percentage passing of Nominal size
IS SIEVE DESIGNATION (mm) 40 mm
20 mm
63
40
20
16 mm
12.5 mm
100
85-100
0-20
-
100
85-100
-
PAGE 15 of 55
1846 of 2461
10 mm
4.75 mm
2.36 mm
0-5
-
0-20
0-5
-
Fine aggregates particle size distribution shall meet the limits of Grading Zone
1 or Grading Zone 2 as recommended in Table 3 of IS: 383-1970 and
presented in Table below. Particle size limits shall be met by the aggregate as
delivered or after blending two or more separate aggregates together before
or during batching.
Proportioning of Fine Aggregates for Pavement Concrete

IS SIEVE DESIGNATION (mm)
10
4.75
2.36
1.87
0.6
0.3
0.150
9.22
Percentage Passing for Fine Aggregates of

Grading Zone I
Grading Zone II
100
90-100
60-95
30-70
15-34
5-20
0-10
100
90-100
75-100
55-90
35-59
8-30
0-10
HANDLING AGGREGATES
Aggregates stockpiles shall be on concrete or other approved hard surfaces,
laid to falls to allow unrestricted drainage. Aggregates shall be stockpiled
separately for each size delivered from each source of supply. Each size from
each source shall be separated in the stockpiles by sturdy bulkheads. The
methods to be adopted to prevent overspill between adjacent stockpiles,
coning or segregation of the aggregate in the stockpile, particularly during
tipping, shall comply project specific requirements. Care shall be taken to
avoid crushing by stockpiling equipment. At all times the aggregates shall be
kept free from contact with deleterious matter. All aggregates shall be handled
from the stockpiles to the batching plant in a way which will ensure a uniform
grading of the material. Aggregates containing more than 5% passing a 4mm
sieve shall not be batched until they have been deposited for at least 8 hours.
All aggregates produced or handled by hydraulic methods or which have been
washed shall be stockpiled for at least 24 hours before batching. For Dry lean
PAGE 16 of 55
1847 of 2461
and Wet lean concrete, aggregates may be delivered either "all-in" or in

separate sizes.
9.23
BATCHING AND MIXING OF CONCRETE

Concrete shall be mixed in approved static mixers. The mixer shall be
controlled by an experienced operator. The proportion of each constituent in
the mixture by weight shall be that approved by the Project Engineer,
allowance being made as detailed below for the weight of free water in the
aggregates.
When Pavement Quality Concrete is specified the mixer and batching plant
shall be within the site boundary in a location to be approved by the Project
Engineer.
For mixers fitted with consister/wattmeter, a fixed amount of water shall be

added to the mixer and the workability shall be achieved by trickling additional
water into the mix as required to achieve the pre-determined reading on the
consister/wattmeter. This additional water shall be reported as part of the total
water by the batch plant computer. For mixing plant not fitted with consistor or
other moisture measuring devices, the allowance made for free water in
aggregates shall be determined, on representative samples from each of the
aggregate stockpiles.
Regular determinations shall be made before mixing starts each day and
afterwards at 4 hourly intervals until mixing stops for the day. Additional
determinations shall be made when mixing restarts after precipitation has
stopped production.
Following each determination of free water in the aggregates the precise

quantity of added water required to make up the total proportion of mixing
water approved shall be calculated. Aggregates from each stockpile and the
cement shall each be proportioned separately by weight to the tolerances
given in IRC: 15 - 2002. When the cement is delivered in bags, proportioning
PAGE 17 of 55
1848 of 2461
by weight of all constituents shall be based on the incorporation of whole

bags. The added water content calculated as detailed above may be
measured by either weight or volume to the tolerance given in IRC: 15 - 2002.
All mixing water shall be added to each batch in the approved static mixing
plant. Each admixture shall be measured separately at the mixer in pre-set
automatic dispensers to within +5% of the quantity approved for the mixture.
Admixtures shall be added with the water and the mixing time shall be such
as to ensure uniform distribution of the admixture throughout the batch.
Mixing within the approved static mixer shall continue until a well-mixed
homogenous concrete has been produced. The total mixing time shall be
agreed following trials with the mixture and mixing shall be carried out for this
period. The consistency of each batch of concrete shall be checked by use of
a watt meter monitoring the power supply to the mixer, or other proven
reliable device, and each batch of concrete shall be inspected prior to
discharge. Mixers shall be emptied before being charged with a new batch of
concrete. When delay of 30 minutes or more occurs during concrete
production, mixing shall not restart until the mixer and handling plant has been
thoroughly cleaned out. Mixing shall be carried out by an experienced
operator.
9.24
CONCRETE MIXERS
Mixers shall be sufficient mixing capacity to provide the required output
without overloading. Continuous mixers will not be allowed for PQ concrete
and bonded concrete. The use of a mixing plant other than that approved will
not be allowed. The weighing mechanism of each batching plant shall be
checked by either its manufacturer or an independent testing authority, who
shall certify its compliance with the tolerances given in IRC: 15 - 2002. The
Contractor shall submit the test certificate to the Project Engineer prior to the
start of mixing. Further checks shall be made and the certificates passed to
the Project Engineer at the end of each month during mixing and whenever a
mixer is re-sited or disturbed. The Contractor shall check the calibration of the
water measuring devices and admixture dispensers prior to start of mixing
and at weekly intervals during mixing. The results shall be passed to the
PAGE 18 of 55
1849 of 2461
Project Engineer. In addition, the Contractor shall himself check the accuracy
of the devices and dispensers each day before mixing starts and retain
records.
9.25
TIME ALLOWED FOR CONCRETING

The total time taken shall not exceed 90 minutes for either:
o
From the addition of water to the dry lean or wet lean mixture to the
completion of the layer (including placing curing membrane if
applicable); or,
From the addition of water to the Pavement Quality Concrete or

bonded concrete mixture to the finishing of the slab including placing
the initial curing membrane.
The method statement shall include details of a sequence of operations

commencing with addition of water at the mixer and finishing with final
texturing of the concrete surface giving estimated times for each operation
and an estimated overall time. The estimates given shall be verified on site
using the actual concreting equipment during the laying of the trial areas. A
record shall be kept for areas of concrete which fail to meet this requirement.
The record shall be produced on daily basis to ensure quality compliances.
9.26
WORK IN ADVERSE WEATHER
Wet Weather
Concrete shall not be laid during precipitation or when precipitation is

imminent. A suitable protection shall be provided to the concrete during
transportation and placing to enable completion of the finishing
processes (including the necessary joint forming) to a standard equal
to that of the approved trial area. Where a new PQC concrete surface
is damaged by precipitation it shall be replaced in accordance with
relevant clause of this document.
PAGE 19 of 55
1850 of 2461
Hot Weather
When the air/shade temperature is above 25C, or has been above

25C in the previous 24 hours, the temperature of the fresh concrete
shall be measured when mixing begins and at hourly intervals during
curing using the method described in IRC: 15 - 2002. Concrete of
temperatures above 30C shall not be placed and all necessary
measures shall be taken to achieve a uniform temperature below 30C
in the concrete at the time of placement.
9.27
CURING LIQUID
1)
For curing of dry lean and wet lean concrete and the vertical faces of
PQC slabs the curing liquid shall be Class A1-40, K1-40 or K1-60
bitumen emulsion. It shall be delivered to the site in weather-proof
containers each clearly marked by the supplier to show the Class and
binder contents of the emulsion, or in bulk carriers accompanied by a
certificate from the supplier stating the Class and binder content of the
consignment. Drums or other containers shall be stored under clean
conditions and protected from freezing. If the storage period exceeds
one month the drums shall be turned or inverted at least once a month.
2)
For initial curing of the top surfaces of PQC slabs: The curing
compound
for
Pavement
Quality
Concrete
surfaces
exposed
immediately after finishing shall be an approved spray-applied resinbased compound containing flake aluminium in finely divided
dispersion which will not separate out when the compound is applied
and which will produce a complete coverage of the sprayed surface
with a metallic finish. It shall become touch-dry within 5 minutes, stable
and impervious to evaporation of water from the concrete surface
within 60 minutes and shall not disintegrate for 3 weeks. When tested
the compound shall have an efficiency index of at least 90%. The
compound shall not react chemically with the concrete.
PAGE 20 of 55
1851 of 2461
SECTION IV: WATER BOUND MACADAM

The construction work for Water Bound Macadam Grading 2 shall be carried out in
accordance to Clause 404 of MORT&H specifications.
SECTION V: PAVEMENT QUALITY CONCRETE
9.28
NOMINAL SLAB THICKNESS

The nominal slab thickness of the PQC slab shall be 150mm. It shall be the
minimum thickness of the slab at any point after compaction and it shall not
be exceeded by more than 25mm.
9.29
MATERIALS
The contractor shall indicate to the Engineer the source of all materials to be
used in the concrete work with relevant test data sufficiently in advance, and
the approval of the Engineer for the same shall be obtained at least 45 days
before the scheduled commencement of the work. If the contractor later
proposes to obtain materials from a different source, he shall notify the
Engineer for his approval, at least 45 days before such materials are to be
used with relevant test data.
All the construction materials (i.e. cement, aggregates, water, admixtures,

mild steel bars, premoulded joint filler, joint sealing compound and separation
layer) shall comply with requirements stipulated in relevant clauses of this
document.
9.30
MIXTURE DESIGN
The PQC mixture shall be designed within the following limits:
o
Cement content per cum of concrete
400 kg/cum
Minimum Cement Content Free Water/Cement ratio
0.45 max
PAGE 21 of 55
1852 of 2461
Volume of entrained air (20mm aggregate)
51%
The Contractor shall be responsible for constructing a Pavement Quality

Concrete pavement slab such that the mean of the corrected core strength
values at 28 days 3 days of cores cut from the slab, then cured, prepared
and tested, all in accordance with relevant clauses of this document, is at
least 40N/mm2. Testing regimes and assessment of compliance shall be as
described in relevant clauses of this document.
The concrete shall be of consistence suitable for full compaction without

undue flow to be achieved with the plant used. When it is proposed to spread,
compact and finish the by semi-mechanized means as specified in relevant
clauses of this document, the aggregates shall be combined so as to comply
with the following requirements.
1.
The masses of the separate nominal single size coarse aggregates, as

specified in relevant clauses of this document, in the mixture shall be in
the fixed proportions chosen so that the total coarse aggregate
satisfies the grading requirements IS: 383.
2.
The mass of fine aggregate, as specified in relevant clauses of this

document, in the mixture shall be of a fixed proportion so that the mass
of fine aggregate is 30% - 37% of the total mass of the aggregate.
When it is proposed to spread, compact and finish the concrete using a
slip-form paver, as specified in relevant clauses of this document, the
aggregates shall be combined so as to comply with the following
requirements: o
The masses of the separate nominal single sized coarse

aggregate, as specified in relevant clauses of this document, in
the mixture shall be in the fixed proportions chosen so that the
total coarse aggregate satisfies the grading requirements for
20mm size aggregate.
The mass of fine aggregate, as specified in relevant clauses of

this document, in the mixture shall be of a fixed proportion so
PAGE 22 of 55
1853 of 2461
that the mass of fine aggregate is 32% - 40% of the total mass
of aggregate. The suitability of the design shall have been
demonstrated by trial mixtures and trial areas in accordance with
relevant clauses of this document.
9.31
TRIAL MIXTURES
The Contractor shall prepare trial mixtures in the approved mixer and with the
approved materials to the design requirements of relevant clauses of this
document. The concrete shall be of suitable consistence for full compaction to
be achieved without undue flow with the plant used. The consistence shall be
determined in accordance with one of the methods given in IS: 4031 Part 4
1995 or Compaction Factor (CF) for slip form concrete or slump for hand lay
concrete as given in IS: 1199 - 1959. A job standard value for the mixture and
plant being used shall be determined by the Contractor. For each mixture
proposed, a set of three pairs of 150mm cubes from at least four separate
batches shall be made, cured and tested in accordance with IS: 516 1959.
The mean of the two results from each pair shall be taken as the test result.
When the difference between a pair of results divided by their mean exceeds
15%, the test result shall be deemed invalid and shall be excluded from
assessment of compliance. If less than 9 valid results remain, the trial shall be
repeated. The mean strength at 7 days of all the valid results shall not be less
than 47N/mm2 for Grade 53 mixture or 41.8N/mm2 for Grade 43 mixture or
whatever higher values the Contractor considers necessary to ensure
compliance with the requirements of relevant clauses of this document.
If the test results fail to satisfy these requirements, the Contractor shall repeat
the trial making such adjustments to the mixture as are necessary to give
compliance. The Contractor shall report the proportions of the complying
mixtures to the Project Engineer. The information provided shall include plots
of the particle size distribution for the fractions of the combined aggregates
retained on a 4.0mm sieve and passing a 4.0mm sieve, confirming
compliance with the requirements of relevant clauses of this document.
Concrete laying shall not begin until consent has been obtained.
PAGE 23 of 55
1854 of 2461
9.32
TRIAL AREAS
Once the trial mixture has been approved trial areas shall be constructed. At
least one month prior to the construction of the trial length, the contractor shall
submit for the Engineers approval a detailed method statement giving
description of the proposed materials, plant, equipment and construction
methods. All the major equipments like paving train, batching plant, tippers,
etc. proposed in the construction are to be approved by the Engineer before
their procurement.
No trials of new materials, plant, equipment or construction methods nor any

development of them shall be permitted either during the construction of trial
length or in any subsequent paving work, unless they form part of further,
approved trials. These trial lengths shall be constructed away from the project
corridor but with at least sub base layer below it.
The contractor shall demonstrate the materials, plant, equipment and

methods of construction that are proposed for concrete paving, by first
constructing a trial length of slab, at least 60 m but not more than 300 m long
for mechanized construction and at least 30 m long for hand guided methods.
If the first trial is unsatisfactory, the contractor shall have to demonstrate his
capability to satisfactorily construct the pavement in subsequent trials.
Transverse joints and longitudinal joints of each type that are proposed for
dowel jointed unreinforced concrete slabs in the main work shall be
constructed with at least 2 expansion joints and first 150 m of longitudinal
construction joint for mechanized paving as the trial length for these joints.
A minimum of 12 pairs of 150mm cubes shall be collected during the laying of

a trial area. Each pair shall be from sample taken from a different delivery at
the point of placing. The cubes shall be cured and tested for compressive
strength for 7 days. The mean of the two results from each pair shall be taken
as a test result. When the difference between a pair of results divided by their
PAGE 24 of 55
1855 of 2461
mean exceeds 15%, the test results shall be deemed invalid and shall be
excluded from assessment of compliance. The mean of all the valid test
results shall not be less than 47/mm2 for Grade 45 & 53 mixes or 41.8N/mm2
for Grade 45/30%PFA blend No more than one result shall be below 35N/mm 2
for Grade 45 & 53 mixes or 31.3N/mm2 for Grade 45/30%PFA blend.
The saturated densities of the cores shall be determined and recorded.

Corrected core strengths shall be determined as described in relevant clauses
of this document. The mean corrected core strength value at 28 + 3 days of all
the cores taken from a trial area shall be at least 45N/mm 2 and no individual
value shall be below 33N/mm2. If this specified mean corrected core strength
value from cores is not achieved, the mixture design procedure shall be
repeated with a design target mean 7-day cube strength calculated to give at
least the specified mean corrected core strength value from cores, using the
relationship between mean values from cubes and cores established on the
trial area. Trial mixtures and trial areas shall be repeated using this revised
target mean 7-day cube strength value in place of the 47N/mm2.
If in the opinion of the Project Engineer, any of the trial areas fail to comply
with any of the Specification requirements, revisions to the mixture or
modifications to plant or working methods shall be made as the Contractor
considers necessary to ensure future compliance. New trial areas shall be laid
in accordance with this clause. All of the failed areas shall be cut out. Each
trial area will be approved by the Project Engineer when it has satisfied all of
the specified requirements and shall then be clearly marked. Until consent
has been given, no laying of Pavement Quality Concrete, other than trial
areas, shall begin. A written statement of the mixture proportions (by weight)
and the job standard value of the trial mix shall be submitted to the Project
Engineer for approval.
Approval of the materials, plant, equipment and construction methods shall be

given when a trial length complies with relevant clauses of this document.
9.33
PREPARATION OF UNDERLYING SURFACES
PAGE 25 of 55
1856 of 2461
In areas of new build PQC before laying the separation layer specified in
relevant clauses of this document, the surface shall be clean, smooth and free
of standing water, mud, grit and other extraneous matter. Where existing
pavements are to be overlaid with new PQC, including the provision of a
regulating layer, the following shall be carried out:
o
All vegetable growth and loose particles shall be removed from the
surface.
All joints and cracks 20mm or more wide in the existing pavement shall
be filled with lightly compacted 0/2mm size fine graded coated
macadam surface laid to a convex finish proud of the general surface
level. All other joints or cracks shall be levelled by removing extruded
material to a finish flush with the adjacent surface level. Potholes shall
also be made good with 0/2mm fine graded surface course or,
alternatively with hot rolled asphalt complying with IRC: 27-1967.
Before the regulating or separation layer is laid, the surface shall be

clean, smooth and free of standing water, mud, grit and other
extraneous material.
9.34
REGULATION OF EXISTING SURFACES

In areas where the existing pavement surfaces are to be overlaid with new
Pavement Quality Concrete, if there are areas where the depth of the new
construction will exceed the nominal slab thickness and tolerance as specified
in relevant clauses of this document, the levels of these areas shall be
regulated in advance of concreting.
The regulating course material along the edge of the area to be regulated
shall be raked and rolled in a way which will feather it out as far as is
practicable and which will obviate an abrupt step. Where existing pavements
are to be overlaid with new PQC, these areas shall be prepared in
accordance with relevant clauses of this document and regulated in advance
of the concreting. Marshall Asphalt and Rolled Dry Lean Concrete shall be
used as regulating materials. Hot Rolled Asphalt and Asphalt Concrete
PAGE 26 of 55
1857 of 2461
(Macadam) will only be permitted with prior consent of the Project Engineer.
When tested by the method, the divergence between the bottom of the
straight edge and the finished surface of the regulating material shall be more
than 15mm and shall show no abrupt steps.
9.35
FORMS
Forms for use with the laying methods specified in relevant clauses of this
document shall be purpose made square angled steel road forms, provided
with adequate devices for secure setting so that, when in place, they will
withstand, without springing or settlement, the impact and vibration of the
spreading, compacting and finishing plant. The depth of the forms shall be
adequate to fully support the slab thickness specified in relevant clauses of
this document. The thickness of packing below the forms shall not exceed
30mm. The ratio of height: base of forms shall not exceed 1.5:1. Forms shall
be set to the correct lines, levelled by careful adjustment with steel shims, and
shall be packed with Portland cement mortar. The mortar shall not extrude
beyond the vertical inside face of the form. The sections shall be tightly joined
by locked joints free from play in any direction. The forms and rails shall be
kept free from dirt, mud, and other extraneous matter. Forms which are not
straight within a tolerance of 3mm in 3m or which are battered shall be
removed from the site. Repaired forms shall not be used without the consent
of the Project Engineer. The line and levels of all forms shall be checked, and
corrected if necessary immediately before placing the concrete. The vertical
inside faces and tops of the forms shall be inspected to see that they are
clean, and shall be generously oiled to facilitate easy removal. Forms shall not
be removed until at least twelve hours after the finishing of the concrete.
Mortar packing along the vertical faces of the finished slabs shall be broken
down and removed.
9.36
PLACING SEPARATION LAYER

The separation layer complying with relevant clauses of this document shall
be checked and any repairs made prior to concreting. A second coat of
PAGE 27 of 55
1858 of 2461
bituminous spray shall then be applied at a rate of 0.7 to 0.9 liter/m 2. If a

smooth finish to the lean concrete cannot be achieved a polythene sheet
separation layer shall be used in accordance with relevant clauses of this
document. The sheet shall be laid flat without folds or ripples. The membrane
shall be laid beneath all joints with the laps specified. Except where it is laid in
strips under forms, the membrane shall be laid immediately before concrete is
spread. It shall be secured without puncturing against disturbance by wind.
Laps shall not be less than 150mm in any direction. Damaged or torn sheets
shall not be used. Standing water on the sheet shall be removed before
concreting is allowed to commence. Any sheets which become torn or
damaged before concrete is spread shall be replaced or overlain with
additional sheets.
9.37
TRANSPORTING AND PLACING OF CONCRETE MIXTURES

Freshly mixed concrete shall be transported without segregation or loss of
constituent materials. It may be required to be covered during transit and
while awaiting discharge to prevent wetting by precipitation or evaporation of
moisture. Sufficient delivery trucks shall be used to maintain a continuous
supply of concrete to the paving operations.
9.38
ROUTINE TESTS ON CONCRETE MIXTURES THROUGHOUT PLANT

MIXING
Workability
The workability requirement at the batching plant and paving site shall
be established by slump tests carried out during trial paving. The
optimum workability for the mix to suit the paving plant being used shall
be determined by the Contractor and approved by the Engineer. A
slump value in the range of 30 15 mm is reasonable for paving
works. These tests shall be carried out on every truck/dumper at plant
site and paving site initially when the work commences but
subsequently the frequency can be reduced to alternate trucks or as
per the instructions of the Engineer.
PAGE 28 of 55
1859 of 2461
Compressive Strength of Cubes
Samples from fresh concrete shall be taken as per IS: 1199 and cubes
shall be made, cured and tested at 28 days in accordance with IS: 516.
In order to get a relatively quicker idea of the quality of concrete,

optional tests on beams for modulus of rupture at 7 days, or
compressive strength tests at 7 days may be carried out in addition to
28 days compressive strength test. For this purpose, the values should
be arrived at based on actual testing. In all cases, the 28 days
compressive strength specified in Clause 3.3.3 shall be alone be the
criterion for acceptance or rejection of the concrete.
The random sampling procedure shall be adopted and spread over the
entire period of concreting with frequency as presented in Clause 15.2
of IS: 456-2000.
Three test specimens shall be made for each sample for testing at 28
days. Additional samples shall also be collected to determine the
strength of concrete at 7 days or at the time of striking or to check the
testing error.
The test results of the sample shall be the average of the strength of
three specimens. The individual variation should not be more than 15
percent of the average.
The concrete shall be deemed to comply with the strength

requirements as specified in Clause 16 & Table 11 of IS: 456-2000.
Air Entrainment
Samples of concrete for air content determination shall be taken in

accordance with the methods described in IRC 15 - 2002. The
Contractor shall measure the volume of entrained air in the concrete
PAGE 29 of 55
1860 of 2461
mixtures by the test method detailed in IRC 15 - 2002. One test shall
be made at the same time as each Compaction Index determination.
The concrete shall be sampled and tested at the point of delivery to the
paving plant. The Contractor shall periodically check the aggregate
correction factor and shall make a re-determination whenever the
aggregates or aggregate proportions are changed. If any tests fail to
come within the limits specified in relevant clauses of this document
two further tests on the same or next delivery shall be carried out. If
any of these also fail to satisfy this requirement the Contractor shall
immediately cease mixing and shall adjust the quantity and/or
uniformity of the air content of the mixture to ensure compliance.
9.39
SPREADING, COMPACTING AND FINISHING CONCRETE BY PAVING

TRAIN
The concrete shall be evenly distributed across the lane with a spreader box
designed to ensure uniformity of pre-compaction and continuity of spread. The
spreader box shall provide a method for striking-off the concrete to a regular
profile at a depth which gives an adequate surcharge so that after compaction
the nominal slab thickness as shown on the drawings or specified in relevant
clauses of this document will be achieved. The spreading equipment and
method will be approved by the Project Engineer on the basis of its
performance on the trial areas specified in relevant clauses of this document.
Equipment not approved shall be removed from the airfield and methods not
agreed will be prohibited. The concrete shall be compacted and finished by
approved self-propelled compacting and finishing machines, running on the
rails on the forms specified in relevant clauses of this document on at least
one side of the lane. Each train shall include units, incorporated in a single
carriage or as a combination of separate units, which strike-off the concrete to
the correct pre-compaction level by means of rotating paddles or a screw
device, compact it by vibration or by a combination of vibration and
mechanical tamping, and finish it with an oscillating screed. A duplication of
one or more units shall be included in the train if necessary to achieve the
compaction and finishing requirements of this Specification. The compacted
PAGE 30 of 55
1861 of 2461
concrete when hardened shall satisfy the test requirements specified in

relevant clauses of this document. All units shall be properly maintained. The
units shall be controlled by experienced operators at all times. Immediately
following the completion of compaction but before texturing or application of
the curing liquid, scraping straightedges shall be used to remove laitance and
minor irregularities from the surface. Scraping straightedges shall have 3 m
long blades and flexible handles of sufficient length to reach across the width
of a concrete lane. A scraping straight edge shall have a 3m long blade and a
flexible handle of sufficient length to reach across the width of a concrete
lane. Alternative designs may be proposed to the Project Engineer for
consent. Floats shall not be used. Concreting shall not commence until
consent has been obtained.
The scraping straightedge shall be operated by two persons, one on either

side of the concrete lane. While the concrete is still plastic and workable, the
blade of the straightedge shall be carefully positioned on the surface of the
concrete and parallel to the forms. The blade shall be worked uniformly
backwards and forwards across the full width of the lane by the first person
until all irregularities and blemishes have been removed from the surface of
the concrete. The blade shall then be picked up on the other side of the lane
by the second person, cleaned and moved along the lane by not more than
half the blade length. The scraping process shall then be repeated.
The concrete surface shall not be overworked. Hand floating shall not be
allowed, apart from the minimum required to finish alongside joints. Each unit
in the train shall be of the type and model recommended by the manufacturer
for mixtures complying with the requirements of this specification and for the
thickness of slab to be laid. The Contractor shall give details of the equipment
he proposes to use, together with a detailed methodology for the spreading,
finishing, texturing and curing operations. If the Contractors proposals are
considered satisfactory in principle, a qualified preliminary acceptance of the
equipment will be given by the Project Engineer. Final consent to the
equipment shall rest with the Project Engineer on the basis of the
performance of the particular units provided following an assessment of their
PAGE 31 of 55
1862 of 2461
compactive efficiency in the laying of the trial areas specified in relevant

clauses of this document. General laying of concrete shall not begin until final
9.40
SPREADING COMPACTING AND FINISHING CONCRETE BY SEMIMECHANISED MEANS

The concrete shall be evenly distributed across the lane by methods which
minimize differential pre-compaction and segregation. Where the maximum
lane width is greater than 4.5m a 360 dig excavator with a materials handling
bucket shall be used The spreader box shall provide a method for striking off
the concrete to a regular profile at a depth which gives an adequate surcharge
so that after compaction the nominal slab thickness as shown on the drawings
will be achieved. The spreading equipment and method will be approved by
the Project Engineer on the basis of performance on the trial areas specified
in relevant clauses of this document. Equipment not approved shall be
removed from the airfield and methods not agreed will be prohibited. Internal
vibration over the whole area of the slab shall be provided by poker vibrators.
These shall be inserted at points not more than 500 mm apart and withdrawn
when air bubbles no longer come to the surface. The vibrators shall not come
in contact with the joint filler boards or the underlying surface. They shall
ensure uniform compaction throughout. After internal vibration, the concrete
shall be struck-off at sufficient level above the forms to ensure that during
surface vibration the concrete is everywhere in contact with the compacting
beam. The concrete shall be compacted and shaped to the correct finished
profile and levels by the use of one or more trussed twin-beam
screed/compactor units providing air-driven multiple point high-frequency
vibration (Bunyan Roller. not tri-screeds) Each of these units shall be
supported on rails, the tops of the forms or on the edges of concrete
previously laid and shall be moved forward at a steady rate of 0.5-2.0 m/min.
If the unit is winched forward against an anchorage, this shall not be made by
fixture into previously laid concrete or the joint grooves thereof. If the profile,
degree of compaction or surface finish after the first pass of the unit(s) is not
adequate, a second pass may be made. The compacted concrete when
PAGE 32 of 55
1863 of 2461
hardened shall satisfy the test requirements specified in relevant clauses of

this document. Immediately following the completion of compaction but before
texturing or application of the curing liquid, Blue-Glider floats, 1.2m long shall
be used to remove laitance and minor irregularities from the surface. While
the concrete is still plastic and workable, the blade of the Blue-Glider float
shall be carefully positioned on the surface of the concrete and parallel to the
forms. The Blue-Glider float shall be worked uniformly across the full width of
the lane by the first person until all irregularities and blemishes have been
removed from the surface of the concrete. The concrete surface shall not be
overworked. Hand floating shall not be allowed, apart from the minimum
required to finish alongside joints. The Contractor shall give details of the
equipment he proposes to use, together with a detailed methodology for the
spreading, compacting and finishing operations. If the Contractors proposals
are considered satisfactory in principle, a qualified preliminary acceptance of
the equipment will be given by the Project Engineer. Final consent to the
equipment shall rest with the Project Engineer on the basis of the
performance of the particular units provided following an assessment of their
compactive efficiency in the laying of the trial areas specified in relevant
clauses of this document. General laying of concrete shall not begin until final
9.41
SPREADING, COMPACTING AND FINISHING CONCRETE BY SLIPFORM PAVER

The concrete shall be spread, compacted and finished in a continuous
operating by a train of approved self-propelled machines. The slip-form paving
machine shall compact the concrete by means of internal vibration and shape
it between sliding side forms by means of a conforming plate. The weight and
rigidity of the plate shall be adequate to enable the concrete to be laid
consistently to required levels and profiles within the tolerances permitted in
this Specification. The concrete shall be deposited without segregation in front
of the slip-form paver across its whole width to a height which at all times is in
excess of the required surcharge. The deposited concrete shall be struck-off
to the necessary differential surcharge by means of a quickly adjustable
PAGE 33 of 55
1864 of 2461
strike-off plate or a screw device extending across the whole width of the lane.
The level of the conforming plate shall be controlled automatically from the
guide wire(s), by sensors attached at the four corners of the slip-form paving
machine. The alignment of the machine shall be controlled automatically by at
least one sensor attached to it. The alignment and level of any ancillary
machines for finishing, texturing and curing of the concrete shall also be
automatically controlled relative to the guide wire(s). The slip-form paving
machine shall have vibration of variable output to suit different concrete
mixture characteristics, slab widths and thicknesses and rates of progress.
The compacted concrete when hardened shall satisfy the test requirements
specified in relevant clauses of this document. The machine shall have
sufficient power and mass to maintain uniform forward movement during the
placing of concrete in all situations. A guide wire shall be provided along each
side of each lane to be laid by slip-form paving plant. This may be reduced to
a single wire if the machine is working from skids on a lane already laid or
with a constant cross fall device from the one wire. Each guide wire shall be at
the required finished level of the edge of the slab as shown on the drawings,
or a constant height above it, and parallel to the required line of the lane joint
within a vertical tolerance of + 3mm. Additionally, one of the wires shall be at
a constant horizontal distance from the required line of a lane joint within a
lateral tolerance of + 6mm. The guide wires shall be supported from stakes
not more than 8m apart by connectors capable of fine vertical and horizontal
adjustment. The guide wires shall be tensioned on the stakes so that a 500gm
weight shall produce a deflection of not more than 20mm when suspended at
the mid-point between any pair of stakes. The end of the guide wires shall be
anchored to fixing points which shall not be closer to the edge of the slab than
the line of stakes. The ends of the guide wires shall not be anchored to the
stakes. Finishing behind the slip-form paving machine shall be carried out
mechanically by means of a longitudinal finishing beam. The concrete surface
shall not be overworked. Hand floating shall not be allowed, apart from the
minimum to finish alongside joints. Purpose made forms with adjustable jacks
may be used immediately behind the slip form paving machine to prevent the
edges of the newly compacted concrete from slumping. Sufficient forms for a
PAGE 34 of 55
1865 of 2461
continuous length of 50m of joint shall be available for use at the beginning of
each laying shift. Use of makeshift forms, props or jacks shall not be allowed.
All units shall be properly maintained. The units shall be controlled by

experienced operators at all times. The Contractor shall give details of the
equipment he proposes to use, together with a detailed methodology for the
spreading, finishing, texturing and curing operations. If the Contractors
proposals are considered satisfactory in principle, a qualified preliminary
acceptance of the equipment will be given by the Project Engineer. Final
consent to the equipment shall rest with the Project Engineer on the basis of
the performance of the particular units provided following an assessment of
their compactive efficiency in the laying of the trial areas specified in relevant
clauses of this document. General lying of concrete shall not begin until final
9.42
METHODS OF FORMING JOINTS

The methods of forming joints and grooves are specified in relevant clauses of
this document. All joints shall be straight throughout their length and shall be
vertical. The pavement surfaces across the joints shall be finished so as to
satisfy the regularity teat requirements of relevant clauses of this document.
9.43
EXPANSION JOINTS
Expansion joints between new and previously laid or existing concrete
pavements, around box-gutters, and where shown on the drawings, around
other obstructions in the continuity of the new slab, shall be formed by placing
the approved joint filler board specified in relevant clauses of this document
against the exposed face of the existing slab, gutter or obstruction, prior to the
laying of the concrete. Only where lengths of joint filler greater than the
standard length for the approved product are required shall two lengths be
butt jointed together. The board shall be held rigidly in position so that it
cannot be displaced or disturbed during subsequent concreting. All necessary
measures shall be taken to ensure that "bridging" of concrete does not occur
PAGE 35 of 55
1866 of 2461
beneath or around lengths of filler. Alternatively, the slip formed concrete shall
be cut to its full depth with a 3mm wide blade at the time of cutting crack
inducing grooves to ensure complete separation before cracking can occur.
After completion of concrete, at the time of forming the sealing grooves, if
required, a 25mm wide blade shall be used to form a void to receive the filler
board. Alternatively, main expansion joints may be performed in advance of
concreting by placing the joint filler board specified in relevant clauses of this
document in the required location prior to the laying of the concrete. The filler
board shall be held rigidly in position against a steel channel secured firmly to
the surface on which the concrete is being laid, or in an approved cradle
assembly designed for the purpose, equally rigid and equally secured, which
cannot be displaced or disturbed during subsequent concreting. The filler
board shall extend the full depth of the joint with no gap between the bottom
of the board and the surface on which it is resting. The concrete shall be
spread, compacted and finished up to the filler board on one side, and after
the initial set of the slab against the board, the channel or cradle shall be
removed before laying of the concrete continues from the other side of the
board.
A purpose-made, bull nosed arris trowel shall be the final tool to be drawn,
lightly and carefully, along the edge of the concrete, on the line of the filler
board, to leave the new joint edge rounded-off to a radius not greater than 5
mm.
9.44
SEALING OF EXPANSION JOINTS

Prior to sealing of the expansion joints specified in relevant clauses of this
document approved rotary cutters shall be used to remove the top of the filler
board to the required depth. Removal of the filler board by ploughs will not be
permitted. The exposed inside faces of the concrete along the edges of the
joints shall be scoured with a power-driven rotary wire brush until all loose
fractions have been dislodged. Scouring shall be carried out with care to
ensure that the arises are not damaged. Each joint shall then be inspected to
ensure that the filler board is exposed for the whole length of the joint and
PAGE 36 of 55
1867 of 2461
extends without bridging either from edge to edge of the lane or continuously
longitudinally. Any deficiency shall be corrected with concrete saws, with
blades suitably set to cut the full width of the joints. The inside faces shall then
be rescoured, grit blasted and re-cleaned. A primer shall be applied to the
cleaned concrete faces as specified by the compound manufacturer. A
separation membrane shall be laid on the exposed filler board. Sealing
compounds in accordance with relevant clauses of this document shall be
prepared and poured by the manufacturer or the manufacturers approved
agent. During sealing, the joint and filler board shall be touch dry. The air
temperature shall exceed the minimum specified for pouring by the
manufacturer of the compound. Cold poured compounds shall be prepared
and poured in accordance with the manufacturers instructions. Hot poured
compounds shall be heated in an indirectly heated melter-pourer to a
temperature within the pouring range recommended by the manufacturer.
They shall not be heated at this temperature for a period longer than the safe
heating time stated by the manufacturer. The method of heating shall be proof
against fire risk and explosive hazard. The melter-pourer shall include a
device for the mechanical agitation of the compound during heating and an
accurate thermometer for gauging the temperature of the compound. It shall
be cleaned out at the end of each days work. Reheated material shall not be
used.
9.45
CONTRACTION GROOVES
Contraction grooves shall be sealed as shown on the drawings. Contraction
grooves shall extend vertically from the surface of the slab to a depth of 40
mm, or to a depth equal to one -fifth of the actual thickness of the slab,
whichever is the greater.
The grooves shall be sawn to a maximum width of 3 mm. The Contractor shall
saw the grooves as soon as the concrete has gained sufficient strength to
prevent the surface being ripped or damages by the operation. The Contractor
shall ensure that random cracking due to late saw-cutting does not occur and
that all sawing is completed within 18 hours of concrete finishing. All sawn
PAGE 37 of 55
1868 of 2461
joints shall be flushed out using a water pressure jet to remove all slurry and
other debris immediately after sawing while not damaging the joint. Joints
shall be kept clean and free of deleterious material until the joint is sealed.
When the trial lanes required by relevant clauses of this document are laid the
Contractor shall conduct trials to prove that the type of saw and blade he
proposes to use is suitable for the intended purpose on the concrete with the
particular ingredients being used. If the cutting of the grooves fails to meet the
time limit given above or if cracking should occur before or during saw cutting,
the placing of the concrete shall stop until the difficulties have been resolved.
Where shown on the drawings construction joints and contraction grooves
shall be widened, prepared and sealed as specified below. After removal of
the polythene sheeting used for curing as specified in relevant clauses of this
document, concrete saws with diamond tipped blades shall be used to form
slots for sealing at the tops of joints. Each slot shall be 13mm (+3, -0mm) wide
and shall be of sufficient depth to allow a minimum sealant depth of 15mm for
cold applied or 20mm for hot applied sealing compound (or the minimum
sealant depth specified by the manufacturer, if this is greater) with the top of
the seal finished 5mm below the pavement surface. An accurate method of
guidance approved by the Project Engineer on the basis of its performance on
the trial area specified in relevant clauses of this document shall be used to
ensure that the edges of the slots area parallel and straight. Each slot shall be
prepared for sealing in the manner specified for expansion joints in relevant
clauses of this document. In contraction grooves, the top of the groove below
each slot shall then be plugged with closed cell polyethylene foam or inert
caulking cord. If recommended by the manufacturer of the sealing compound
a bond breaking tape shall be placed at the base of each slot. The slots shall
then be primed and sealed in the manner specified for expansion joints in
9.46
CONSTRUCTION JOINTS
All construction joints shall be sealed joints as shown on the construction
drawings. The longitudinal construction joints shall be made against the forms
specified in relevant clauses of this document or against the travelling forms
PAGE 38 of 55
1869 of 2461
or conforming plate of a slip form paving machine, and against previously laid
concrete as the laying of the concrete proceeds. At the end of a days work,
and when mixing stops for more than 90 minutes, transverse construction
joints shall be made. They shall be constructed against a form, in lieu of the
contraction grooves specified in relevant clauses of this document. A purposemade bull nosed arris trowel shall be the final tool to be drawn, lightly and
carefully, along the edge of the concrete between it and the forms to leave it
rounded off to a radius not exceeding 5 mm. The surface texture, specified in
relevant clauses of this document shall extend to the edge of the 5 mm arris
next to the forms. The forms shall be removed without damaging the concrete,
particularly the rounded arris. Any minor surface cavities exposed shall
immediately be filled with mortar composed of 1 part cement to 2 parts fine
aggregate. The exposed vertical face of the slab shall then immediately be
painted with a uniform film of bitumen emulsion as specified in relevant
clauses of this document.
When the lane of concrete has been placed by slip-form paver, before an
adjacent lane is laid against it the straightness of the vertical edges of the lane
shall be checked using a 1m long straightedge. Any deviations in excess of
5mm beneath the straightedge shall be corrected by grinding, or by any other
means acceptable to the Project Engineer. Any concrete which may have
escaped beneath the side forms of the paver shall be trimmed back the same
straightedge tolerance. Any minor surface cavities left by the slip forming
process shall be filled with mortar composed of 1 part cement to 2 parts fine
aggregate. The exposed vertical face of the slab shall then immediately be
painted with a uniform film of bitumen emulsion as specified in relevant
clauses of this document.
Where concrete is to be placed against hardened concrete laid under this

contract the exposed edge of the hardened concrete shall be examined
immediately before laying commences. Any cracks which have been induced
in the hardened concrete by the contraction grooves shall be noted and taped
over to prevent ingress of grout from the fresh concrete. In addition,
contractions grooves which are found to have induced cracks shall be sealed
PAGE 39 of 55
1870 of 2461
temporarily by use of paper cord or other approved means to prevent ingress

into the cracks of slurry created while sawing contraction grooves in the new
slab. The cord and any slurry, grout or other materials lodged in the grooves
shall be removed before the pavement is considered complete. During the
laying of the adjacent slab, the concrete along the surface margin shall not be
overworked. Only a minimum of hand tool finishing will be allowed. For
unsealed joints when the slab on the second side of a construction joint is
laid, a purpose-made bull nosed arris trowel shall again be the final tool to be
drawn, lightly and carefully, along the edge of the slab to produce an arris of
5mm maximum radius to match that on the first side. All sealed construction
joints shall be widened, prepared and sealed in the same manner as
contraction grooves as specified in relevant clauses of this document.
9.47
JOINTS BETWEEN
SURFACING
NEW
PQC
AND
EXISTING
BITUMINOUS
The joints shall be made in accordance with the drawings. The existing
bituminous pavement shall be cut back from the line of the junction between
the bituminous pavement and the new concrete pavement by a maximum
distance of 500mm to permit the erection of the forms specified in relevant
clauses of this document or to allow the passage of the side forms of a slipform paver. The dry lean concrete base shall then be carried through to abut
the cut-back edge of the existing pavement. If the existing pavement is thicker
than the new pavement, the extra thickness at the base of the pavement in
the cut-back area shall be restored with dry lean concrete, laid and
compacted in separate layers if necessary to comply with the specified
requirements for maximum dry lean concrete layer thickness. After the
specified forms have been fixed on the surface of the dry lean concrete, the
new Pavement Quality Concrete surfacing shall be completed. Immediately
after the forms have been removed, or, when a slip-form paver has been
used, prior to refilling the space between the new concrete and the bituminous
surfacing, the exposed vertical edge of the new concrete slab shall be painted
or sprayed with the bitumen emulsion specified in relevant clauses of this
document. The space between the new concrete slab and the existing
PAGE 40 of 55
1871 of 2461
pavement shall then be filled with dry lean concrete compacted to within
100mm of the surface of the new slab. The remainder of the space shall be
filled with hot rolled asphalt complying with IRC 27 -2000 Designation 35%
0/14 incorporating crushed rock aggregate and 70/100 pen bitumen binder.
Before any asphalt is placed, all exposed surfaces to which it is to be bonded

shall be tack coated in accordance with BS 434-2, Clause 14. The asphalt
shall be placed in two layers, each of 50mm and separately compacted. At the
time of compaction, the temperature of the mixture shall not be less than
120C. The final layer shall be laid slightly proud of the existing asphalt
surfacing. Hand tampers shall have a mass of not less than 25 kg and a face
area not exceeding 0.065 m2.
Where ramps are to be provided between new Pavement Quality Concrete

and existing bituminous pavements, these shall be constructed to the details
shown on the project drawings.
9.48
ROUTINE TESTS
ACCURACY)
ON
CONCRETE
AFTER
LAYING
(SURFACE
The finished surface levels of the concrete shall conform to the levels, profiles
and contours shown on the drawings and the finished levels of the underlying
courses are to be such that at no points will the thickness of the concrete be
less than the nominal thickness specified. Levelling shall be undertaken on
the corners of each bay. Where the Project Engineer so directs, deviations
from the required levels exceeding 6 mm shall be corrected by cutting out and
replacing the concrete in the offending area by the means specified in
relevant clauses of this document. Where the Project Engineer is satisfied that
the permitted deviation is exceeded only at a local high spot, correction by an
approved grinding method and/or scoring as specified in relevant clauses of
this document will be permitted. At junctions between new and existing or new
and new pavements the level difference must not exceed 3mm at any point.
Tests for the surface regularity of the finished Pavement Quality Concrete
shall be carried out as soon as the polythene sheet used for final curing is
PAGE 41 of 55
1872 of 2461
removed, i.e. 4 days after laying unless delayed by frost. The following
minimum number of tests shall be made on each lane: 1.
One test at each longitudinal construction or expansion joint, with test

alignment normal to the joint, for each 10m of such joint. The
straightedge shall be positioned with 2m of its length on the test lane
and 1m on the adjacent lane. When the adjacent lane has yet to be
laid, the straightedge shall be positioned with one end on the joint line.
2.
Two tests across each transverse construction or expansion joint, with

test alignment normal to the joint.
3.
Two tests on the interior of the lane, one test aligned normal to and one
parallel to the longitudinal joints, for each 50 m 2 of surface laid. The
positions for test shall be selected by the Project Engineer and the
testing shall be carried out in his presence. Neither the clearance
beneath the straightedge between points of contact with the surface
during test nor the calculated height of any high spot shall exceed 6mm
in tests at longitudinal joints or 3mm in other test positions. Points on
the surface which fail to comply with this requirement shall be marked
and the following action taken: o
At each failure position at a longitudinal joint, ten further tests,

five in each direction, shall be made at 1m intervals along the
lane. If more than two of these additional tests also fail, or if in
any test, including the initial one, clearance beneath the
Straightedge between points of contact with the surface or
calculated height of any high spot exceeds 8mm, the length of
the lane concrete bounding the failure positions shall be
condemned.
At each failure position on a transverse construction or

expansion joint, further tests shall be taken at 1m intervals along
the whole length of joint to determine the extent of the
deficiency. Correction by an approved grinding method and/or
scoring as specified in Clause 3.3.31 may be allowed but, if this
is not feasible, one or both of the bays of concrete adjoining the
joint shall be condemned.
At each failure position on the interior of a lane, the straightedge
PAGE 42 of 55
1873 of 2461
shall be used as directed by the Project Engineer within the bay

containing the failure to determine whether the failure is due to
an isolated high spot. Isolated high spots may be corrected by
an approved grinding method and/or scoring as specified in
Clause 3.3.31. Bays containing more than one high spot or one
or more depressions which will cause water to pond shall be
condemned. If the Contractor fails to meet the specified
requirement for surface accuracy in any two consecutive days
work all concreting work shall stop until the spreading,
compacting and finishing processes have been checked, the
cause of the failure has been established and corrections have
been made, to the satisfaction of the Project Engineer.
9.49
TEXTURING OF SURFACE
After eliminating surface blemishes with scraping straightedges, as specified in

relevant clauses of this document or longitudinal finisher as specified in relevant
clauses of this document and before the application of the curing liquid specified
in relevant clauses of this document, the surface of the concrete shall be textured
as detailed below.
1.
All surfaces except aircraft wash downs and hangar floors While the
concrete is still soft enough to take an impression, a 900mm wide
texture brush with 100mm long flat steel bristles shall be drawn,
mechanically or by hand, from a bridge platform spanning the lane,
lightly across the surface at right angles to the slab edges and square
to the runway or taxiway centreline, to match existing texture direction
in areas of bay replacement or with the cross fall of the pavement.
Care shall be taken not to damage that arises on the joints during this
operation.
2.
Hangar Floors: The surface shall receive no texturing treatment.

Following the use of the scraping straightedge or longitudinal finisher,
steel floats may be used to the minimum extent necessary to remove
minor blemishes. If a proprietary finish to the floor is shown on the
PAGE 43 of 55
1874 of 2461
drawings, the manufacturers instructions n finishing and texturing the

concrete shall be followed.
3.
Trial Areas: The trial area(s) specified in relevant clauses of this

document shall be textured as above and clearly defined section(s) of
the trial area(s) shall be approved as standard(s) by the Project
Engineer. They shall be permanently marked Àpproved Texture` and
dated. Uniform texture(s) similar to the approved texture(s) shall be
reproduced throughout the work. The surface texture shall satisfy the
texture depth test requirements specified in relevant clauses of this
document.
9.50
INITIAL CURING
Immediately after the surface of the compacted concrete has been textured as
detailed in relevant clauses of this document, initial curing of the concrete
surface shall be carried out with the approved compound specified in relevant
clauses of this document. The curing compound shall be handled and applied
strictly in accordance with the manufacturers instructions. Each container of
curing compound shall be agitated vigorously immediately prior to use to
ensure full dispersal of the flake aluminium within the compound. The
compound shall be sprayed on at a uniform rate of spread, which shall be
sufficient to obtain a complete coverage of the surface and shall be at least
equal to that specified by the manufacturer on the consignment certificate.
After application, the compound shall give a continuous film of uniform
thickness with an unbroken metallic finish, free from pinholes or other
imperfections, over the entire surface of the concrete. When the concrete has
been compacted by a slip-form paving machine, as specified in relevant
clauses of this document, the compound shall be applied by hand held lances
operated from the work platform, supplied by mechanical pump. The
compound shall be continuously agitated and mixed in its container during
spraying by mechanical means. The nozzles shall be arranged in a manner
that will ensure a uniform coverage, free of streaks and lines, and shall be
protected by an efficient shield to prevent wind-blown losses. Hand operated
spraying equipment shall be held on each site to complete the spraying of
PAGE 44 of 55
1875 of 2461
concrete already laid in the event of temporary breakdown of the mechanical

sprayer. In this event further concreting shall cease until the Contractor
provides an efficiently operating mechanical sprayer to the satisfaction of the
Project Engineer. When the concrete has been laid by semi-mechanized
means in accordance with relevant clauses of this document, or by hand, the
Contractor will be allowed to use hand operated spraying equipment for the
whole of the application. Immediately after removal of forms, exposed vertical
edges shall be painted or sprayed with the bitumen emulsion specified in
9.51
FINAL CURING
Where there is a risk of rain, following the initial curing specified in relevant
clauses of this document the concrete shall be immediately protected for a
period of not less than 4 hours by covered frames, spanning the lane. Frames
shall be wheeled and secured once in place to avoid movement by wind or jet
blast. The covering shall be of an approved opaque light coloured material. It
shall be stretched over the top of the form so that it is not less than 75 mm or
more than 500 mm above the surface of the concrete. The sides and ends of
the frames shall be panelled down to the surface level of the concrete. The
frames shall be positioned to give complete coverage of the concrete.
Tentage shall be available at all time in case of unforeseen heavy showers.
All covered frames and sheeting shall be kept in good condition.
9.52
ROUTINE TESTS ON CONCRETE AFTER LAYING (CORES)

The density of the compacted concrete shall be such that the total air voids
are not more than 3 per cent. The air voids shall be derived from the
difference between the theoretical maximum dry density of the concrete
calculated from the specific gravities of the constituents of the concrete mix
and the average value of three direct density measurements mad on cores at
least 150 mm diameter.
The mean value, for the purpose of testing shall be defined as the mean result
PAGE 45 of 55
1876 of 2461
for each construction phase calculated separately. Similarly sets for the
testing regime shall be defined as for each phase of pavement construction.
Depth, Voidage and Compressive Strength of Cores
1.
For the first 500 m3 of routine production of Pavement Quality

concrete, one core shall be cut from each 50 m 3 of concrete laid
or one per day. Thereafter, the rate shall be one core per 100 m 3
laid or one per day. Each core shall be taken from a location
corresponding to a delivery of concrete sampled for cube testing
in accordance with Clause 3.3.11(2).
2.
The cores shall be prepared by trimming and capping or

grinding each end for compression testing. Each core shall be
reduced in length by sawing off the top so that the lower section
shall have a length/diameter ratio in the range of 1.0 to 2.0 as
recommended below. The core shall then be stored in a curing
tank before testing at 28 3 days. The saturated density and
compressive strength shall be determined in accordance. The
corrected core strength of the concrete shall be calculated using
the values presented as below.
Length/diameter ratio
3.
Correction factor
1.00
1.00
1.25
1.07
1.50
1.12
1.75
1.16
2.00
1.18
Each core shall comply with all of the following three

requirements: o
The total length of the core shall not be less than the
nominal slab thickness nor exceed it by more than 25mm.
The results shall be no worse than those of the
PAGE 46 of 55
1877 of 2461
approved core, which was cut from the approved trial

area in accordance with Clause 3.3.5, in respect of
honeycombing and visible voids.
o
The corrected core strength at 28 + 3 days shall not be

less than 33N/mm2.
4.
If any core fails to satisfy any of the requirements of 3) above,

four additional cores shall be cut at 5m spacing along the lane in
positions symmetrical about the position of the failed core. All 4
new cores shall satisfy requirements 3(i) and 3(ii).
If the failure of the original core included lack of compliance with

requirement 3(iii), the 4 new cores shall be prepared and tested
for compressive strength and using the correction as presented
above at 35 3 days. The mean 35-day corrected core strength
value of the 4 cores shall be at least 40N/mm2 and no more
than one individual value shall be below 36N/mm2. If either or
both of these requirements and/or either or both of requirements
(i) and (ii) are not satisfied, the area of pavement slab
represented by the 4 cores shall be condemned. The minimum
area shall be taken as the 20 m length of the pavement lane
symmetrical about the core positions and the area shall extend
to the nearest transverse joint. The extent of any further
unacceptable concrete in each direction along the lane adjacent
to the condemned are shall be investigated by cutting at 5m
spacing and testing additional groups of 4 cores until a group in
each direction satisfies all of the requirements.
5.
The mean 28-day corrected core strength value for the set of
routine cores representing the first 500 m3 of normal production
and for subsequent sets each representing 1000 m 3 of
production (to correspond with sets of 7-day cube strength
values specified in 2) above shall not be less than 45N/mm2. If
the mean value from any set of results falls below 45N/mm2,
either: -
PAGE 47 of 55
1878 of 2461
The concrete mixture shall be adjusted to increase its

strength, using the relationship between cube and core
strengths obtained from this set of results to estimate the
revised
target
mean
7-day
cube
strength
value
necessary, or,
o
If core densities indicate that compaction is inadequate,

measures shall be taken to the satisfaction of the Project
Engineer to improve compaction.
If the mean value from a set of results is below 40N/mm2, work

shall cease until the trial mixture and trial area procedures
specified in Clauses 3.3.4 and 3.3.5 have been repeated. The
area of pavement from which a set of
cores fail to achieve
mean 28-day corrected core strength of 45N/mm2 shall be

condemned should the Project Engineer so instruct.
9.53
ROUTINE TESTS
TEXTURE)
ON
CONCRETE
AFTER
LAYING
(SURFACE
Where a surface texture is required, it shall be measured by volumetric patch

tests as soon as final curing is achieved, i.e. 4 days after laying, unless
delayed by frost. Three sets of five tests shall be made with a frequency of
one set along each lane of concrete for each 150m laid, or a minimum of one
set per days work when this is less. The position of the test shall be selected
by the Project Engineer. The 5 positions for each set of tests shall be at the
center point of each quarter of the bay on a diagonal line drawn between
opposite corners of the bay and at the intersection point of the diagonals. For
runways, short take-off and landing (STOL) strips, concrete dummy deck
facilities and rapid exit taxiways, the average mean texture depth (MTD) for
each set of tests shall not be less than 0.85mm or greater than 1.1mm. Not
more than one test of each set shall show a MTD less than 0.75mm or greater
than 1.2mm. For taxiways and hard standings, the average MTD for each set
of tests shall not be less than 0.5mm and not more than one test of each set
shall show a MTD less than 0.35mm When compliance with minimum MTD
PAGE 48 of 55
1879 of 2461
requirement is not achieved over localized areas less than 20m 2 the
deficiencies shall be made good by transverse scoring by the method
specified in relevant clauses of this document. For widespread or repeated
failure the concrete shall be broken out and replaced as specified in relevant
clauses of this document. When compliance with the maximum MTD
requirement is not achieved, the Contractor shall submit proposals to the
Project Engineer for remedial actions to reduce the MTD to acceptable levels.
Where the proposals are not accepted or the deficiencies cannot be
subsequently achieved, the concrete shall be broken out and replaced as
specified in relevant clauses of this document.
9.54
FILLING CORE HOLES

Before refilling the hole from which a core has been cut the base of the hole
shall be coated with two coats of bitumen tack coat or a layer of building
paper cut to suit. The hole shall be filled with the approved Pavement Quality
Concrete mixture and shall be tamped in separate lifts of not greater than
100mm. The surface shall be finished flush with the adjacent concrete and
with a texture to match it. All cores shall be filled within 24 hours of being
taken.
9.55
TRAFFIC ON FINISHED CONCRETE

Except for the saws specified in relevant clauses of this document and the
coring rigs specified in relevant clauses of this document, the concrete shall
not be subjected to the weight of any traffic or equipment for at least 7 days
after laying. Then, and only subject to the consent of the Project Engineer, the
concrete shall only be used by the minimum of equipment essential for
continuing the work, and only by traffic when no other means of access to the
lane under construction is possible. Metal wheels shall not be allowed to run
on the concrete at any time. The crawler tracks of slip-form pavers shall be
fitted with neoprene pads.
The Contractor shall be responsible for the protection of the finished concrete
PAGE 49 of 55
1880 of 2461
and shall take precautions to prevent damage to the edges, marking of the
surface, or shattering of the joint or groove arises. Any defacements, defects,
or damage shall be made good by the methods and to the standards of this
Specification.
9.56
CUTTING OUT CONCRETE

Existing pavement concrete or new pavement quality concrete that has been
condemned shall be removed within 3 days of the Contractor being notified of
such condemnation. When concrete is cut out it shall be removed for the full
depth of the slab. When the concrete bays are less than 4.5 m square, or
equivalent area, or have an irregular shape, the whole bay shall be removed.
When the bays a 4.5m square or larger, a half bay only may be removed,
providing the half bay which will remain is free of defects. The bay to be
removed shall be defined on four sides by bay joints or grooves. When only
three sides are so defined, the additional side shall be marked out by a
straight saw cut at least 40mm deep. The joints and grooves shall be cleaned
out and a leg of a length of rolled steel angle wrapped in Hessian or other
shock absorbing material shall be carefully tamped into the saw cut and joints
to cover and protect the arises of adjoining concrete during drilling and
breaking out. Full depth cores shall be made adjacent to grooves and joints
and the bay or section shall be carefully broken out between the holes with
percussion chisels or feather wedges. The exposed edges of the adjoining
bays or section shall be trimmed to a vertical and reasonably fair face. With
the consent of the Project Engineer, full depth saw cuts may be used instead
of coring and wedging. Care shall be taken to ensure that all concrete
remaining in the vicinity of cutting-out is sound and without fracture. If damage
or fractures are discovered, an additional area of concrete shall be cut out by
the means specified in this Clause until only sound concrete remains.
9.57
REPLACEMENT OF CONCRETE
Before replacing the concrete the separation layer shall be repaired, as
specified in relevant clauses of this document. If an exposed edge of the
PAGE 50 of 55
1881 of 2461
adjoining bay was that of an expansion joint, filler board shall be placed
against the exposed edge, and the joint shall be reformed and sealed in the
manner in relevant clauses of this document. All other edges of adjoining bays
or sections exposed by cutting out, shall be replaced as construction joints as
specified in relevant clauses of this document. The approved Pavement
Quality Concrete mixture shall be spread and compacted as specified in
relevant clauses of this document and finished to the surface accuracy
specified in relevant clauses of this document. The concrete shall be textured
to relevant clauses of this document, and shall be cured, as specified in
9.58
SCORING AND GROOVING HARDENED CONCRETE
Scoring
All areas to be scored shall be treated transversely by a single pass of

a cutting drum incorporating 3mm diamond saw blades at 6mm
centers. The drum shall be set to give a uniform 3mm depth of scoring
over the whole surface. If the requirements, specified for texture depth
are not achieved scoring shall stop until either adjustment have been
made to the setting or new drums have been fitted to the satisfaction of
the Project Engineer.
Grooving
Where indicated on the Contract drawings grooving shall be carried out

using a suitable machine with diamond tipped saw blades. Grooves will
be continuous for the entire length of the relevant area and
perpendicular to the centreline. Grooves shall terminate within 1.5 to 3
meters of the pavement edge to allow for operation of grooving
equipment and shall not extend into the drainage channel. The grooves
shall be 4mm in depth by 4mm in width at a spacing of 25mm center to
center. Grooving shall not be carried out within 150mm of the runway
centreline, or within 50mm of transverse joints or working cracks,
PAGE 51 of 55
1882 of 2461
through compression seals, in-runway lighting fixtures or similar items,

or the first three meters either side of an arresting barrier cable which
requires hook engagement for operation.
9.59
SAW CUTS ADJACENT TO AGL FITTINGS, MANHOLE COVERS, PIT

COVERS ETC.
Where the manhole covers or pit covers are closer than 1m to the edge of the
bay, additional grooves shall be sawn to a maximum width of 3mm and to the
depth shown for contraction joints. The location of the grooves shall be as
shown on the construction drawings.
9.60
HIGH PERFORMANCE JOINT

A high performance joint shall be constructed in the locations shown on the
drawings between Pavement Quality Concrete and bituminous materials. The
joint shall be an Armourscreed AS100, Fibrescreed or similar approved inset
joint installed as the manufacturers instructions.
SECTION VI: TESTING
9.61
TEST RESULTS
The Contractor shall be responsible for carrying out all the testing in
accordance with the requirements of this Section and shall provide the Project
Engineer with a written copy of all results on request. Testing shall be started
on specimens within 2 working days of sampling and shall be carried out in an
expeditious manner.
9.62
TESTS FOR INITIAL APPROVAL OF MATERIALS

Before mixing starts and as part of the Quality Assurance requirements the
Contractor (or his materials supplier/s on his behalf) shall carry out relevant
tests to determine the properties and grading of the aggregates for
comparison with the relevant specification clauses as listed in Table below.
PAGE 52 of 55
1883 of 2461
Tests for Initial Approval of Materials

Test
Test Reference
Coarse Aggregate
Sieve Analysis
IS: 2386 1963 Part 1
Flakiness Index (Shape Index)
IS: 2386 1963 Part 1
Resistance to Fragmentation (Crushing

Value or Impact Value)
Fines
Content
(Material
Finer
than
0.075mm Sieve)
IS: 2386 1963 Part 4

IS: 2386 1963 Part 1
IS: 2386 1963 Part 3
Shrinkage
Magnetic Permeability
Fine Aggregate
Sieve Analysis
IS: 2386 1963 Part 1
Durability (Magnesium Sulphate Value)
IS: 2386 Part 5
Fines
Content
(Material
Finer
than
0.075mm Sieve)
IS: 2386 Part 1
Magnetic Permeability
In addition, the Contractor shall obtain and incorporate in site records the
appropriate certificates for:
o
Cement
Water
Admixtures
Joint filler
Curing compound for exposed surfaces
Joint sealing compound
Concrete for ancillary purposes
9.63
ROUTINE TESTS ON BULK SUPPLIES THROUGHOUT PLANT MIXING

The Quality Assurance procedures for the supply of component materials
shall include carrying out tests in order to check on the consistency of bulk
supplies, to compare the properties and grading of bulk supplies with the
samples provided and to enable actions to be taken to cope with variations.
PAGE 53 of 55
1884 of 2461
The tests should include the following:
Test
Reference
Sieve analysis of aggregates
IS: 2386 Part 1
Fines content of aggregates
IS: 2386 Part 1
Chloride ion content in aggregates
Moisture content in aggregates
IS: 2386 Part 3
Loss on ignition of cement
IS: 4031 1968
If the result of any test indicated that the bulk deliveries are not of a grading or
quality consistent with the approved samples, the Contractor shall, at his own
expense, carry out further tests to establish the location and extent to which the
materials already stockpiled fail to meet the approved standard and, if stored on site,
shall remove all non-compliant from the airfield.
9.64
ROUTINE TESTS ON PLANT THROUGHOUT PLANT MIXING

The Contractor shall arrange for checks on the calibration of weighing, water
measuring and admixture dispensing mechanisms to be checked before
mixing starts and at specified intervals during production.
9.65
ROUTINE TESTS ON CONCRETE THROUGHOUT PLANT MIXING

As part of the Quality Assurance requirements, the Contractor shall carry out
the tests as listed in Table below on concrete (including trials). The procedure
shall ensure that the positions of concrete batched from which tests samples
are taken fully traceable in the finished pavement.
Routine Tests on Concrete throughout Production

Test
Degree
Reference
of
Compactability
Compaction Index (CI)

Slump
of
IS: 1199-1959
IS: 1199-1959
PAGE 54 of 55
1885 of 2461
Air content
IS: 1199-1959
Cube strength
IS: 516-1959
Temperature (Hot or Cold weather BS EN 206-1 &

only)
9.66
BS 800-2
ROUTINE TESTS ON CONCRETE AFTER LAYING

The Contractor shall undertake the series of tests on hardened concrete
incorporated in the necessary to comply with the relevant specifications.
9.67
CERTIFICATES THROUGHOUT THE WORK

Throughout the course of the work, the Contractor shall obtain certificates for
all consignments of the following and retain in site records:
o
Cement
Curing compounds for exposed surfaces
Joint sealing compounds
Storm drain arrangement on one side of roads shall be provided

for collecting and disposing dewatering rain and other water with
interconnectivity. The water shall be disposed from storm drain
from the area at safe and suitable disposal point. The drains
shall be constructed as per MORT&H guidelines.
Low growth Tree plantation on both side of road shall be carried

out and it shall be conserved.
PAGE 55 of 55
1886 of 2461



dEDDZt^ZD
/^Zt^^
t^ZDDZDDZ
DKdDKd

OCTOBER 2016

1887 of 2461
SECTION 6C.1
SYSTEM AND HYDRAULIC DESIGN
REQUIREMENTS
1888 of 2461
MMRDA
Table of Contents
SUB-SECTION 6C.1: SYSTEM AND HYDRAULIC DESIGN REQUIREMENTS ...................... 1
1.1
General Requirements .......................................................................................................... 1
1.2
Water Levels at Intake & MBRs .......................................................................................... 1
1.3
Hydraulic Design .................................................................................................................... 2
1.3.1
Flowrates in various Components ................................................................................. 3
1.3.2
Determination of Friction Loss........................................................................................ 4
1.3.3
Residual Head and TWL of BPT .................................................................................... 5
1.3.4
Minimum HGL V/s Profile of Transmission System .................................................... 5
1.3.5
Design Pressure and Field Test Pressure.................................................................... 6
1.4
Water Treatment Plant .......................................................................................................... 7
1889 of 2461
MMRDA
SUB-SECTION 6C.1: SYSTEM AND HYDRAULIC DESIGN REQUIREMENTS

1.1
Flow diagram, P&I diagram and map showing Surya river and service areas
and other applicable tender drawings show water supply system from the
Intake at Kawadas pick up weir, raw water transmission to and treat at Water
Treatment Plant at Suryanagar, further transmission system comprising
pipelines and tunnels to two destinations i.e. MBR at Kashidkopar and MBR at
Chene. Further transmission from MBRs, feeder mains etc. are not in scope
of the contract.
The water supply system (WSS) shall operate @ 22 hours per day to supply
daily flowrates. Daily bulk water supply to VVCMC, enroute 7 tappings for 27
villages and MBMC are as under.
Bulk Supply Point & Capacity
Beneficiary
VVCMC
Kashidkopar MBR, 38 ML Capacity
27 Villages
Enroute
seven
tappings
Quantity
170 ML/day
between
15 ML/day
Kashidkopar to Sasunavghar
MBMC
Chene MBR, 45 ML capacity
218 ML/day
The daily quantity supply and capacities of the two MBRs are obligatory.
1.2
Water Levels at Intake & MBRs
The water levels at Intake and top water levels at two MBRs are obligatory
and are as under.
i)
Intake
High Flood Level (HFL)
SECTION 6C.1: SYSTEM HYDRAULIC DESIGN REQ
68.90 m RL
PAGE 1 of 8
1890 of 2461
MMRDA
Full Reservoir Level (FRL)
Minimum Draw Down Level (MDDL)
65.25 m RL
-
60.50 m RL
The Intake shall be designed on basis of above water levels. Low

water level (LWL) at Intake shall be based on permissible head loss at
Inlet to Intake as specified in design criteria for Intake.
ii)
MBRs
Top Water Level (TWL) in both MBRs are as under.

TWL at Kashidkopar MBR
70.0 m RL
TWL at Chene MBR
52.5 m RL
Low Water Level (LWL) at two MBRs are 65.0 m and 47.5 m RL
respectively as per conceptual design. However, LWL is not
obligatory and the contractor can vary LWL and water depths in
the tanks.
1.3
Hydraulic Design
The hydraulic design of the WSS shall be based upon following criteria and
basis covering;
Flowrates in various components taking into account losses in WTP

and transmission system
Friction loss, formula to be used, values for frictional coefficient over

design life of 30 years
Minimum hydraulic grade level
PAGE 2 of 8
1891 of 2461
MMRDA
TWL in BPT
Design pressure and test pressure
Residual head
1.3.1 Flowrates in various Components

Losses in transmission pipelines and tunnel cannot be totally eliminated.
Similarly, some quantity shall be required in WTP for washing filter beds and
desludging. Losses as under are considered.
i)
0.5% of flowrate per 10 km of transmission mains
ii)
2.5% of flowrate in WTP
On above basis and considering 22 hours daily operation, the flowrates are
determined as per Table 1.1 below.
Table 1.1 : Calculation for Daily Quantity /Flowrate in various
Components
S No.
Parameter
Quantity/Flowrate
Net bulk supply to MBR at Chene for Mira
ML/d*
m3/h
218
9909.09
2.983
135.60
220.98
10044.69
185
8409.09
0.093
4.21
Bhayandar (MBMC)
2
Losses in treated water transmission main

and
two
tunnels
from
junction
near
Kashidkopar to MBR at Chene

3
Outflow at junction near Kashidkopar for MBR

at Chene
Treated water supply at MBRs at Kashidkopar

for Vasai Virar Municipal Corporation (VVMC)
PAGE 3 of 8
1892 of 2461
S No.
MMRDA
Parameter
Quantity/Flowrate
ML/d*
m3/h
185.09
8413.30
from junction near Kashidkopar to MBR at

Kashidkopar
6
Outflow at junction near Kashidkopar to MBR

at Kashidkopar (as worst case when drawl
from tappings is NIL)
Inflow at junction near Kashidkopar [(3)+(6)]
406.076 18457.99
12.794
and tunnel from WTP
581.56
Suryanagar to
Kashidkopar Junction
9
Output at WTP required
418.870 19039.56
10
Losses in WTP
12.955
11
Raw water flow to WTP
431.825 19628.41
12
Losses in raw water transmission main from
0.389
588.85
17.68
Intake to WTP
13
Raw water drawl from Kawadas
432.214 19646.09
*ML/day in 22 hours
Above flowrates in various compartments are obligatory and shall be basis for
system design.
1.3.2 Determination of Friction Loss
Friction losses in the transmission system shall be computed on basis of
following criteria. The criteria are obligatory and no variation is permitted.
The friction losses in pipeline and tunnel shall be calculated by use of

Hazen Williams equation. No other formula is acceptable
The diameter for computation shall be finished inside diameter of the

pipeline, fitting and tunnel
Hazen Williams coefficient C shall be of following two values to cover

likely variation in C values over entire life period of 30 years
PAGE 4 of 8
1893 of 2461
For Tunnel
C = 120
MMRDA
for entire period
For Pipeline
C = 145
for new pipes
C = 120
for aged pipes
Minor losses due to friction resistance in valves, fitting and other

appurtenances, Inlet loss, exit loss shall be computed @ 10% of friction
losses determined as per Hazen Williams equation.
1.3.3 Residual Head and TWL of BPT

Margin in the form of residual head is provided to account for minor variation
in length and assumed friction coefficient.
Residual head = 5.0 m shall be added to computed HGL @ BPT at C = 120 to
determine TWL at BPT. This residual head is obligatory.
1.3.4 Minimum HGL V/s Profile of Transmission System
Minimum HGL required at BPT shall be worked out on basis of C (tunnel) =
120 and C (pipeline) = 145 plus 10% minor losses and nil residual head.
The minimum hydraulic grade line shall be drawn on combined longitudinal
section of BPT Pipeline Tunnel MBR system to demonstrate that the
minimum HGL does not cut profile of transmission system.
It is desirable to the extent feasible that at least 5 m pressure is available
above the profile of transmission system to ensure effective air exit through air
valve.
PAGE 5 of 8
1894 of 2461
MMRDA
1.3.5 Design Pressure and Field Test Pressure

i)
Raw and Clear Water Pumping Mains
Design pressure for these two pumping mains shall be higher of

following two sums. No reduction in water hammer head due to
control device shall be accounted for determining design
pressure.
Maximum working head over profile

+
Water hammer head without protection
OR
Maximum static head over profile

+
Water hammer head without protection
Class of all valves, dismantling joint, flange adapter etc. shall be

selected such that seat test pressure is not less than working
pressure and body test pressure is not less than above design
pressure
Field test pressure for hydraulic testing of pumping main shall

not be less than the design pressure
ii)
Gravity Pipeline downstream of BPT
Design pressures for three stretches of gravity mains i.e. one

from BPT to Kashidkopar junction and second from Kashidkopar
junction to Chene MBR and third from Kashidkopar junction to
Kashidkopar MBR shall be separately determined
PAGE 6 of 8
1895 of 2461
MMRDA
Design pressure for the respective gravity pipeline shall be 1.5

times maximum static head based on TWL in BPT and lowest
invert level over entire length of pipeline in that stretch
Class of all valves, flange adapter etc. shall be such that seat
test pressure is not less than maximum static head and body
test pressure is not less than above design pressure
Field test pressure for hydraulic testing of pipeline shall not be

less than above design pressure
iii)
Tunnels
-
Design pressures for respective tunnels shall be separately

worked out for each tunnel
Design pressure shall be 1.5 times maximum static head based

on TWL in BPT and lowest invert level of particular tunnel
1.4
Field test pressure shall not be less than design pressure

Process and hydraulic design requirement are specified in particular
specification for WTP.
PAGE 7 of 8
1896 of 2461
SUB-SECTION 6C.2
INTAKE AND RAW WATER PUMPING STATION
1897 of 2461
MMRDA
Table of Contents
SUB-SECTION 6C.2: INTAKE AND RAW WATER PUMPING STATION ................................ 1
2.1
General...................................................................................................................................... 1
2.2
Requirements of Intake ........................................................................................................ 1
2.3
Obligatory Parameters and Values.................................................................................... 3
2.4
Components in Intake ........................................................................................................... 4
2.5
Combination of Pumps for Raw water.............................................................................. 5
2.6
Hydraulic Design of Intake for Vortex-free Operation of Pumps............................... 7
2.6.1
Parameters for Vortex-Free Operation Pumps ............................................................ 7
2.6.2
Mitigation measures for parameters not satisfied ....................................................... 7
2.6.3
Silt Deposition Allowance ................................................................................................ 8
2.7
Criteria for General Arrangement of Pumping Station................................................. 8
2.7.1
Design Velocity ................................................................................................................. 8
2.7.2
Valves in Individual Delivery ........................................................................................... 8
2.7.3
Space Requirements ....................................................................................................... 9
2.7.4
Floors in Pump Room ...................................................................................................... 9
2.7.5
Pump Foundation ........................................................................................................... 10
2.7.6
Truck Access Bay........................................................................................................... 10
2.7.7
GA of Superstructure ..................................................................................................... 10
2.7.8
Other Facilities ................................................................................................................ 11
2.8
Mechanical Equipment ....................................................................................................... 11
2.8.1
Stop-log Gate .................................................................................................................. 11
2.8.2
Bar Screen....................................................................................................................... 11
2.8.3
Sluice Gate ...................................................................................................................... 12
2.9
Raw Water Pumps................................................................................................................ 13
2.9.1
General requirements .................................................................................................... 13
2.9.2
Pump Duty Conditions ................................................................................................... 14
2.10
Valves and Pipework ........................................................................................................... 15
2.10.1
General Requirements .................................................................................................. 15
2.10.2
Valves - General ............................................................................................................. 15
2.10.3
Pump Automatic Air Inlet/Release Valves .................................................................. 16
2.10.4
Pipework -General.......................................................................................................... 16
2.10.5
Pump Common Delivery Manifold ............................................................................... 16
2.10.6
Valves on Common Delivery Manifold ........................................................................ 17
1898 of 2461
MMRDA
2.11
Electric Overhead Travelling Crane and Other Lifting Equipment ......................... 17
2.12
Desilting Plant and Tools ................................................................................................... 18
2.12.1
Truck mounted Suction cum Jetting and De-Silting Machine .................................. 18
2.12.2
Plant and Tools ............................................................................................................... 18
2.13
Ventilation System ............................................................................................................... 19
2.14
Provision of safe access .................................................................................................... 21
1899 of 2461
MMRDA
SUB-SECTION 6C.2: INTAKE AND RAW WATER PUMPING STATION

2.1
General
Raw water Intake is planned in impounding reservoir upstream of Kawadas

pickup weir. Functions of the Intake are;
To abstract raw water into Intake
To pump raw water for transmission to aeration fountain of water

treatment plant located at about 2000 m distance
The reservoir data are as under:
High Flood Level (HFL)
68.90 m RL
Full Reservoir Level (FRL)
65.25 m RL
Minimum
Draw
Down
Level 60.50 m RL
(MDDL)
9.96 Mm3
Live Storage
2.2
Requirements of Intake
The Intake and pumping station shall be suitable to meet following

requirements.
i)
To abstract raw water as near water surface level as possible.
ii)
To prevent ingress of vegetation and floating matter into Intake by

providing screens.
iii)
The inflow velocity shall be sufficiently low to enable fishes to swim

away against stream so as to prevent fish nuisance.
SECTION 6C.2: INTAKE AND RAW WATER PUMPING STATION
1900 of 2461
PAGE 1 of 21
iv)
MMRDA
To admit water in Intake through sluice gates at minimal head loss over
entire range of water levels in the impoundment. Each gate shall be
suitable to function as port as well as weir.
v)
To ensure streamlined flow at permissible flow velocity to Inlet bell

mouths of vertical turbine pumps as well as meeting all other
parameters such as approach length, spacing of bell mouths, minimum
submergence etc. ensuring that the requirements for vortex-free
operation of pumps are fulfilled as given in following literature.
Hydraulic Institute Standard

Ohio, USA, HI 9.8 / American National Standard for Intake,
ANSI-1998
Standard by British Hydrodynamic Research Association

(BHRA)
vi)
IS 1710 for V.T. Pumps
Pump Hand Book, 4th Edition, edited by Karassic etc.
To house adequate margin below bellmouth level for deposition of silt

as silt cannot be removed frequently.
vii)
To house openings and facilities for periodical removal of silt from

pump well.
viii)
To house required number of vertical turbine pumps including standby

pumps and spare bays for future pumps.
ix)
To house motors, motor control center, delivery piping, valves,

common header.
x)
To house control room for control and automation equipment.
1901 of 2461
PAGE 2 of 21
xi)
To
provide
lifting
MMRDA
equipment
for
handling
of
pumps,
other
electromechanical equipment, screen and stop-log gates.

xii)
To provide well designed ventilation system so as to remove excess

heat and maintain temperature rise within acceptable limit.
xiii)
To stop inflow to the Intake or Intake compartment by providing stop

log gate(s).
2.3
Obligatory Parameters and Values
i)
Flow rates
The Intake shall be designed to handle 1.5 times present flow rate
ii)
Q(present)
19646.0 m3/h
Q(design)
29649 m3/h
Design WL in Intake shall be;

HFL
68.90
RL
Head loss in screen and

gates
TWL
65.25
to
be
ignored
being small
RL
LWL
59.70
m (based
RL
on
permissible
head loss 0.8 m below

MDDL)
Mean WL
62.50
RL
The mean WL shall be design WL for determining pump head.
1902 of 2461
PAGE 3 of 21
iii)
MMRDA
Shape and number of compartments
Shape of Intake, pump well and superstructure shall be

rectangular
The Intake shall be in two compartments from bottom of well to

TWL
iv)
Number of floors shall be two; lower floor for pump installation and
accommodating piping end valves and upper floor for operation and
electrical panels
v)
Lower floor i.e. pumps floor shall be at least 2.0 m above the HFL
vi)
Number of pumps shall comprise required number of duty pumps as

per Contractors design plus minimum two number standby pumps +
empty bay for additional two pumps to provide for additional 150 ML
/day abstraction
vii)
2.4
The pumps shall be self water lubricated vertical turbine pumps
Components in Intake
The Intake shall accommodate following components.

i)
Stop log gate, one for each compartment to stop flow; with
arrangement for access and handling of stop-log gate with lifting
equipment. Seal level of stop-log gate shall be at MDDL.
ii)
Inlet channels from stop log gates to screens; the walls of diverging
channel shall be at 45 to approaching flow path.
iii)
Bar screens at Inlet face of Intake well.
iv)
Multiple sluice gates for each pump bay.
1903 of 2461
PAGE 4 of 21
MMRDA
v)
Pump well.
vi)
Pump mounting floor (lower floor) above HFL.
vii)
Operation floor (upper floor) with adequate head room between two
floors.
viii)
Truck access bay.
ix)
Suitable openings in both floors of each compartment for silt removal

from Intake bowl to operation floor.
x)
Superstructure to accommodate lifting equipment
Electrically operated travelling crane for pumps and associated

equipment
Monorail for lifting up for cleaning and placing down screen
Structural steel section placed vertically above gates so as to

mount chain pulley block or suitable lifting tackle to lift any gate
2.5
Combination of Pumps for Raw water
Combination of pumps needs to be decided for planning & space requirement

in Intake and pumping station. Design parameters are as under:
Type of pumps is VT pump
Number of duty pumps suitable for pumping combined flow 19646 m3/h
Minimum standby pumps and spare pump bays
2 numbers standby
1904 of 2461
PAGE 5 of 21
MMRDA
2 numbers spare pump bays for future pumps
Combination of pumps shall be optimum combination from the

following.
3 (duty) + 2 (standby)
RPM 1000 (synchronous)
Parameters for optimum selection
Specific speed between 2500 (USCU) 4200 (USCU) - United

states customary Units
Maximum attainable efficiency as per chart given in Pump Hand

book (latest edition), Book of Dicmas Vertical Turbine, Mixed
Flow & Propeller Pump and / or CPHEEO manual
Preferable shape / curve of H-Q characteristic for the specific

speed
Stable / rising so as to be suitable for parallel operation
Lesser variation in Q for relatively more variation in H
Wear and tear v/s speed
Magnitude of required submergence as per HI 9.8 / ANSI - 1998
Dynamic load on foundation
1905 of 2461
PAGE 6 of 21
2.6
MMRDA
Space requirement for the size and number of pumps
Hydraulic Design of Intake for Vortex-free Operation of Pumps
2.6.1 Parameters for Vortex-Free Operation Pumps

Following parameters for vortex-free operation of pumps MUST be satisfied
on basis of criteria given in HI 9.8 / ANSI 1998 and pump well need to be
planned accordingly.
Streamlined uniform flow from Inlet gate to pump centre at low velocity
W, spacing between bellmouths of adjoining pumps
S, submergence from minimum WL (LWL) in pump bay to lip of bell

mouth
X, straight approach length from Inlet to bellmouth centre
No obstruction and change in flow direction in approach bay
Any structural column coming in flow path shall be rounded /ogive
2.6.2 Mitigation measures for parameters not satisfied

Mitigation measures for not satisfying following two parameters shall be
adopted as recommended in HI 9.8/ Intake / Sump design
C, bottom clearance required under bellmouth (generally D/2, where D

= bell mouth diameter)
B, back clearance (generally 0.75 D)
Preferable mitigation measures are;

1906 of 2461
PAGE 7 of 21
MMRDA
RCC cone under bell mouth
RCC splitter under bell mouth
Mitigation measure for vortex prevention shall preferably not cause any dead
spot resulting in nuisance in movement as well as obstruction for silt removal
Any other parameter for vortex free operation not stated above, but required
as per HIS 9.8 / ANSI shall be satisfied.
2.6.3 Silt Deposition Allowance
Silt deposition in Intake bowl cannot be avoided. Hence, silt allowance is
required.
Silt allowance shall be minimum 0.8 m.
The silt allowance is measured
between bottoms of pump well floor to dynamic WL under bell mouth given by
the following,
Dynamic WL under bell mouth
Where D
2.7
Lip of bell mouth (-) D/2
bellmouth diameter
Criteria for General Arrangement of Pumping Station
2.7.1 Design Velocity

V bell mouth
1.5 m/s
V column
2.75 m/s
V delivery
2.0 m/s
2.7.2 Valves in Individual Delivery
1907 of 2461
PAGE 8 of 21
MMRDA
NRV / DPCV
BFV (long body)
SV / Knife gate valve (KGV)
2.7.3 Space Requirements
Clear space between foundation frames / sole plates of two adjoining

pumps shall be minimum 600 mm
Spacing between end pump and side wall shall be such to obtain clear
space of minimum 600 mm from delivery valves / piping as well as to
ensure that the crane hook reaches is at least up to centre of end
pump
Clear space between two adjoining motors or adjoining valves shall be

minimum 1000 mm
End space between downstream SV / KGV and wall shall be minimum

500 mm
Rear space behind MCC / Panel shall be minimum 1000 mm
Clear space between MCC / Panel and wall of panel room shall be 600
mm higher than draw out position of circuit breaker
Clear space between motor and wall of panel room shall be minimum
1000 mm
2.7.4 Floors in Pump Room
Floors in pump room shall be two numbers, one lower and second
upper
1908 of 2461
PAGE 9 of 21
MMRDA
Pumps and motors shall be founded on lower floor
Panel shall be mounted on upper floor in separate room
Head room between the two floors shall be minimum 2.5 m
Control room for automation and SCADA either on upper floor or

additional room above upper floor shown in conceptual drawing
Removable grating shall be provided in upper floor above delivery line

to facilitate handling of valves
2.7.5 Pump Foundation

The structural members for founding pump shall be designed for dynamic load
of pump and motor. The dynamic load shall be worked out as per IS: 2974
Part IV code of practice for design and construction of machine foundation
for rotary type machines of low frequency.
2.7.6 Truck Access Bay
A purpose designed access bay for truck shall be provided in pump room so
as facilitate truck entry and loading or unloading of pump, motor and other
equipment by means of EOT crane onto / from truck.
2.7.7 GA of Superstructure
Superstructure shall house panel / MCC, other indoor electrical

equipment, ventilation system and electrically operated double bridge
girder travelling (EOT) crane, service / maintenance bay, tool room and
on external side shall accommodate EOT monorail for lifting screen,
head stock for manual operation of all gates
The general arrangement shall include an opening of 0.9 x 0.9 m in

pump floor & motor floor slab for removal of silt in well with EOT
1909 of 2461
PAGE 10 of 21
MMRDA
Corbel level shall be such that EOT crane can be erected with
minimum clearance of 500 mm above upper most part of crane.
Head room up to crane hook (uppermost position) shall be at least

1000 mm higher than any equipment, column pipe and line shaft
required to be lifted up during dismantling of any item of equipment
EOT monorail on external side shall be suitable to handle screen for

cleaning
Slit with removable grating shall be provided for above operation of

screen
2.7.8 Other Facilities

Following facilities shall be required.
Access staircase from Pump floor level to bottom of Intake well
Access staircase from motor floor to pump floor & control room at upper
floor
2.8
Mechanical Equipment
2.8.1 Stop-log Gate

The stop-log gate shall be provided in each of two Inlet channels. The stoplog gate shall generally conform to IS 5620-Recommendations for Structural
Design Criteria for Low Head Side Gate.
Suitable monorail / with lifting beam as per IS 13591 shall be provided as
shown in conceptual drawing for handling stop-log gate.
2.8.2 Bar Screen
1910 of 2461
PAGE 11 of 21
MMRDA
Vertical bar screen shall be provided at Inlet of each pump bay including two
spare bays for future pumps. Screens shall be designed for easy cleaning by
manual raking.
The screen shall be as per IS 11388 and shall be fully
galvanized.
Bar screen shall be fabricated from SS 316 flat 50 mm x 10 mm minimum.
The spacing between two flats shall not exceed 25 mm.
Screen bars shall be provided with stiffeners for reinforcement, and the
stiffeners shall be designed and installed to avoid impeding raking.
Four rakes shall be provided, each designed for use by one man. Rake handles
shall be of non-corrodible lightweight tubular alloy. Rake spikes shall fit the
screen apertures and shall be of softer material than the screen bars to ensure
bars are not damaged by raking.
Four rakings containers shall be provided, designed for ease of handling and
lifting. The weight of loaded containers shall not exceed 50 kg. They shall be
free draining, with mesh apertures not larger than 25mm square. They shall be
fitted with lifting handles designed for use by hand or with the hoist.
A manual wire rope hoist with supporting derrick shall be provided to raise the
containers to the structure top level for safe disposal. The hoist shall be fitted
with a suitable hook, designed for quick attachment and release, and shall be
designed for operation by one man.
The safe working load of the hoist and associated equipment shall be not less
than 75kg.
2.8.3 Sluice Gate
Manually-operated thimble mounted sluice gate shall be installed inside the
pumping station to shut off each of the 6 inlets bay, as shown on the drawings.
Minimum two number of sluice gate per pump bay shall be provided. The upper
gate shall be positioned to draw water as near FRL as possible. The lower gate
1911 of 2461
PAGE 12 of 21
MMRDA
shall be positioned about 800 mm below MDDL so as to draw full quantity at

sea level.
Both gates shall be suitable to operate as port and weir. Each gate shall be
provided with a headstock mounted at floor level complete with extension shaft
and couplings.
Sluice gate and their frames shall be cast iron, and the frames shall be
provided with cast iron mounting thimbles for building-in the frame to the
structure.
The gate shall be the seating type, with rising spindles. The gate opening shall
be rectangular.
The sluice gate shall be designed for the maximum pressure to which they could
be subjected in service.
2.9
Raw Water Pumps

The Contractor shall review the pumping station design and the pump
mounting proposals shown on the drawings, and shall ensure that the pumps
he provides will operate satisfactorily as specified in all possible operating
conditions, including any possible water level with any combination of pumps
running. The drawings show one possible arrangement of pumps but the
Contractor may select a different arrangement which complies with the
Specification.
The design of the pump wells shall be in collaboration between pump supplier
and civil works designer to ensure the required hydraulic conditions are met in
any possible operating condition.
Pumps shall be all identical and of type vertical turbine pump with waterlubricated bearings. Unless otherwise approved, no pump shall incorporate
1912 of 2461
PAGE 13 of 21
MMRDA
more than two stages. Pumps shall be driven by directly-coupled, verticalshaft induction motors, as described in the Electrical Specification. Speed of
pump shall be maximum 1000 RPM (Syn).
Bowl efficiency shall not be less than 87%.
Velocity in column pipe shall not exceed 2.75 m/s.
Length of each column pipe shall be 1500 mm. Velocity of entrance of
bellmouth shall not exceed 1.5 m/s.
Unless otherwise approved, pump casings shall be of close-grained cast iron,
and impellers and guide vanes of zinc-free bronze or stainless steel.
If the Contractors design includes the need to streamline the flow into the
pump inlet bellmouths, this may be achieved by providing flow straighteners
within the bell mouths using integrally-cast vanes.
2.9.2 Pump Duty Conditions
Conceptual design envisages 4 number of duty pumps with 2 number of
standby to pump 19646 m3/s. Duty head of the pump is 26.5 m.
The contractor shall review and recalculate duty head which shall be sum of
the following five elements.
i)
Static head from mean WL in Intake to RL of aeration fountain in WTP
ii)
Friction losses in raw water rising main @ C = 145
iii)
Minor losses due to fitting and valves at 10% of (ii) above
iv)
Station losses about 2.0 m
v)
Residual head 1.5 m
1913 of 2461
PAGE 14 of 21
MMRDA
The pump shall also be suitable for operation when Intake WL falls to LWL
which is about + 10% variation. The pump shall also be suitable for head
when WL in Intake rises to HFL which is about 25%.
Covering above variation operation head range of the pump shall be +15%
and -30%.
2.10
Valves and Pipework
2.10.1 General Requirements

Pump valves, pipework, and their supports shall be designed to withstand the
maximum stresses imposed by any operating condition, including the shock
resulting from pump starting when the advancing inrush of water strikes the
closed non-return valve.
The design maximum velocity through the valves and pump branch pipework
shall not exceed 2m/s.
The design pressure rating of valves and pipework shall be 1.5 times the
pump shut valve pressure or PN 1.0, whichever is greater.
2.10.2 Valves - General
Each pump shall be provided with a delivery non-return valve, a delivery
isolating valve, additional isolating valve and an automatic air inlet/release
valve. The air valve shall be fitted to the delivery pipework near to the
discharge bend and upstream of the non-return valve.
Pump delivery isolating valves shall be resilient-seated butterfly valves, fitted
with electric actuators. Valve operation when manual shall be by handwheel
through integral reduction gearing.
Additional isolating valve shall be non-rising spindle sluice valve. This valve
shall be manually operated. Alternately knife gate valve can be accepted.
1914 of 2461
PAGE 15 of 21
MMRDA
Non-return valves shall be of the swing-check type, designed for rapid closing
as soon as forward flow stops. Alternately, dual plate check valve as per
standard specification can be accepted.
2.10.3 Pump Automatic Air Inlet/Release Valves
Each pump air inlet/release valve shall be designed and sized to ensure:
a)
On pump stopping, the pump column pipe drains into the pump well so
that negative pressures which could be damaging when the pump is
restarted cannot occur.
b)
On pump starting, air is expelled from the column pipe fast enough to
prevent air being forced past the pump non-return valve and into the
delivery mainfold, and the air cushion in the column pipe prevents
damage to pipework or non-return valve from the advancing water
column.
2.10.4 Pipework -General

Pump delivery pipework shall be fabricated steel, with flanged connections.
Pressure ratings shall match those for valves as given above.
Dismantling joints shall be incorporated wherever needed to facilitate the
removal of pumps and valves. The dismantling joint shall be suitable for pump
duty and when assembled shall be suitable to withstand tensile force imposed
due to thrust at end of delivery piping at manifold.
Pipework shall be protected from corrosion as detailed for exposed steel
pipes elsewhere in the Specification.
2.10.5 Pump Common Delivery Manifold
The pump deliveries shall be joined to a fabricated-steel delivery manifold, with
flanged connections which shall be connected to the raw water pipeline
1915 of 2461
PAGE 16 of 21
MMRDA
delivering to the treatment works. The manifold shall be of nominal diameter

2000 mm.
The manifold shall be connected to the raw water pipeline,
generally as shown on the drawings.

The manifold design pressure rating shall be 1.5 times the pump shut valve
pressure or 160 m, whichever is greater. Protection shall be as specified for
pump delivery pipework.
2.10.6 Valves on Common Delivery Manifold
Two valves as under shall be provided on downstream of common delivery
manifold.
2000 mm diameter PN 1.0 rating non-return valve or dual plate check

valve
2.11
2000 mm diameter PN 1.0 rating butterfly valve
Flange adopter between the two valves
Valves shall be in valve chamber
Electric Overhead Travelling Crane and Other Lifting Equipment
An electric overhead travelling crane shall be provided in the raw water

pumping station, designed to serve the pumps and all the plant installed in the
motor hall, and to lift and lower the skips provided for de-silting the pump wells.
Enough hoisting cable shall be incorporated to lower skips to the bottom of the
pump well.
The Contractor shall determine the maximum Safe Working Load required for
the crane, which shall be not less than 20 tonnes.
The pendant control shall be designed for operation from the upper hall floor.
1916 of 2461
PAGE 17 of 21
MMRDA
Crane operating speeds shall be as follows:
Long travel
Not more than 40m/min
Cross travel
Hoisting and lowering
A fixed ladder with safety handrailing shall be provided for access to the crane
for servicing, and to gain access the maintenance platform for use when
servicing high-level lighting and ventilation units.
Other lifting equipment shall include monorails for screens and stop-log gates
and hoist for raking containers.
2.12
Desilting Plant and Tools
2.12.1 Truck mounted Suction cum Jetting and De-Silting Machine

The Truck mounted heavy duty machine shall be capable for removal of choke
ups from intake wells, accumulated silt from the sump, tanks and drains. The
machine shall be equipped with necessary tools, pipes for suction and delivery
of silt.
2.12.2 Plant and Tools
The plant and tools to be provided for de-silting shall include:
4 No. of long-handled shovels;
4 No. of hand picks;
4 No. of skips for loading with recovered silt.
1917 of 2461
PAGE 18 of 21
MMRDA
Tools shall be of first-class commercial quality, designed for rough handling and
frequent use. Shovel blades and pick heads shall be steel, and handles of best
quality ash or hickory wood.
Skips shall be robustly built of fabricated steel, designed for hard wear and
protected from corrosion by painting. They shall be designed for emptying by
tipping. They shall be provided with handles suitable for hand carrying and for
safe lifting without tipping when using the station crane.
The total weight of each skip when fully loaded with silt shall not exceed 50kg.
2.13
Ventilation System
The upper floor pumping station shall be provided with a ventilation system
designed to limit the air temperature rise to not more than 5 deg. C. when the
plant is operating. The system shall be designed to provide uniform ventilation
throughout the pumping station, to promote plant cooling and eliminate
pockets of stagnant air.
The system shall be sized based on the maximum number of motors operating
together, with all the lights switched on, and with three operating personnel
present, but the design ventilation rate shall be not less than five air changes
per hour for the complete operating area.
The ventilation system shall be combination of forced ventilation system and
extraction / exhaust system. Essential features and requirements are as under:
i)
Air supply fans and exhaust fan shall be positioned staggered to avoid
short circuit.
ii)
Ventilation ducts shall be provided such that forced air flow out at about
750 mm above operating floor and extracted out of exhaust at about
2000 mm above the floor level.
1918 of 2461
PAGE 19 of 21
iii)
MMRDA
Ventilation fans shall be sized for 75-85% exhaust and 100% air
supply.
iv)
The air velocity in duct shall not exceed 20 m/s.
Fans shall be controlled from wall-mounted contactors, accessible from

pumping station floor level.
Exhaust fans shall be provided between two floors to achieve minimum four
number of air changes per hour.
Pump well ventilation system
General
A ventilation system shall be provided to supply fresh air to the bottom of the
dewatered pump well during de-silting, to promote safe working. Only one half
of the pump well will be de-silted and need ventilation at any time. De-silting is
expected to last for up to 24h, and to be needed not more often than once
every three months. The design shall provide not less than four air changes per
hour for one pump well.
The system shall include one or more wall-mounted electric fan units, designed
to draw fresh air from outside the pumping station, and to deliver it to the pump
wells through fixed and flexible ducts.
Fans
Fans shall be sized to deliver required fresh air through the duct system,
discharging at the bottom of either pump well. Fan motors shall be rated for
Fan inlets shall be protected from ingress of harmful foreign matter by robust
grilles at the inlets.
1919 of 2461
PAGE 20 of 21
MMRDA
Ducts
Fixed ductwork shall lead the airflow from the fan to a suitable point near the
top of each pump well. If a single fan is used, a damper shall be provided to
direct airflow to the selected well. Fixed ducts shall end with a spigot and
clipping arrangement, designed for connection to the flexible duct, which will be
used only during de-silting.
Fixed ducts shall be of fabricated galvanized sheet steel or other approved
material. Ducts shall be reinforced or protected where they could be damaged
by the passage of personnel or goods in transit. Rectangular or circular
sections may be used. Ducts shall be manufactured and installed to an
approved code.
Flexible ducts shall be of tough, flexible, non-metallic construction, designed for
hard wear in the conditions at Site. The length of flexible duct provided shall be
not less than 25 m. One end of the duct shall be arranged to connect to the
fixed duct and the other to discharge safely at the bottom of either pump well,
with an outlet which can be secured and directed as required.
Fixed and flexible ducts shall be sized to limit air velocity to not more than
20m/s.
2.14
Provision of safe access
RCC access platforms and ladders shall be provided wherever needed. The
arrangements shall ensure that all parts of the plant are made readily
accessible for maintenance or operation in safety.
1920 of 2461
PAGE 21 of 21
SUB-SECTION 6C.3
WATER TREATMENT PLANT
1921 of 2461
MMRDA
Table of Contents
SUB-SECTION 6C.3: WATER TREATMENT PLANT ........................................................................... 1
3.1
General ....................................................................................................................................... 1
3.2
Water Treatment Process Description .................................................................................... 2
3.3
Treatment Works Layout .......................................................................................................... 4
3.3.1
Cascade Aerator ..................................................................................................................... 4
3.3.2
Parshall Flume ........................................................................................................................ 5
3.3.3
Flash Mixing Tanks ................................................................................................................. 6
3.3.4
Flocculation and Clarification .................................................................................................. 7
3.3.5
Rectangular Clarifier with Plate Settlers ................................................................................. 8
3.3.6
Rapid Sand Filter .................................................................................................................. 10
3.4
Sludge Handling Facilities ..................................................................................................... 18
3.4.1
Process Water ....................................................................................................................... 18
3.4.2
Sludge Balancing Tank ......................................................................................................... 18
3.4.3
Sludge Transfer Pump (Sludge Balancing Tank to Thickener)............................................. 19
3.4.4
Sludge Thickener .................................................................................................................. 20
3.4.5
Sludge Transfer Pump (Thickener to centrifuge) .................................................................. 20
3.4.6
Centrifuge .............................................................................................................................. 21
3.5
Recirculation Sump and Pump House .................................................................................. 22
3.6
Chemical Handling Facilities ................................................................................................. 23
3.6.1
Chemical Application ............................................................................................................. 23
3.6.2
Alum and Lime Dosage ......................................................................................................... 24
3.7
Chlorination System ............................................................................................................... 25
3.7.1
Chlorine Gas Neutralization System ..................................................................................... 27
3.7.2
Chlorination System Operation ............................................................................................. 28
3.7.3
Safety .................................................................................................................................... 29
3.7.4
Statutory Approvals ............................................................................................................... 30
3.8
Other WTP Buildings .............................................................................................................. 30
3.9
Clear Water Sump and Pumping Station .............................................................................. 32
3.10
WTP Complex Camp Office .................................................................................................... 33
3.11
Compound Wall and Fencing: ............................................................................................... 34
1922 of 2461
MMRDA
SUB-SECTION 6C.3: WATER TREATMENT PLANT

3.1
General
The water treatment plant (WTP) shall be constructed at Suryanagar WTP

Site for a gross capacity of 432 MLd. Provision shall be made for the addition
of process units for capacity of 150 MLd.
The average raw water quality parameters are listed below in Table 3.1.
However, these are only indicative and the bidder shall conduct his own
comprehensive raw water quality analyses before designing the WTP process
units.
Table 3.1: Raw Water Quality Parameters from Raw Water Samples
Raw Water Parameter
Units of
Design Value
Measurement
Turbidity
NTU
0.5 min, 57.2 max
pH
pH units
7.5
Dissolved Oxygen
Bmg/L
Total Suspended Solids
mg/L
6.8 min, 7.0 max

76.0 min, 117.0 max
Raw water parameters considered for conceptual design are as per Table 3.2
below.
Table 3.2: Raw Water Quality Parameters considered for Water Treatment
Parameters
Input Design Value
Turbidity
35 NTU
Total Suspended Solid

100 mg/l
Treated water quality guarantees have been based upon the criteria stated in
IS 10500 and CPHEEO Guidelines is given below in Table 3.3.
Table 3.3: Treated Water Quality Guarantees
SECTION 6C.3: WATER TREATMENT PLANT
PAGE 1 of 35
1923 of 2461
MMRDA
Parameters
Turbidity of the Effluent from the Clarifiers
Units
Required Output
NTU
Standard
10
NTU
< 1.0
(Units on
Treated Water Quality Parameters

Turbidity of filtered water
Color
Platinum
scale)
Taste and Odor
Unobjectionable
pH
7- 8.5
Fecal Coliforms
No. per 100
Total Coliform Organisms
No. per 100
Total Iron as Fe
mg/L
0.1
Residual Aluminum as Al
mg/L
0.03
Manganese as Mn
mg/L
0.05
Chlorides as (Cl)
mg/L
200
Sulphates as (SO4)
mg/L
200
Fluorides as (F)
mg/L
1.00
Nitrates (NO3)
mg/L
45.00
Alkalinity
mg/L
200
Treatment unit processes have been identified based on above raw water
quality data that is available along with required performance parameters. It is
also based on the experience of using similar impounded reservoir of raw
water as a source in the design of water treatment works.
3.2
Water Treatment Process Description
Raw water will be admitted into the WTP through cascade aerator. From
cascade aerators water will flow through Parshall flume and flash mixer
through single stream.
Onwards flash mixer, water will be bifurcated into two streams for admitting
the flow into Flocculator plate settler unit. Clarified water shall be finally
filtered, disinfected by chlorination and stored in clear water sump.
Sludge generated in the plate settler clarifier and waste generated in filter
PAGE 2 of 35
1924 of 2461
MMRDA
backwash process will be taken into sludge buffer tank and thickener and will
be dewatered through centrifuge. Supernatant of thickener and filtrate of
centrifuge will be recycled.
The major process units and associated systems to be provided in WTP has
been chosen as under Table 3.4:
Table 3.4: Process Units and Flowrates
Process Unit
a. Cascade type Aerator
Phase 1
Design Flow
Rate
26672
1 unit
Remarks
Includes
further
b. Parshall flume
c. Flash Mixing Tanks
1 unit
4 units
26672
26672
d. Flocculation Tanks
16 units
19630
e. Plate Settler clarifier tanks
8 units
19630
f. Rapid Sand Filters

32 units
Backwash Water Storage
1 unit
Tank
g. Clear Water Sump with baffled
Chlorine contact tank
1 (2
compartments)
Augmentatio
n
19630
19040 m3/h
with Detention
time 1.5 h
h. Sludge Handling Facilities,

including:
Sludge Buffer Tank
1 unit (2
Sludge Thickener
compart4 units
Sludge Centrifuge
3 units
585
58.50
(incl. 1
Ancillary Buildings, including:
Administration Building
1 unit
Chemical Building
1 unit
Chlorine Building
1 unit
Dewatering Building
1 unit
PAGE 3 of 35
1925 of 2461
Process Unit
MMRDA
Phase 1
Design Flow
Remarks
Rate
Maintenance / Storage
1 unit
Building
3.3
Treatment Works Layout
The layout of the treatment will take account of the following factors:
a)
the arrangement of the raw transmission mains into the plant and the
clear water transmission mains from the pumping station at the works;
b)
The hydraulic profile through the works
c)
Requirement of the plant process units ;
d)
Provision of future phases of the project
The total head loss is worked out between aeration unit and the clear water
sump and includes losses of all the units, the connecting pipelines/ channels,
control devices like valves, weirs, gates etc.
The limiting hydraulic levels are indicated in Drawing
Hydraulic Grade level at the lip of the Aerator
85.50 m RL
Top Water level in clear water reservoir
80.00 m RL
Ground level variation at the proposed plant site =
88.0 m to 78.0 m
RL
-
Proposed finished Ground level at site
81 m RL
3.3.1 Cascade Aerator

Aeration processes shall be designed to achieve an efficient mass transfer of
PAGE 4 of 35
1926 of 2461
MMRDA
gases, normally oxygen, into water for imparting freshness or for removal of
gases, such as carbon dioxide and hydrogen sulphide or volatile compounds
causing taste and odour from the water by air stripping and also for removal of
iron by oxidising the iron from the soluble ferrous state to the insoluble ferric
state.
The iron content in the raw water is marginally higher than acceptable limits
and also the raw water withdrawal is from an impounded reservoir. Hence
single cascade type aerator shall be provided to oxidize constituents in the
water such as iron and manganese and to raise the dissolved oxygen content
of the raw water and release of CO2 from raw water.
The aerator shall be sized for the ultimate stage capacity.
The design criteria for the cascade aerator are presented in Table 3.5 below.
Table 3.5: Design Criteria and unit sizes for the Cascade Aerator
Parameter / Component
Design Flow(Ultimate Phase flow)
Space Requirement
Number of steps
No. of Units
Cascade Diameter Required
Freeboard in Outlet Launder
Units
Phase 1
26672
0.018
4
1
25
500
m /h
m2/m3/h
No.
No.
*m
mm
3.3.2 Parshall Flume

Flow measurement at the treatment plant is a fundamental requirement.
Parshall flume is a tried and tested flow measurement option and is suitable
for large flow measurements as in this proposed plant. Hence the same shall
be provided as per the design criteria presented in Table 3.6 below.
Table 3.6 : Design Criteria and unit sizes Parshall Flume
Design Flow (Ultimate Phase flow with 20% over
Units
Value
m3/h
26672
load)
PAGE 5 of 35
1927 of 2461
MMRDA
No. of Units
No.
Throat Width
Ultrasonic level sensor for flow measurement
mm
No.
1500
1
3.3.3 Flash Mixing Tanks

Coagulants (alum) solutions shall be added on line prior to the flash mixing
tank so as to assure the dispersion of the chemicals throughout the flow
stream. Proper design shall be based on providing adequate detention time,
mixing velocity, tank geometry, mixer design and positioning the chemical
injection point correctly to provide adequate mixing of the chemical solution
into the raw water.
Mechanical flash mixing shall be provided for the WTP. The driving motor
shall be of suitable capacity and furnished with a gear reducer to achieve the
specified impeller speed (mixing gradient).The motor, gear reducer and other
accessories shall be enclosed in a weatherproof enclosure. The Flash mixer
shall be designed to provide a mixing intensity that will impart a velocity
gradient (G) required for proper mixing using following formula:
G = (P/ V)0.5
where,
G = velocity gradient in s-1
P = power input in Watt
= dynamic viscosity of water in newton-seconds/m2
V = volume of Flash Mixing Chamber in m3
The design criteria and sizes for the flash mixing tanks are presented in Table
3.7 below.
PAGE 6 of 35
1928 of 2461
MMRDA
Table 3.7: Design Criteria and sizes for the Flash Mixing Tank
Units
Value
Design Flow (Ultimate Phase flow)
m3/h
26672
No. of Units
No.
Minimum Hydraulic Detention Time
sec
40
Mixing Velocity Gradient Range
-1
300 to 600
Volume Required, each mechanical
m3
(adopted 400)
14
Hydraulic Mixing Tank

Dimensions
Width
mm
4000
SWD
mm
5000
Freeboard
mm
500
Outlet Flow Control
Weir
Mixers
No. per Tank
No.
Type
1
Mechanical with
Axial Impeller
Vertical
Mounting
3.3.4 Flocculation and Clarification
For efficient settling of the suspended matter, aggregation of the destabilised

matter from the rapid mixing unit shall be done in the flocculation unit. In the
flocculation unit, slow and gentle fluid motion by mechanical mixing shall
create aggregates. These aggregates then shall be settled out in the
clarification unit.
Plate settler clarifiers shall be provided for the WTP.
The Rectangular clarifier with plate settlers having a smaller footprint and
compactness of the plant, lower power consumption and flexibility for use due
to its short start up time shall be provided. The clarification unit shall have
bypass arrangement, if the raw water is to be passed on for direct filtration.
The plates shall be of SS 316.
PAGE 7 of 35
1929 of 2461
MMRDA
3.3.5 Rectangular Clarifier with Plate Settlers

In these settlers, water shall flow under gravity from the flash mixer to
flocculators and then to the clarifier. The clarifier is proposed with plate settler.
Typical details of the settlers are described below.
The coagulated water from the flash-mixing tank shall be fed by gravity into
flocculation tanks each fitted with four paddle type agitators for the
flocculation of coagulated suspended solids. Gentle and prolonged mixing by
paddle agitation of slow speed shall create large and readily settleable flocs.
Adequate retention time shall be provided in the flocculation tank for mixing
and the water shall move successively through all sections and then enter the
outlet.
The flocculation tanks and plate settler clarifiers shall be one, built integral
with each other. The inlet launder shall serve the function of a weir for equal
and uniform distribution of coagulated raw water. The flocculated water shall
enter the respective clarifiers for clarification, through openings in the
flocculation tank side-walls, below the overflow launders of clarifiers. The
rectangular clarifier with plate settlers shall be designed for the removal of
suspended solids from the coagulated raw water, which shall increase during
the monsoon season.
There shall be a quantitative hydraulic separation of sludge and clarified water
compartment. The system shall be designed so that it remains insensitive to
hydraulic shock loads and can take a load increase of up to 100% for short
duration. Laminar flow conditions shall prevail within the plates flow paths.
The clarifiers shall be of rectangular RCC construction, with two perfect
squares so that it shall be suitable to provide the bottom with circular hopper
configuration, for providing two sludge scraper mechanisms in each clarifier.
The clarifiers shall be provided with a bottom slope of 1:12.
The clarifiers shall have distinct plate separation zone, sludge thickener zone
and clear water zone. Within each clarifier, plates shall be so arranged that
PAGE 8 of 35
1930 of 2461
MMRDA
the incoming solids shall be distributed between the rows of plates, whereby
the flocs can enter the plate packs in the lower portion through special inlet
feed ports. The clarified water overflow shall take place over adjustable
overflow weirs on the upper edge of the plate pack. Each water layer in
between two plates shall have individual overflow assisting in equal
distribution of solids and water over the whole of the projected sedimentation
area.
The overflow weirs shall be attached to both the upper corners of the plate
rows. Heavy solids shall settle even whilst travelling between the plate rows
and shall
be directly entering the thickener zone underneath the
sedimentation area. Thus it shall have a polishing function for the residual
smaller solids and the projected settling area shall not be fully loaded with the
total solids to be treated.
As a standard, the angle of the plates to the horizontal inlet flume, outlet
trough and its bottom shall create a H-shaped cross section of the main
girders that span the length and carry lamella plates and accessories. It shall
be possible to take out each plate individually for cleaning and maintenance
purposes. A minimum depth shall be provided below the plates to allow
sludge to settle without breaking.
Clarified water shall be directed to the outlet weir launders. The outlet
launders shall convey clarified water towards the common collecting channel,
leading to the clarified water collection chamber.
The sludge settling on the floor of the clarifiers shall be scraped by the
mechanical scraper to the central pit and the solids sludge from each clarifier
shall be discharged for further treatment. The Typical design criteria and unit
sizes for Flocculator and plate settler clarifier are given below in Table 3.8 and
3.9.
Table 3.8 : Design criteria and unit sizes (Flocculators)
Parameters / Component
Unit
Value
PAGE 9 of 35
1931 of 2461
MMRDA
Total Design raw water flow

Nos. of Units (Flocculator)
Minimum hydraulic retention range
Mixing velocity gradient range
Volume required of each tank
Dimension
Length
Width
SWD
Free Board
Outlet flow control
Mixing paddles
Type
Mounting
Motor each
m3/h
Nos.
Minutes
-1
m3
19630
16
15
10 to 75 (adopted 40)
410
m
m
m
m
15.0
7.5
4.5
0.30
Valve
4
Mechanical with axial impeller
vertical
0.5
Nos.
kW
Table 3.9: Design criteria and unit sizes (Plate Settler Clarifier)
Parameters /
Total Design raw water flow
Nos. of Units
Surface loading rate
Surface area required for each tank
Length
Breadth
Liquid Depth
Outlet flow control
Plates dimension
Height
Width
Thickness
No. of plates each clarifier
Plate Material
Angle of inclination
Scrapper
Unit
m3/h
Nos.
m3/m2/hr
m2
m
m
m
Value
19630
8
1
2455
30
15
4.5
Weir
m
m
mm
1.50
1.22
0.80
2412
Stainless Steel 316
55
Mechanical
degree
3.3.6 Rapid Sand Filter

3.3.6.1 Design Details
Declining Rate Rapid Sand Filters shall be provided for filtration of settled
water. Flow control arrangements shall be provided. Sand shall be used as
the single filter medium. The filter shall be cleaned periodically using
backwash water and air scour combination. Nozzle type or Hollow
PAGE 10 of 35
1932 of 2461
MMRDA
Partitioned Block Type or pipe for under drain system under drains shall be
provided. The filter beds shall be covered with permanent RCC roof
structure so that dust and other elements do not affect the settled water
quality in the filter beds. The provision of roof shall also prevent algal
growth in the filter beds during sunlight hours.
This design shall provide for single filter medium. Medium size of filter sand
shall be preferable since the allowable turbidity of filtered water is <1.0
NTU, which shall allow longer filter runs. Air + backwashing for filter shall be
more suitable for medium size filter sand. From the above selection, the
combination of following filter type is proposed:
The design criteria and Unit Sizes for the rapid sand type filters are
presented in Table 3.10 below.
Table 3.10: Design Criteria and Unit sizes for the Filters
Units
Value/Type
Design Raw Water Flow
m /h
19630
No. of Units (minimum)
No.
32
Type of Filtration
Declining Rate
3
Maximum Filtration Rate
m /hr/m
5.0
Velocity in the Outlet Channel to the Filters
m/s
1.0 to 1.5
Height of Troughs above Filter Sand
mm
700
Surface (maximum)
Minimum Freeboard
mm
600
Depth and Gradation of Support
mm
According to the
Gravel Layer(s)
Manufacturers
Depth of Sand Media
mm
Recommendation
Not
less than 750 mm
Effective Size of Sand Particles
mm
0.45
Uniformity Coefficient of Sand
1.3 to 1.7
Velocity of Water at Inlet to Filter
m/s
Not to exceed 1.0
Velocity of Wash Water at Inlet to Filter
m/s
2.4 to 3.5
Velocity of Water at Outlet of Filter
m/s
0.9 to 1.8
Velocity of Wash Water at Outlet of Filter
m/s
1.2 to 1.8
PAGE 11 of 35
1933 of 2461
MMRDA
Units
Value/Type
Filter Backwashing
No. of Backwashes per day per Filter
No.
3
1.0
Design Max Backwash Water Flow Rate
m /min/m
0.60
Design Max Backwash Air Flow Rate
m3/min/m2
1.00
Filter Unit Size

Length
12.5
Width
10.0
mm
0.6
1.5
mm
700
Filter Media
Filter Sand
Effective Size
Uniformity Coefficient
Thickness of sand layer
Supporting Gravel
mm
500
No. of Layers
nos
Range of size (diameter)
mm
2 to 40
Thickness of each layer
mm
90 to 20 mm
Filter Washing
Method of Washing
Air + Backwash
Washing Rate
Air Scouring
m/h
45
Backwashing (after air wash)
m/h
36
Backwashing (with water only)
m/h
36
Washwater Trough
No. of Trough per cell
nos.
Material of construction
-- --
Concrete
Width
mm
500
Depth
Gullet
Width
mm
350
mm
900
Dimensions (internal)
Depth
Piping (for each bed)
mm
800
PAGE 12 of 35
1934 of 2461
MMRDA
Units
Value/Type
Inlet Gate
mm
450 x 450
Filter outlet pipe and valve
mm
400
Air scouring pipe and valve (ND)
mm
250
Backwash pipe and valve (ND)
mm
750
Filter outlet header conduit common
mm
2800
Air Scouring main (ND)
mm
300
Backwash main (ND)
mm
750
Filter drain (ND)
mm
200
Backwash Drain Gate
mm
900 x 900
m3
Backwash Water Storage Tank
1100
Structure
RCC
No. of tanks / compartments
nos.
Back wash pumps
Nos.
(2W + 1S)
3.3.6.2 Backwash System

A backwash water storage tank shall be provided and equipped with the
following instrumentation:
a.
A high water level sensor which shall activate an alarm and close the
storage tank inlet valve
b.
A low water level sensor which shall activate an alarm, indicating the
tank is empty and not allow a backwash event to proceed.
c.
An ultrasonic level sensor shall be provided to continuously indicate

the level in the storage tank. A level switch shall not allow a
backwash event to proceed until the water in the storage tank has
reached that setpoint level.
d.
An outlet backwash water regulating valve and flow meter shall be

provided to control the flow rate by open/close/throttling the valve to
achieve backwash water flow rates as programmed into the PLC.
PAGE 13 of 35
1935 of 2461
MMRDA
Backwash air (air scour) shall be provided by blowers located in the filter
house. Operation of these blower units and the air scour valves will be
sequenced with the operation of the BW water valves as determined by the
PLC software or the operator in case where backwashing is being
performed in Manual mode.
a)
Washing Sequence
The PLC in the Filter ICP shall be programmed to operate the

following Filter Backwash Sequence when in automatic or semiautomatic mode. The time durations of each stage of the backwashing
cycle shall be adjustable by the WTP Operator at the PLC human
machine interface (HMI). Adjustable timeframe durations are shown in
minutes.
Normal washing sequence shall be as follows:
Firstly, starting air scouring with the rate of 0.6 - 1.5 m 3/min/m 2
for about a 2 minute period
Followed by water backwashing, after release of air from sand

layer for one minutes, at the rate of 0.6 - 0.8 m 3/min/m
for
for
about a 5 minute period
Only water backwashing at the rate 0.6 - 0.8 m 3/min/m

about a 3 minute
b)
Draining out water through gullet and backwash drain pipe
Backwash Water Storage Tank
A backwash water storage tank shall be provided, with the capacity to

hold enough water to supply two (2) backwash events. The BW water
shall be conveyed to an individual filter under gravity flow from this
PAGE 14 of 35
1936 of 2461
MMRDA
storage tank.
The BW water lift pump, installed at Filter Building shall transfer
filtered water to BW tank. Flow shall be controlled by a flow meter
and a control valve installed on pipeline to the BW Storage Tank.
This control valve shall be opened and closed by signals from the low
and high water level switches, respectively, located in the storage
tank.
This shall increase the overall reliability of the plant, as once the
storage tank is half full the backwash process can proceed in case of a
power outage.
The capacity of tank shall not be less than 1100 m3.
This wash water tank shall also be used as one way surge tank for
water hammer control of clear water pumping main. The outlet for
back wash water will be kept 0.3-0.5 m above the bottom of tank and
outlet for water hammer control shall be at bottom.
c)
Backwash Water Lift Pumps
Backwash water for the Filter shall be stored in Backwash tank which
will be filled by the Backwash Water Lift Pumps installed at the Filter
House. The pumps shall be designed to fill backwash tank (volume of
BW Tank: 1100 m3) in 1 hr. A summary of the major design criteria
for the backwash lift pumps is given in Table 3.11 below.
Table 3.11: Design Criteria for Backwash Water Lift Pumps
Description of Item
Type of Pump
Units
Value/Type
Horizontal centrifugal
Number of Pumps to be Furnished
nos.
Normal Number of Duty Pumps
no.
No. of Pump Spaces to be Installed
nos.
Pump Output each, at design point
m /hr
1100
Pumping Head Required, at design
15
Minimum Allowable Guaranteed
80
Pump Efficiency, at design point

PAGE 15 of 35
1937 of 2461
MMRDA
Maximum Pump Efficiency point
within 3 % of the
location
Maximum Synchronous Motor Speed
rpm
design point
1,000
Maximum Driver (Electric Motor)
kW
30
Rating 30 kW (2W + 1S)

d)
Air Blower for Filter Washing
The filter washing air blower designed in the preliminary design shall
be of the twin-lobe rotary type or Turbo blower type. The blower shall
be air-cooled and driven by electric motor. They shall be mounted in
the horizontal position with the motor mounted side by side or piggybacked and connected to the blower with v-belts. The design shall
provide for (2W + 2S) blowers. Each air blower shall have a capacity
of 2500 m3/hr. The design parameters of air blower are summarized
in Table 3.12 below.
Table 3.12 : Design Parameters of Air Blower
Description of Item
Units
Phase 1
(This Project)
Type of Blower Units
-- --
Rotary Twin
Number of Blowers to be
Nos.
4 (2W+2S)
Nos.
m3/hr
2500
Furnished
Normal Number of Duty Blower
Discharge Capacity (each)
3.3.6.3 Filter House (Building)
Control equipment and other ancillary equipment for filter operation as
follows:
At Basement Floor:
Filtered water outlet chamber with weir
PAGE 16 of 35
1938 of 2461
MMRDA
Filtered water flow meter (electro-magnetic
Backwash water flow meter (electro-magnetic) and control valve

(butterfly valve with metal seat)
Exhaust fans for ventilation of pipe gallery of filter
At Ground Floor:
Air Blowers and backwash pump house.
An electric room and ICP
Duty room with washroom
3.3.6.4 Waste Backwash Water

Waste Backwash water flow shall be conveyed via a pipeline to the sludge
buffer tank (sludge balancing tank) where it get shall get mixed with clarifier
sludge and then pumped to thickener and further to dewatering system.
3.3.6.5 Chlorine Contact Tank and Clear Water Sump
The Clear Water Sump shall be preceded with a chlorine contact tank
(CCT). Clear water shall be conveyed to the CCT from the filter house via
a filter outlet chamber where chlorine solution will be injected for postchlorination disinfection at the outlet of the chamber. Filtered water shall be
measured by a flow meter (Electro-Magnetic) at inlet of the filter outlet
chamber. Design Criteria and sizes for CCT and clear water tank are shown
Table 3.13: Design Criteria and sizes for CCT and Clear Water Tank
Chlorine Contact Tank
PAGE 17 of 35
1939 of 2461
MMRDA
Detention time for chlorine contact tank
Minutes
30
Compartment (Baffles to be provided in tank
Nos
m3
9525
Minutes
Nos
m3
m
mxm
90
2
28600
5
65 x 88
for mixing of Chlorine)

Total Storage
Clear water Tank
Detention time for clear water tank
No of Compartment
Total storage
Depth
Size
(65 44
Note: The Clear water tank will be provided with chlorine contact tank to
economize the construction.
3.4
Sludge Handling Facilities
3.4.1 Process Water

The process water in treatment process is generated at following locations.
i.
Backwashing of filters.
ii.
Sludge from plate settler.

As the Sludge from plate settler clarifier contains high concentration of polyelectrolytes, salts of alumina and ferric which need to be removed prior to
disposal, sludge treatment shall be provided.
Waste backwash water shall be conveyed to the sludge buffer tank where it will
get mixed with clarifier sludge and shall be pumped to the thickener and further
the thickened sludge shall be pumped to dewatering unit. The supernatant and
filtrate generated at thickener and centrifuge respectively shall be conveyed to
the inlet of the WTP.
3.4.2 Sludge Balancing Tank

PAGE 18 of 35
1940 of 2461
MMRDA
Clarifier sludge from the plate settler tank shall be removed from the sludge
hoppers controlled by the opening and closing of control valves. The control
valves shall operate based on a signal from a timer in the automatic mode. The
valve will open for a set period at regular intervals, as established by the plant
operation staff. The solids mass balance and operational testing will determine
the frequency and duration of sludge draw-off from these tanks.
Sludge removed from the plate settler tank shall be conveyed under gravity to
the Sludge Balancing (SB) tank. Waste backwash from filter will also be
conveyed to sludge balancing tank. This tank will serve as an equalization tank
for feeding sludge to the thickeners. The capacity of tank shall be 1300 m3.
Sludge Balancing Tank shall be provided with mixer or blower to prevent sludge
from settling down and keep it homogeneous.
3.4.3 Sludge Transfer Pump (Sludge Balancing Tank to Thickener)
The sludge from Sludge Balancing Tank shall be pumped to the thickener
periodically. The alum sludge to be pumped shall have a consistency close to
that of water, with the solids content ranging from 0.8% to 1.2%. A solids
handling pump shall be used. The design criteria for the sludge pumps feeding
the thickeners is given in Table 3.14 below.
Table 3.14: Design Criteria for the Sludge Pumps to the Thickeners
Description of Item
Units
Phase 1 (This Project)
Type of Pump
-- --
Non-Clog submersible
Mounting Configuration
-- --
Vertical
Nos.
No.
m /hr
195 (each)
Pumping Head Required, at design point
12a +/-
Minimum Allowable Guaranteed Pump
75%
Efficiency, at design point

Maximum Pump Efficiency point location
-- --
within 5 % of the design
rpm
1,500
Maximum Driver (Electric Motor) Rating
kW
9.32=18.6
PAGE 19 of 35
1941 of 2461
MMRDA
Electrical Service to be Provided
V/ph/hz
415/3/50
Type of Lubrication for bearings
-- --
Grease
Type of Shaft Seal
-- --
Mechanical seal
a The pumping head shall be estimated from the Sludge Buffer Tank LWL to the
HWL in the Thickener
3.4.4 Sludge Thickener

The sludge generated from plate settler shall be inorganic sludge, however the
volume of shall be large and sludge thickening and dewatering to increase the
solid concentration shall be essential. A gravity thickener of fill and draw type
shall be provided with slow revolving stirrers to improve its efficiency. The
overflow (Supernatant) from the thickener shall be returned to the inlet channel
(before Parshall Flume) by recirculation sump and pumps.
3.4.5 Sludge Transfer Pump (Thickener to centrifuge)
Sludge withdrawn from the sludge thickeners shall be pumped to a centrifuge in
the sludge dewatering building. The thickened sludge shall have a consistency
more viscous at pump start-up. The thickened sludge will have a maximum
solids content normally ranging from 2.0% to 4.0%. A progressive cavity type
solids handling pumps shall be used for this application. The design criteria for
the sludge pumps conveying sludge from the thickeners to the centrifuge is
given in Table 3.15 below.
Table 3.15: Design Criteria for the Thickened Sludge Transfer Pumps
Description of Item
Units
Value/Ty
Type of Pump
-- --
Mounting Configuration
-- --
Nos.
3a
No.

Pumping Head Required, at design point
Progressive
Horizontal
m /hr
30
15b +/-
PAGE 20 of 35
1942 of 2461
MMRDA
Minimum Allowable Guaranteed Pump
38%
rpm
kW
1,500
5.5 b
Type of Drive
Electrical Service to be Provided
-- -V/ph/hz
V-belt
415/3/50
Type of Lubrication for bearings
-- --
oil or grease
Type of Shaft Seal
-- --
gland packing
Inspection Ports on Body

Notes:
-- --
or mechanical
Yes
Efficiency, at design point

Maximum Driver (Electric Motor) Rating
a) One (1) duty + one (1) standby pump per thickener shall be provided
b) Four working (4W) thickeners shall be provided in initial phase and
one (1)
additional thickener will be installed in second phase.

3.4.6 Centrifuge
Thickened sludge shall be dewatered in the Centrifuge units by pumping it
individually to each centrifuge from the storage tank. Coordinating the operation
of the components of the entire sludge handling system shall depend on the
operating schedule (8 hours per day) of the Centrifuge units. Filtrate discharged
from the Centrifuge units shall be returned to the inlet channel upstream of
Parshall flume (or to the sludge balancing tank depending upon concentration of
filtrate).
The Centrifuge units shall be located on the first (upper) level of the dewatering
building so that the dewatered sludge cake can be dropped into the bucket of a
tipper truck for handling to disposal in a landfill or to a reuse site. The design
criteria of the sludge handling system are presented in Table 3.16 below.
Table 3.16: Design Criteria and unit sizes for the Sludge Handling
Systems
Units
Value
No.
Sludge Balancing Tank

Number
PAGE 21 of 35
1943 of 2461
MMRDA
m3
1300
Diameter
20.5
SWD
mm
600
kg/h
1950
585
Volume(15% of total sludge generated per day)

Dimensions
Minimum Freeboard
Sludge Thickeners
Sludge Transfer to Thickener
m /h
Number of Thickener
No.
Solids Loading Rate
kg/h/m
Diameter Required
SWD
Hydraulic Loading Rate
4
2
m /h/m
2
17.50
4
2
0.60
Thickened Sludge Holding Tank

Size
mxm
5 x 10
Nos.
(3 + 1)
m /h
kg/h
hrs/d
m3/hr
58.50
1760
16
25
Sludge Cake Produced (Initial)

Average Sludge Cake Concentration
m3/d
%
6.32
25
Total supernatant flow from thickener

Supernatant flow from centrifuge
m3/hr
m3/hr
526.2
52.1
Sludge Centrifuge
Minimum Number (duty + standby)
Thickened Sludge Loading
Centrifuge Operation
Capacity of Centrifuge, each
3.5
Recirculation Sump and Pump House
Supernatant from sludge thickeners and centrifuge units shall be conveyed by

gravity to recirculation sump and pump house. The supernatant shall be
further conveyed by pumping to Inlet channel upstream of the Parshall Flume.
The Design details shall be as under:
i)
ii)
Flow from thickeners

Flow from centrifuge
526.2 m3/h
52.1 m3/h
iii)
Total Inflow to sump
578.3 m3/h
PAGE 22 of 35
1944 of 2461
3.6
MMRDA
iv)
Capacity of sump @ 2 hrs.
1200 m3
v)
Pumping rate
600 m3/h
vi)
No. of Pumps 1(W) + 1(S)
2 Nos.
vii)
Pump head
12 m
viii)
Speed
1000 RPM
ix)
Motor kW
37.5 kW
x)
Diameter of pumping main
500 mm <|>
xi)
MOC of pipe
DI
Chemical Handling Facilities
3.6.1 Chemical Application

Alum and poly-electrolytes shall be used as coagulants. The solid alum with
16% concentration or liquid alum with 8% concentration shall be used.
Lime in the form of dry calcium hydroxide (hydrated lime) in 50 kg bags having
a purity of 80 to 86% shall be used.
Chlorine gas shall be used for pre-chlorination and post chlorination and shall be
normally supplied as liquid chlorine in tonner.
Chemical Dosage shall vary as per the raw water turbidity. However, following
minimum or maximum dosages shall be used as guidelines. The coagulant
doses will be decided by jar test. Lime dose shall depend on the pH of raw
water. Details about Chemical Dosage and Application Point are listed in
Table 3.17 below.
Table 3.17: Chemical Dosage and Application Point
Chemical
Alum
Purpose
Coagulation
Dosage Rate
Max.
40
Ave.
Min.
20
10
Dosage Point
Prior to flash mixing
tank
PAGE 23 of 35
1945 of 2461
Chemical
Lime (Optional)
MMRDA
Purpose
Dosage Rate
pH adjustment for
Dosage Point
Max.
10
Prior to flash mixing
Ave.
Min.
Max.
5
5
Filter outlet prior to
Coagulation Aid
Ave.
Min.
Max.
3
1.0
Oxidization
Ave.
Min.
Max.
0.5
0.3
1.5
Coagulation (Optional
if required)
pH adjustment for
water(Optional)
Polymer
Pre-Chlorine
chlorination
Prior to thickener or
centrifuge
Aerator
Outlet Pipe
Post-Chlorine
Disinfection
Max.
1.0
Filter (outlet)/CCT
Inlet
3.6.2 Alum and Lime Dosage

The alum and lime required for WTP shall be stored in the chemical storage
house. The solutions will be prepared in chemical house in solution tanks. The
alum solution will be injected into water before entry to flash mixer units. The
pH of raw water is marginally alkaline and thus heavy dose of alum will make
the water acidic (i.e. pH less than 7). The pH of treated water supply shall be
in the range of 6.8 to 7.5 and thus lime solution may be required to bring the
water to the permissible pH.
The alum and lime dry storage shall be located on the ground floor (lower
level) of the chemical house. The dissolving / mixing tanks have been
designed as solution tanks which shall be filled twice daily. The solution tanks
shall be RCC structures with coating or lining. Two tanks shall be provided for
preparation of solution and dosing operations.
The alum and lime dosing shall be by gravity flow from the solution tanks placed
at the upper floor to the points of application. The tanks and dosing devices
will be installed at a sufficient elevation to convey chemical solution to the
dosage points by gravity. Duplicate (2) dosing solution lines with isolation
PAGE 24 of 35
1946 of 2461
MMRDA
valves shall be provided between the dosage tanks and the dosing points
such that dosing of chemical need not be stopped to do maintenance on one
of the solution lines. Isolation and flow regulating valves shall be provided on
both lines at the chemical house. Where required, isolation valves shall be
provided at the dosing points also. The flow regulating valve shall be motor
operated SS full port ball type control valve. These valves shall be of the
same diameter as the dosing solution lines. The diameter of the pipes in the
chemical plant and to the injection points shall be suitable for high flow
velocity to prevent deposition. The dosage tank shall be of stainless steel (SS
304) for both Alum and Lime having adequate volume for receiving chemical
solution and stable dosage. Each tank shall have device for stable water level.
An overflow pipe to return to the Dissolution/Mixing tank and drain pipes with
a stop valve shall be provided in each tank.
For preparation of Polymer solution, the package type solution system shall be
installed. Dosage of polymer to the application point will be by gravity.
Alum and lime solution feed shall be controlled by the PLC in the chemical
building instrument control panel (ICP). A dosage of each chemical shall be
selected by the operations staff based upon their jar testing to optimize the
flocculation process. The chemical feed rates required shall be calculated by
the PLC based upon the measured raw water flow rate and the concentration
of the chemical in the day tank, as entered by the operations staff. The
concentration of either alum or lime in the day tank shall be dependent upon
the amounts of dry chemical and the volume of water added to the tank.
These values shall be entered at the PLCs HMI by the operations staff.
3.7
Chlorination System
Chlorine shall be used for two (2) major functions at the WTP and one (1) minor
function at the MBRs exit point (booster dose):
Pre-chlorination shall be provided to oxidize compounds of iron and manganese
to assist in their removal. As post chlorination it will offer a safety margin till the
water is conveyed to the MBRs. In MBRs booster chlorine dose will be given
PAGE 25 of 35
1947 of 2461
MMRDA
before water goes into the distribution networks.

The chlorine withdrawal rate from tonne container / cylinder at the WTP shall
allow chlorine to be withdrawn from a cylinder in the gaseous state. The gas
shall be drawn from multi cylinders in battery to meet the required rate.
Chlorine gas is very toxic chemical which is a severe irritant, an asphyxiant
and an oxidizing agent. To provide as safe as possible working conditions, a
vacuum type chlorination system will be provided.
The design criteria for the components of the chlorination system are presented
Table 3.18: Design Criteria for the Chlorination System
Units
Design Raw Water / Production Flows
MLd
No. of Units
No.
Pre-chlor Post-chlor
472
458
Design Dosage
mg/L
1.5
1.0
Dosage
kg/h
29.50
19.10
Chlorinators
Number (duty + standby)
Capacity, each
no.
1+1
1+1
kg/h
30
25
Total chlorine requirement

Total chlorine requirement
Capacity per cylinder
Nos. of cylinders
Nos. of cylinders
kg/h
48.60
kg/d
1067
kg
900
per day
1.2
per 20
24
With space in the tonner storage room for 24 tonners (including those in use),
approximately 20 days of storage will be provided.
Booster doses required at MBRs (2 Nos.) will be provided at the rate of 1
mg/l. The capacity of chlorinator, wall mounting type shall be 10 Kg/hr with
storage of 4 Tonners at each site. The configuration of chlorinators will be 1+1
(duty + standby).
PAGE 26 of 35
1948 of 2461
MMRDA
3.7.1 Chlorine Gas Neutralization System

A chlorine gas neutralization system shall be provided in case a leak in a
cylinder or elsewhere in the gas conveyance system occurs. The
neutralization system shall draw air from the cylinder storage and chlorinator
rooms and convey it to an absorption tower where it shall be neutralized with
Caustic Soda solution. The caustic solution will be re-circulated through the
absorption tower by a pump. Since chlorine gas is heavier than air the draw
off points for the normal ventilation system shall be located close to the floor
level and In the case of heavy leakage, normal ventilation system shall be
closed down and will pull air from the building, through the absorption tower
and then expel it to atmosphere through a stack.
Chlorine Gas Neutralization System Components are presented in Table 3.19
below.
Table 3.19: Chlorine Gas Neutralization System Components
Component / Parameter
Unit
Value
kg/h
200
Maximum Chlorine neutralisation
kg
900
Air to Chlorine Mixture
-- --
6 to 1
(volume/volume)
Absorption Tower
-- --
Packed with Rashig Rings or
kg
Equivalent
1140
Chlorine Leak neutralisation
Caustic
Soda
(50%
NaOH)
Storage Capacity
Remarks
m3
8.5
deg-C
60
Connected Power
kW
<5
Recirculation Pump Only
Emergency Ventilation Fan
kW
As required to ventilate
Water Storage Capacity

Solution Temperature after
the cylinder storage

and chlorinator rooms
Emergency Ventilation Rate
m3/min
Control of Gas Neutralization
Signal from the chlorine leak
System
detection system
PAGE 27 of 35
1949 of 2461
MMRDA
Installation
Outdoors
with a canopy roof
Notes:
a The chlorine gas neutralization system as per manufacturers design
3.7.2 Chlorination System Operation

The operating parameters and control scheme for the components of the
chlorination system are presented in Table 3.20 below. The chlorination
system shall be operated in an automatic mode controlled by the chlorine
building PLC or manually.
Table 3.20: Operation of the Chlorination System
Operati
Mode of
Pre-chlorination and Post-
onal
Regulation of the
Operation
Manual
Chlorination Control Scheme

The dosage in mg/L shall be set manually at the PLC
chlorine dosage
dosage
and a signal from the Raw Water or Filtered Water flow
rate
meter shall vary the chlorine solution feed rate

based upon the variations in plant flows
Automated
flow pacing
Control of the utility
Automatic
water flow rate
Based upon a demand signal from the Raw Water or

Filtered Water flow meter, with a minimum set point to
the chlorine will be dosed automatically
Stop of chlorine
Manual
Normally
gas flow
Stop of utility
Automatic
When the Raw Water flow is zero
Automatic
If an ejector fails
Automatic
If cylinders on the Chlorine Scale are empty
Manual
Normally
water to the
ejectors
Automatic
If cylinders on the Chlorine supply are empty or in

case of a gas leak
PAGE 28 of 35
1950 of 2461
Stop of
Manual
MMRDA
Normally
chlorine flow
at the
chlorine
cylinders
Automatic
If cylinders on the Chlorine supply are empty or in

case of a gas leak
Acoustic alarm
Automatic
Normal ventilation
Manual
Actuated in case of leakage in the Chlorine

Cylinder Room or Chlorinator Room
On/Off,
exhaust fans and

exhaust louvers
Automatic
Thermostatically controlled and will shutoff and

louvers will close if a gas leaks is detected
Start of
Automatic
emergency

Cylinder Room or the Chlorinator Room and must
ventilation
fans
Start chlorination
Manual
be shutoff manually
system
Start of Chlorine
Automatic
Gas
Cylinder Room or the Chlorinator Room and must
Neutralization
be shutoff manually
System
3.7.3 Safety
The safety requirement according to all statutory Rules & Regulations for
hazardous chlorine shall be observed.
Following safety measures but not limited to be provided at each site.
i.
Safety emergency kit
1 No.
ii.
Breathing apparatus, self-contained
1 No.
iii.
Emergency showers
1 No.
iv.
Eye fountain
1 No.
v.
Weather cock
1 No.
PAGE 29 of 35
1951 of 2461
MMRDA
vi.
First Aid Box
1 No.
vii.
Safety signs
As per site requirement
viii.
Scrubbing system NaOH Type
1 No.
ix.
Chlorine leak detector sensor
Online
x.
Chlorine residual testing kit
xi.
Safety shoes as per requirement
xii.
Ammonia torch
1 No.
3.7.4 Statutory Approvals

All statutory approvals required for shortage, handling and operation of
chlorine cylinders and chlorination system shall be responsibility of Contractor
at his cost. The employer shall extend required co-operation.
3.8
Other WTP Buildings
Nine (9) major buildings shall be provided for operation and maintenance and
to house major process equipment including:
Filter House
Clear Water Pump Station
Chemical House for Alum, Polymer and Lime Dosage Equipment
Chlorine Building for Chlorination Equipment
Thickened Sludge Extraction Pump House
Dewatering Building for Centrifuge Equipment
Recirculation pumping station
PAGE 30 of 35
1952 of 2461
MMRDA
Maintenance / Storage Building
The rooms and area of the above buildings are summarized in Table3.21
below.
Table 3.21: Major Buildings
Building / Room
Area (m2)
Area (m2)
Building / Room
(Ground Floor)
(First Floor)
Entrance / Reception Area
50
Control Room
55
Managers Room
20
Laboratory
70
Offices
35
Conference / Training
65
Meeting / Break Room
20
Storerooms
15
Duty Room
25
Bathrooms
15
Bathrooms
15
Mechanical/Electrical
20
Storeroom
30
Stairways / Corridors
60
Mechanical / Electrical Room
30
Stairways / Corridors
96
Total Area
321
Total Area
300
Filter House
(Basement Floor)
Filter Area
Total Area
(Ground Floor)
3000
3000
Backwash Air Blower
68
Electrical room
16
Operator cum
68
Stairway / Corridor
20
Total Area
172
Clear Water Pumping Station
Chlorine Building
(Ground Floor)
(Ground Floor)
Pump Room (4020)
Total Area
800
Cylinder Storage Room
165
Chlorinator and
77
Booster
Pump Room
Total Area
242
Chemical House (Alum, Polymer, Lime Dosage)

(Ground Floor)
Alum Storage
Lime Storage
(First Floor)
450
Alum /Polymer / Lime Solution
32
50
Room
Electrical / Control
24
Duty Room
12
PAGE 31 of 35
1953 of 2461
Building / Room
MMRDA
Area (m2)
Total Area
500
Area (m2)
Building / Room
Bathroom
Total Area
74
Thickened Sludge Extraction Pump House (two Houses for four thickeners)
(Basement Floor)
Pump Room
(Ground Floor)
32
Electrical / Control
32
Dewatering Building
(Ground Floor)
Truck Loading Bay
(First Floor)
95
Centrifuge Room including
325
electrical and control

Pump Room (incl. sludge storage
232
tank & Polymer)

Total Area
500
Maintenance / Storage Building

(Ground Floor)
3.9
Stairway / Corridors
Total Area
50
375
(Ground Floor)
Mechanical Shop
72
Flammable Storage
16
Electrical Shop
16
Chemical / Battery
20
Paint Shop
Dry Goods / Spare Storage
16
54
Electrical Room
Bathroom
10
6
Total Area
210
Clear Water Sump and Pumping Station
The treated water from water treatment plant after chlorination in chlorine
contact tank shall be admitted to clear water sump for pumping and
transmission to break pressure tank located at about 315 m from the clear
water pumping station.
The clear water sump shall be designed for 1 hour capacity of projected future
flow. The hydraulic design of the sump shall be based on ensuring uniform
and streamlined flow at low velocity for vortex-free operation of clear water
pumps without any hydraulic disturbance.
Clear water Pumping station is planned above clear water sump.
The Clear water Sump data are as under:
PAGE 32 of 35
1954 of 2461
MMRDA
Top Water Level (TWL)
80.0 m
Lowest Water Level (LWL)
75.0 m
Floor level is kept @ 81.5 m i.e. 1.5 m above TWL. Suitable overflow with weir
shall be provided. The overflow shall be conveyed and disposed to nearby
nallah.
3.10
WTP Complex Camp Office
The contractor shall provide the following camp office facilities for use by the
MMRDA. The facilities shall be controlled by the Project Director designated
by the MMRDA.
1.
Office Complex of MMRDA (as distinct from the O & M Office complex):
This complex shall be separated from other facilities and technical area
of the WTP at Suryanagar and shall be developed in a plot of about
5000 sq m. The complex shall be isolated by a compound wall and
access controlled security gate as directed by the Employer.
2.
The complex shall have G+1 storied an Inspection Bungalow with three
(3) fully air conditioned and three non-AC guest suites each of size 50
sq m. The guest suites shall be fully furnished with good quality
furniture and furnishings. Each suite shall also be provided with Cease
Fire bottle extinguishers and First Aid kits.
3.
The Inspection Bungalow shall also have a suitable size kitchen with
fully provided store room, suitable size pantry, private and common
dining rooms, lounge and sit out areas with furnishings.
4.
The complex shall also provide for an office having a built up area of
about 100 sq m in two / three stories. The office building shall have
fully furnished offices of sizes 20 sq m (8 Nos.) to 50 sq m (6 Nos).
The offices shall be provided with individual desktop computers of the
PAGE 33 of 35
1955 of 2461
MMRDA
latest configuration, internet and cloud connections and UPS.

5.
A meeting room of size not less than 200 sq m and suitable to seat
about 30 dignitaries shall be provided with full furniture, projection
systems, toilets and pantry.
6.
The entire complex shall have rooftop solar panels for power
generation and heating requirements.
7.
The whole complex shall have internal and external LED lighting.
8.
The areas around the buildings shall be landscaped and dotted with
exotic shrubs and trees as approved by the Employer.
9.
Fountains and water bodies shall be created and merged with the
landscaped garden surrounding the complex.
10.
All the buildings and structures shall be internally and externally

painted. The MMRDA logo shall be displayed boldly at designated
locations in the complex.
11.
The contractor shall plan this as showcasing the MMRDAs water

production complex as distinct from other entities and shall be
developed as a world class facility.
12.
The WTP Complex and other infrastructure facilities planned at

Suryanagar shall be provided with septic tank.
13.
The plant shall be designed and built for continuous operation all
through the year without any stoppage under normal operating
conditions, and the bidder shall guarantee the same.
3.11
Compound Wall and Fencing:
Compound wall, fencing and security gates shall be provided as per WTP
PAGE 34 of 35
1956 of 2461
MMRDA
layout drawing and as per following details:

1.
Compound on periphery of entire WTP plots, WTP Complex camp

office and quarters;
2.
Compound wall and fencing as WTP layout drawing to segregate

following:
(i)
WTP
(ii)
Quarters
(iii)
WTO complex camp office.
PAGE 35 of 35
1957 of 2461
SUB-SECTION 6C.4
CLEAR WATER PUMPING STATION
1958 of 2461
MMRDA
Table of Contents
SUB-SECTION 6C.4: CLEAR WATER PUMPING STATION ..................................................... 1
4.1
General...................................................................................................................................... 1
4.2
Requirements of Pumping station..................................................................................... 1
4.3
Obligatory Parameters.......................................................................................................... 2
4.4
General Arrangement of Pumping Station ...................................................................... 2
4.5
Combination of Pumps for Clear Water ........................................................................... 3
4.6
Hydraulic Design of pump well and approach bay for Vortex-free Operation of
Pumps ................................................................................................................................................... 4
4.7
Criteria for General Arrangement of Pumping Station................................................. 5
4.7.1
Design Velocity ................................................................................................................. 5
4.7.2
Valves in Individual Delivery ........................................................................................... 5
4.7.3
Space Requirements ....................................................................................................... 6
4.7.4
Floors in Pump Room ...................................................................................................... 6
4.7.5
Pump Foundation ............................................................................................................. 7
4.7.6
Truck Access Bay............................................................................................................. 7
4.7.7
GA of Superstructure ....................................................................................................... 7
4.7.8
Other Facilities .................................................................................................................. 8
4.8
Clear Water Pumps ................................................................................................................ 8
4.8.1
General Requirements .................................................................................................... 8
4.8.2
Pump Duty Conditions ..................................................................................................... 9
4.9
Valves and Pipework ............................................................................................................. 9
4.9.1
General requirements .................................................................................................... 10
4.9.2
Valves - General ............................................................................................................. 10
4.9.3
Pump Automatic Air Inlet/Release Valves .................................................................. 10
4.9.4
Pipe Work -General........................................................................................................ 11
4.9.5
Pump Common Delivery Manifold ............................................................................... 11
4.9.6
Electric Overhead Travelling Crane ............................................................................ 12
4.10
Ventilation System ............................................................................................................... 12
4.11
Provision of Safe Access ................................................................................................... 14
1959 of 2461
MMRDA
SUB-SECTION 6C.4: CLEAR WATER PUMPING STATION

4.1
General
Clear water Pumping station is planned in clear water sump. Functions of the
Clear water shall be pumped and delivered to adjacent BPT for onward
transmission to two MBRs.
The Clear water Sump data are as under:
4.2
Top Water Flood Level (TWL)
80.0 m RL
Lowest Water Level (LWL)
75.0 m RL
Mean water Level ( Mean WL)
77.5 m RL
Requirements of Pumping station
The clear water pumping station shall be suitable to meet following

requirements.
i)
To house required number of vertical turbine pumps including standby

pumps and spare bays for future pumps.
ii)
To house motors, motor control centre, delivery piping, valves,

common header.
iii)
To house control room for control and automation equipment.
iv)
To
house
lifting
equipment
for
handling
of
pumps,
other
electromechanical equipment.
v)
To house well designed ventilation system so as to remove excess
SECTION 6C.4: CLEAR WATER PUMPING STATION
PAGE 1 of 14
1960 of 2461
MMRDA
heat and maintain temperature rise within acceptable limit.

vi)
To ensure streamlined flow at permissible flow velocity to Inlet bell

mouths of vertical turbine pumps as well as meeting all other
parameters such as approach length, spacing of bell mouths, minimum
submergence etc. ensuring that the requirements for vortex-free
operation of pumps are fulfilled.
4.3
Obligatory Parameters
i)
Shape and number of compartments
Shape of pumping station and superstructure shall be

rectangular.
ii)
The pump well shall in two compartments from bottom to TWL.
Number of floors shall be two; lower floor for pump installation and
accommodating piping end valves and upper floor for operation and
electrical panels.
iii)
Lower floor i.e. pumps floor shall be at least 1.5 m above the TWL.
iv)
Number of pumps shall comprise required number of duty pumps as

per contractors design plus minimum two number standby pumps +
empty bay for additional two pumps to be installed in future.
v)
4.4
The pumps shall be self water lubricated vertical turbine pumps.
General Arrangement of Pumping Station
The Clear water pumping station shall comprise the following,

i)
Pump well.
PAGE 2 of 14
1961 of 2461
MMRDA
ii)
Pump mounting floor (lower floor) above TWL.
iii)
Operation floor (upper floor) with adequate head room between two
floors.
iv)
Truck access bay.
v)
Superstructure to accommodate electrically operated travelling crane

for pumps & associated equipment.
4.5
Combination of Pumps for Clear Water
Combination of pumps needs to be decided for planning & space requirement

in pump house and pumping station. Design parameters are as under:
Type of pumps is VT pump
Number of duty pumps suitable for pumping combined flow 19039 m3/h
Minimum standby pumps and spare pump bays
2 numbers standby
2 numbers spare pump bays for future pumps
Combination of pumps shall be optimum combination from the

following.
PAGE 3 of 14
1962 of 2461
MMRDA
RPM 1000 (synchronous)
Parameters for optimum selection
Specific speed between 2500 (USCU) 4200 (USCU) - United

states customary Units
Maximum attainable efficiency as per chart given in Pump Hand

book (latest edition), Book of Dicmas Vertical Turbine, Mixed
Flow & Propeller Pump and / or CPHEEO manual
Preferable shape / curve of H-Q characteristic for the specific

speed
4.6
Stable / rising so as to be suitable for parallel operation
Lesser variation in Q for relatively more variation in H
Wear and tear v/s speed
Magnitude of required submergence as per HI 9.8 / ANSI - 1998
Dynamic load on foundation
Space requirement for the size and number of pumps
Hydraulic Design of pump well and approach bay for Vortex-free

Operation of Pumps
Following parameters for vortex-free operation of pumps MUST be satisfied

on basis of criteria given in HI 9.8 / ANSI 1998 and pump well need to be
planned accordingly.
Streamlined uniform flow from sump to pump centre at low velocity
PAGE 4 of 14
1963 of 2461
MMRDA
W, spacing between bell mouths of adjoining pumps
S, submergence from minimum WL (LWL) in pump well to lip of bell

mouth
C, bottom clearance below bellmouth
X, straight approach length from Inlet of pump well to bell mouth centre
No obstruction and change in flow direction in approach bay
Any structural column coming in flow path shall be rounded /ogee
Floor of approach bay which is part of clear water sump, shall be at

maximum 100 slope , required to achieve minimum submergence
below LWL and required bottom clearance .The slope is shown in
tender drawing for sump and pumping station
To ensure that back clearance does not exceed 0.75 D , a back wall
from floor of pump well to 500 mm above LWL shall be provided
4.7
Criteria for General Arrangement of Pumping Station
4.7.1 Design Velocity

V bell mouth
1.5 m/s
V column
2.75 m/s
V delivery
2.0 m/s
4.7.2 Valves in Individual Delivery
NRV / DPCV
PAGE 5 of 14
1964 of 2461
MMRDA
BFV (long body)
SV / Knife gate valve (KGV)
4.7.3 Space Requirements
Clear space between foundation frames / sole plates of two adjoining

pumps shall be minimum 300 mm
Spacing between end pump and side wall shall be such to obtain clear
space of minimum 600 mm from delivery valves / piping as well as to
ensure that the crane hook reaches is at least up to centre of end
pump
Clear space between two adjoining motors or adjoining valves shall be

minimum 1000 mm
End space between downstream SV / KGV and wall shall be minimum

500 mm
Rear space behind MCC / Panel shall be minimum 1000 mm
Clear space between MCC / Panel and wall of panel room shall be 600
mm higher than clear out position of circuit breaker
Clear space between motor and wall of panel room shall be minimum
1000 mm
4.7.4 Floors in Pump Room
Floors in pump room shall be two numbers, one lower and second
upper
Pumps and motors shall be founded on lower floor
PAGE 6 of 14
1965 of 2461
MMRDA
Panel shall be mounted on upper floor in separate room
Head room between the two floors shall be minimum 2.5 m
Control room for automation and SCADA either on upper floor or

additional room above upper floor shown in conceptual drawing
Removable grating shall be provided in upper floor above delivery line

to facilitate handling of valves
4.7.5 Pump Foundation

The structural members for founding pump shall be designed for dynamic load
of pump and motor. The dynamic load shall be worked out as per IS: 2974
Part IV code of practice for design and construction of machine foundation
for rotary type machines of low frequency.
4.7.6 Truck Access Bay
A purpose designed access bay for truck shall be provided in pump room so
as facilitate truck entry and loading or unloading of pump, motor and other
equipment by means of EOT crane onto / from truck.
4.7.7 GA of Superstructure
Superstructure shall house panel / MCC, other indoor electrical

equipment, ventilation system and electrically operated double bridge
girder travelling (EOT) crane, service / maintenance bay, tool room
Corbel level shall be such that EOT crane can be erected with
minimum clearance of 500 mm above upper most part of crane.
Head room up to crane hook (uppermost position) shall be at least

1000 mm higher than any equipment, column pipe and line shaft
required to be lifted up during dismantling of any item of equipment
PAGE 7 of 14
1966 of 2461
MMRDA
4.7.8 Other Facilities

Access staircase from motor floor to pump floor & control room at upper floor
shall be provided.
4.8
Clear Water Pumps

The Contractor shall review the pumping station design and the pump
mounting proposals shown on the drawings , and shall ensure that the pumps
he provides will operate satisfactorily as specified in all possible operating
conditions, including any possible water level with any combination of pumps
running. The drawings show one possible arrangement of pumps but the
Contractor may select a different arrangement which complies with the
Specification.
The design of the pump wells shall be in collaboration between pump supplier
and civil works designer to ensure the required hydraulic conditions are met in
any possible operating condition.
Pumps shall be all identical and of type vertical turbine pump with waterlubricated bearings. Unless otherwise approved, no pump shall incorporate
more than two stages. Pumps shall be driven by directly-coupled, verticalshaft induction motors, as described in the Electrical Specification. Speed of
pump shall be maximum 1000 RPM (Syn.)
Bowl efficiency shall not be less than 87%.
Velocity in column pipe shall not exceed 2.75 m/s.
Length of each column pipe shall be 2000 mm; Velocity of entrance of bell
mouth shall not exceed 1.5 m/s.
PAGE 8 of 14
1967 of 2461
MMRDA
Unless otherwise approved, pump casings shall be of close-grained cast iron,

and impellers and guide vanes of zinc-free bronze or stainless steel.
If the Contractors design includes the need to streamline the flow into the
pump inlet bell mouths, this may be achieved by providing flow straighteners
within the bell mouths using integrally-cast vanes.
4.8.2 Pump Duty Conditions
Conceptual design envisages 4 number of duty pumps with 2 number of
standby to pump 19039 m3/s. Duty head of the pump is 33 m.
The contractor shall review and recalculate duty head which shall be sum of
the following five elements.
i)
Static head from mean WL in clear water sump
ii)
Friction losses in clear water rising main @ C = 145
iii)
Minor losses due to fitting and valves at 20% of (ii) above as number of
bends are large
iv)
Station losses about 2.0 m
v)
Residual head 5.0 m to provide safe margin for deterioration in C value
The pump shall also be suitable for operation when WL falls to LWL which is
about + 7.5 % variation. The pump shall also be suitable for head when WL in
sump rises to TWL which is about 7.5% . As per IS 1710-1989 head range
is + 10% and -25%
Covering above variation operation head range of the pump shall be +10 %
and -25%.
4.9
Valves and Pipework
PAGE 9 of 14
1968 of 2461
MMRDA

Pump valves, pipework, and their supports shall be designed to withstand the
maximum stresses imposed by any operating condition, including the shock
resulting from pump starting when the advancing inrush of water strikes the
closed non-return valve.
The design maximum velocity through the valves and pump branch pipework
shall not exceed 2m/s.
The design pressure rating of valves and pipework shall be 1.5 times the
pump shut valve pressure or PN 1.0, whichever is greater.
4.9.2 Valves - General
Each pump shall be provided with a delivery non-return valve, a delivery
isolating valve, additional isolating valve and an automatic air inlet/release
valve. The air valve shall be fitted to the delivery pipework near to the
discharge bend and upstream of the non-return valve.
Pump delivery isolating valves shall be resilient-seated butterfly valves, fitted
with electric actuators. Valve operation when manual shall be by handwheel
through integral reduction gearing.
Additional isolating valve shall be non rising spindle sluice valve. This valve
shall be manually operated. Alternately knife gate valve can be accepted.
Non-return valves shall be of the swing-check type, designed for rapid closing
as soon as forward flow stops. Alternately, dual plate check valve as per
standard specification can be accepted.
4.9.3 Pump Automatic Air Inlet/Release Valves
Each pump air inlet/release valve shall be designed and sized to ensure:
PAGE 10 of 14
1969 of 2461
a)
MMRDA
On pump stopping, the pump column pipe drains into the pump well so
that negative pressures which could be damaging when the pump is
restarted cannot occur.
b)
On pump starting, air is expelled from the column pipe fast enough to
prevent airbeing forced past the pump non-return valve and into the
delivery manifold, and the air cushion in the column pipe prevents
damage to pipework or non-return valve from the advancing water
column.
4.9.4 Pipe Work -General

Pump delivery pipework shall be fabricated steel, with flanged connections.
Pressure ratings shall match those for valves as given above.
Dismantling joints shall be incorporated wherever needed to facilitate the
removal of pumps and valves. The dismantling joint shall be suitable for pump
duty and when assembled shall be suitable to withstand tensile force imposed
due to thrust at end of delivery piping at manifold.
Pipework shall be protected from corrosion as detailed for exposed steel
pipes elsewhere in the Specification.
4.9.5 Pump Common Delivery Manifold
The pump deliveries shall be joined to a fabricated-steel delivery manifold, with
flanged connections which shall be connected to the clear water pipeline
delivering to the treatment works. The manifold shall be of nominal diameter
2000 mm.
The manifold shall be connected to the clear water pipeline,
generally as shown on the drawings.

The manifold design pressure rating shall be 1.5 times the pump shut valve
pressure or 160 m, whichever is greater. Protection shall be as specified for
pump delivery pipework.
PAGE 11 of 14
1970 of 2461
MMRDA
4.9.6 Electric Overhead Travelling Crane

An electric overhead travelling crane shall be provided in the clear water
pumping station, designed to serve the pumps and all the plant installed in the
motor hall
The Contractor shall determine the maximum Safe Working Load required for
the crane, which shall be not less than 20 tones.
The pendant control shall be designed for operation from the motor hall floor.
Crane operating speeds shall be as follows:
Long travel
Cross travel
Hoisting and lowering
A fixed ladder with safety hand railing shall be provided for access to the crane
for servicing, and to gain access the maintenance platform for use when
servicing high-level lighting and ventilation units mounted in the roof.
Other lifting equipment shall include monorails for screens and stop-log gates.
4.10
Ventilation System
The upper floor pumping station shall be provided with a ventilation system
designed to limit the air temperature rise to not more than 5 deg. C. when the
plant is operating. The system shall be designed to provide uniform ventilation
throughout the pumping station, to promote plant cooling and eliminate
pockets of stagnant air.
The system shall be sized based on the maximum number of motors operating
PAGE 12 of 14
1971 of 2461
MMRDA
together, with all the lights switched on, and with three operating personnel
present, but the design ventilation rate shall be not less than five air changes
hourly for the complete pump hall.
The ventilation system shall be combination of forced ventilation system and
extraction / exhaust system. Essential features and requirements are as under:
i)
Air supply fans and exhaust fan shall be positioned staggered to avoid
short circuit.
ii)
Ventilation ducts shall be provided such that forced air flow out at about
750 mm above operating floor and extracted out of exhaust at about
2000 mm above the floor level
iii)
Ventilation fans shall be sized for 75-85% exhaust and 100% air supply
iv)
The air velocity in duct shall not exceed 20 m/s
Fans shall be controlled from wall-mounted contactors, accessible from

pumping station floor level.
Exhaust fans shall be provided between two floors to achieve minimum four
number of air changes per hour.
Fans
Fans shall be sized to deliver required fresh air through the duct system,
discharging at the bottom of either pump well. Fan motors shall be rated for
Fan inlets shall be protected from ingress of harmful foreign matter by robust
grilles at the inlets.
Ducts
PAGE 13 of 14
1972 of 2461
MMRDA
Fixed ductwork shall lead the airflow from the fan to a suitable point near the
top of each pump well. If a single fan is used, a damper shall be provided to
direct airflow to the selected well. Fixed ducts shall end with a spigot and
clipping arrangement, designed for connection to the flexible duct, which will be
used only during de-silting.
Fixed ducts shall be of fabricated galvanized sheet steel or other approved
material. Ducts shall be reinforced or protected where they could be damaged
by the passage of personnel or goods in transit. Rectangular or circular
sections may be used. Ducts shall be manufactured and installed to an
approved code.
Flexible ducts shall be of tough, flexible, non-metallic construction, designed for
hard wear in the conditions at Site. The length of flexible duct provided shall be
not less than 25 m. One end of the duct shall be arranged to connect to the
fixed duct and the other to discharge safely at the bottom of either pump well,
with an outlet which can be secured and directed as required.
Fixed and flexible ducts shall be sized to limit air velocity to not more than
20m/s.
4.11
Provision of Safe Access
RCC access platforms and ladders shall be provided wherever needed. The
arrangements shall ensure that all parts of the plant are made readily
accessible for maintenance or operation in safety.
PAGE 14 of 14
1973 of 2461
SUB-SECTION 6C.5
MS PIPELINE
1974 of 2461
MMRDA
Table of Contents
SUB-SECTION 6C.5: MS PIPELINE
5.1
SCOPE AND EXTENT OF WORKS
5.2
VARIATION IN PIPE DIAMETER AND DETERMINATION OF SHELL THICKNESS

2
5.2.1
5.2.2
Permissible Variation in Diameter and Corresponding Shell Thickness ............... 3

Tolerance in Shell Thickness......................................................................................... 5
5.3
THE SITE
5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
General Requirements.................................................................................................... 5
ROW and Constraints of Construction ........................................................................ 6
Shifting of Utilities and Crossings ............................................................................... 12
Tree Cutting .................................................................................................................... 13
Additional Working Area ............................................................................................... 13
5.4
PIPE LAYING
13
5.5
VALVES ON PIPELINE
14
5.5.1
5.5.2
5.5.3
Air Valve........................................................................................................................... 15
Line Valve ........................................................................................................................ 15
Wash Out......................................................................................................................... 15
5.6
THRUST BLOCK AND ANCHOR BLOCKS
16
5.7
CULVERT, SMALL RIVER AND NALLAH CROSSINGS
17
5.8
INTERNAL PROTECTION LINING
17
5.8.1
5.8.2
Cement Mortar Lining....................................................................................................17

Other Internal Coating................................................................................................... 17
5.9
EXTERNAL PROTECTION
5.9.1
5.9.2
5.9.3
5.9.4
Tape Coating System.................................................................................................... 18

Other Exterior Coating .................................................................................................. 21
Coating of Welded Joints ............................................................................................. 21
Protection for above ground pipeline ......................................................................... 22
5.10
CATHODIC PROTECTION
5.10.1
5.10.2
5.10.3
5.10.4
General ............................................................................................................................ 22
Investigation Work ......................................................................................................... 24
Sacrificial Anodes Cathodic Protection System ....................................................... 25
Special Requirements ................................................................................................... 27
5.11
HYDRAULIC TESTING OF PIPELINE
18
22
1975 of 2461
29
MMRDA
SUB-SECTION 6C.5: MS PIPELINE

5.1
Scope and Extent of Works

This subsection covers particular requirements applicable to supply of pipe
and pipe laying works, fittings, valves other appurtenances, internal-external
protection of pipeline and testing.
The works for the transmission main shall include manufacturer, supply,
transportation,
excavation,
laying,
jointing,
testing,
backfilling
and
reinstatement of roads. The works shall also include all valves i.e. air valves,
line valves, washouts, all related pipeline works, chambers and all works and
items necessary for transmissions pipelines.
The total length of MS transmission mains is approximately 81km as per
particulars and conceptual design in the Table 5.1 below. The table also
shows category of road on pipeline route.
Table 5.1: Details of transmission main
From
To
Nature of
Length
Outer
Category of
Main
(m)
Diameter x
Road on
Shell
Pipeline Route
Thickness
(mm x mm)
Intake
WTP
Raw
2035
2235 x 16
Approach road
Water
to
weir,
Pumping
crossing
Main
SH, new road

to
of
be
constructed
under
the
contract
Clear water BPT
Clear
315
2235 x 16
SECTION 6C.5: MS PIPELINE
New road in
PAGE 1 of 30
1976 of 2461
sump
MMRDA
Water
WTP
Pumping
Main
BPT
Kashidkopar Clear
Junction
56400
2235 x 12.5
Suryanagar
Water
colony
road,
Gravity
RoW for 3 km
Main
on
SH
RoW
30,
on
km
3.3
on
ZP
road, balance
along NH8
Kashidkopar Kashidkopar Clear
Junction
MBR
2000
1829 x 12.5
Cross country
Water
1.5 km, 0.5 km
Gravity
on MBR site
Main
road
Kashidkopar Chene MBR
Clear
20845
1829 x 12.5
Along
NH8,
Junction
Water
crossing
Gravity
NH8
Main
Thane
of
and
Ghodbunder
road, about 1
km
on
road
new
to
be
constructed
under
the
contract
A preliminary estimate of the length, diameter and the like of the pipelines is
given in the price schedule. The actual pipe length shall be subject to be
measured on site after the pipelines are installed, in accordance with the
agreed pipeline
route between the Contractor and the
Employers
representative.
5.2
Variation in Pipe Diameter and Determination of Shell Thickness
PAGE 2 of 30
1977 of 2461
MMRDA
5.2.1 Permissible Variation in Diameter and Corresponding Shell Thickness

The tenderer is permitted to vary the diameter by 100 mm subject to justifying
the following requirements.
Shell thickness proposed meets following criteria
Includes minimum 1.0 mm corrosion allowance
Shell thickness after deducting corrosion allowance is suitable for design

pressure determined as per system design criteria specified and as per
IS 5822 Code of practice for laying electrically welded steel pipes for
water supply
The shell thickness without any reduction for corrosion allowance shall
be suitable to withstand collapsing pressure under vacuum as stated
below.
The collapsing pressure Pc in psi is based on Stewarts formula given in
AWWA manual M-11
502 10 ( )3
shell thickness, inches
dn
(Outside diameter t), inches
Pc
Where
Vacuum level inside the pipeline with due consideration of vapour

pressure shall be as under:
Gravity main
4.85 psi
Pumping main
13.85 psi
PAGE 3 of 30
1978 of 2461
MMRDA
The shell thickness shall be suitable for handling as per AWWA M-11
The combination of pipe diameter and shell thickness shall meet

following requirements depending on internal coating / lining and
external protection wrapping / taping
Deflection under soil over entire range cover from 1.5 m to 3.5 m
and live load HS 20 as per AWWA M-11 is less than allowable
pipe deflection 3% of diameter for internally cement mortar lined
and externally flexible coated.
Summation of external water load, dead load under buoyancy

and external pressure due to inside vacuum shall not exceed
allowable buckling pressure.
Summation of external water load, dead load under buoyancy

and live load shall not exceed allowable buckling pressure.
The calculation for deflection and buckling shall be on base of

formula given in Chapter 6: External load AWWA M11 (4th edition).
The values for variable shall be as under.
i)
DL = Deflexion lag factor
= 1.0
ii)
Density of soil load
= 114.5 1b / ft3
= 18 KN/m3
iii)
E = modulus of soil reaction in psi as under for range of depth

of cover
Depth of Cover
E (psi)
2-5 ft
700
5-10 ft
1000
PAGE 4 of 30
1979 of 2461
MMRDA
10-15 ft
iv)
1200
hw = height of water surface above top of pipe

= Maximum soil cover
v)
FS = Factor of safety for buckling

= 2.0
vi)
Live load HS-20 shall be as follow
Depth of Cover
Load
4 ft
400 psf
5 ft
250 psf
6 ft
200 psf
7 ft
176 psf
8 ft
100 psf
Above 8 ft
NIL
5.2.2 Tolerance in Shell Thickness

Positive tolerance upto maximum + 20%
Negative tolerance NIL
5.3
The Site

The Contractor shall carry out a detailed survey of the pipeline route and draw
up plans in consultation with Employers representative, indicating the working
width available. Plans and L-Section shall be drawn at 1:1000 scale. If the
Contractor considers that at any location there is insufficient working width,
then he shall indicate this on the plans, and produce a schedule of the
PAGE 5 of 30
1980 of 2461
MMRDA
locations with proposals for achieving the working width whilst taking into
consideration the requirements of the regulating authority regarding
movement of vehicular traffic etc.
The plans shall be submitted to the Employers representative for approval.
The plans shall be submitted well in advance of the date scheduled for
commencement of pipe laying as specified in the Specifications and
Employers Requirements. The handing over of the site shall be generally
made such that 200m length of pipeline is available for the Contractor for pipe
laying at any time.
The Contractor shall provide road reinstatement depending on the particular
type of road, should open trench pipe laying method be adopted for that
particular road. National and State Highways and those maintained by the
Public Works Department shall be permanently reinstated up to the top of the
base course in accordance with the type of the road to be reinstated and as
per the Standard Specification and Project Brief and Project Requirements.
Depending on the requirements from the National highways, State highways
and Public Works, the final reinstatement of the running surface shall be done
directly by these authorities. In such case, a temporary wearing course shall
then be laid down by the Contactor, or as otherwise in a way as directed by
the Employers representative. Under this scenario, final reinstatement of the
road surface shall be done by the authority. Roads under the authority of local
panchayat or any other municipal authority shall be fully reinstated by the
Contractor in accordance with the constructed road and Specification. The
Contractor shall also be responsible for maintaining existing road at Kawades
intake and Zilla Parishad Road in the motorable condition by filling potholes
and required metalling and asphalting.
5.3.2 ROW and Constraints of Construction
Available RoW on all roads is generally 4000 mm which is just adequate to
make trench and lay buried pipeline to required depth. Cover above the top of
pipeline shall generally be as under:
PAGE 6 of 30
1981 of 2461
Soil Cover
MMRDA
ZP Road
NH, Thane Ghodbunder Road &
(including Forest
SH (including Forest Stretches)
Stretches)
Minimum
1500 mm
2000 mm
Maximum
3000 mm
3500
Thus for 2235 mm diameter pipeline with 300 mm sand cushion at bottom,
depth of trench shall vary from 4035 mm to 6035 mm. Similarly for 1829 mm
diameter pipeline, depth shall vary from 3629 mm to 5629 mm. It is obvious
that it may not be possible to make such deep trench with natural slope. The
tenderers shall therefore, be responsible to develop methodology for
excavation, providing shuttering, sheet piling etc.
The pipeline alignment shall generally be at 4000 mm distance from edge of
the ROW of road along SH, NH and Thane Ghodbunder Road and 2000 mm
from edge in case of ZP road. Available RoW of the roads also passes
through diverted forest land. The available ROW and pipeline alignment on
SH 30 and ZP are as under:
Road
Available ROW
Pipeline Alignment
from C/L of Road
from C/L of Road
SH 30
20 m
16 m
ZP
6m
4m
As regards RoW on NH, the pipeline alignment is as per statement below. At some
stretches where ROW is less, forest land is proposed for diversion, for laying pipeline
where forest land is not available private land is being acquired.
PAGE 7 of 30
1982 of 2461
MMRDA
Statement showing Chainage-wise RoW of NH-8
S.
No
NH Chainage
From
To
Lengt
RoW of
NHAI (m)
(km)
East/
Centerlin
West of e of Virar
NH-8
Pipeline
Surya
Wheth
Pipeline
er
Alignme
within
nt from
RoW of
Centerlin
NHAI,
e (m)
Forest
or
Private
421.10
421.30
421.30
421.80
421.80
425.30
425.30
426.25
426.25
429.10
429.10
430.90
0.200
38
East
34
NHAI
0.500
29 - 31
East
26
Forest
3.500
38
East
34
NHAI
0.950
20.6 to
East
31
Forest
31.5
2.850
38
East
34
NHAI
1.800
N/A
Crossin
N/A
Forest
West
31
Forest
38
West
34
NHAI
g from
East to
West
10
11
430.90
433.00
2.100
20.8 to
433.00
444.60
11.60
444.60
445.00
0.400
36
West
32
NHAI
445.00
445.40
0.400
38
West
34
NHAI
445.40
445.80
0.400
36
West
32
NHAI
30.5
PAGE 8 of 30
1983 of 2461
S.
No
NH Chainage
From
To
MMRDA
East/
Lengt
RoW of
NHAI (m)
(km)
Centerlin
West of e of Virar
NH-8
Pipeline
Surya
Wheth
Pipeline
er
Alignme
within
nt from
RoW of
Centerlin
NHAI,
e (m)
Forest
or
Private
12
13
14
15
16
17
18
19
20
21
22
23
24
445.80
455.00
455.00
455.10
455.10
455.60
455.60
457.20
457.20
458.00
458.00
460.50
460.50
461.00
461.00
462.60
462.60
463.20
463.20
464.00
464.00
465.20
465.20
466.40
466.40
467.00
9.200
38
West
34
NHAI
0.100
36
West
32
NHAI
0.500
24
West
31
Private
1.600
38
West
34
NHAI
0.800
24
West
31
Forest
2.500
30
West
26
NHAI
0.500
36
West
32
NHAI
1.600
38
West
34
NHAI
0.600
36
West
32
NHAI
0.800
38
West
34
NHAI
1.200
36
West
32
NHAI
1.200
38
West
34
NHAI
0.600
36
West
32
NHAI
PAGE 9 of 30
1984 of 2461
S.
No
NH Chainage
From
To
MMRDA
East/
Lengt
RoW of
NHAI (m)
(km)
Centerlin
West of e of Virar
NH-8
Pipeline
Surya
Wheth
Pipeline
er
Alignme
within
nt from
RoW of
Centerlin
NHAI,
e (m)
Forest
or
Private
25
26
27
28
29
30
31
32
33
34
35
36
37
467.00
467.30
467.30
467.50
467.50
469.00
469.00
469.20
469.20
475.00
475.00
475.50
475.50
475.70
475.70
475.90
475.90
476.10
476.10
476.30
476.30
476.50
476.50
477.10
477.10
477.35
0.300
38
West
34
NHAI
0.200
36
West
31
Forest
1.500
36
West
32
NHAI
0.200
24
West
31
Forest
5.800
38
West
34
NHAI
0.500
24
West
19.6
22
NHAI
0.200
24
West
14.2
22
NHAI
0.200
24
West
24.2
18
NHAI
0.200
24
West
17.2
22
NHAI
0.200
24
West
21.3
18
NHAI
0.200
24
West
24
18
NHAI
0.600
24
West
19.1
22
NHAI
0.250
24
West
19.2
22
NHAI
PAGE 10 of 30
1985 of 2461
S.
No
NH Chainage
From
To
MMRDA
East/
Lengt
RoW of
NHAI (m)
(km)
Centerlin
West of e of Virar
NH-8
Pipeline
Surya
Wheth
Pipeline
er
Alignme
within
nt from
RoW of
Centerlin
NHAI,
e (m)
Forest
or
Private
38
39
40
41
42
43
44
45
46
47
48
477.35
477.60
477.60
478.55
478.55
478.85
478.85
480.40
480.40
482.10
482.10
487.20
487.20
491.80
491.80
493.40
493.40
495.30
495.30
495.40
495.40
495.90
0
Total
0.250
24
West
18.3
22
NHAI
0.950
24
West
19.4
22
NHAI
0.300
24
West
19.8
22.3
NHAI
1.550
24
West
21
NHAI
1.700
38
West
34
NHAI
5.100
Tunnel
West
Tunnel
Forest
4.600
24
West
21
NHAI
1.600
30
West
27
NHAI
1.900
36
West
33
NHAI
0.100
35
West
32
NHAI
0.500
55
West
59
Private
74.80
0
Total length of the pipeline along NH-8 is 74.8 km. Part of the alignment is on
PAGE 11 of 30
1986 of 2461
MMRDA
east of NH-8 and major part on west of NH-8. In few stretches, the pipeline
alignment is in fresh forest land and part alignment passes through private
land. Even in stretches, where alignment is within ROW of NH8, diverted
forest land is involved. The alignment also includes two tunnels. Both tunnels
are in fresh forest land.
The statement also shows that existing pipeline of Vasai-Virar WSS is laid
from chainage NH 475.000 km to NH 478.850 km at alignment varying from
14.2 m to 19.8 m from centre line with ROW on that side as 24 m. Thus at
edge barely 4.2 m is available at edge for laying 1825 mm diameter Surya
pipeline. The tenderer shall take all these constraints for proposing pipeline
construction. The alignment of Virar pipeline is based on available data which
should be considered indicative. No extra payment shall be admissible if the
alignment varies from indicative alignment given in the statement.
On basis of indicative alignment of Virar pipeline and feasibility of laying Surya
pipeline on west of Virar pipeline, it appears it may not be possible to keep
entire 3.85 km long Surya pipeline alignment on west of Virar pipeline.
Conceptual drawing shows relative alignments of two pipelines involving
crossings.
Surya pipeline at all such crossings shall be below the Virar
pipeline. Tender drawing shows conceptual arrangement with RCC padding

at all such crossings.
Another aspect of construction in 24 m wide RoW along part length of NH-8 is
that Surya pipeline is under service road. The entire length of pipeline in 24 m
RoW as well as 30 m RoW within the section from chainage NH 475.000 km
to NH 493.400 km shall be with concrete encasing. Total length of encased
pipeline in above stretch shall be 11.6 km. Encasing is not proposed if RoW
is above 30m.
5.3.3 Shifting of Utilities and Crossings
If required for facilitating the work to be carried out, the Contractor shall be
responsible for shifting utilities such as service lines, cables, gas pipes, water
pipes and drainage pipes, overhead or buried, after obtaining permission from
PAGE 12 of 30
1987 of 2461
MMRDA
relevant utility authority. The role and involvement of the Employer at all these
works will be to provide endorsement letters with the Contractors letters to
these authorities to make application for the aforesaid shifting of utilities by
the utility authorities and the contractor. In case the Contractor could not get
permissions from these authorities on time and the works are delayed, the
Employer shall not make any compensation and all time and financial impacts
shall be borne by the contractor. The Contractor shall assist these authorities
to carry out their diversion work which shall include all other necessary work
not within the scope of these authorities and its cost shall be deemed to be
included in the price of the Contract.
5.3.4 Tree Cutting
The Contractor shall be responsible for felling or transplanting any trees as
necessary after obtaining permission from the relevant authority.
5.3.5 Additional Working Area
The Contractor shall make his own arrangements and pay all expenses for
any additional area that he may require outside 4000 mm wide available
RoW, in order to complete the pipeline work. The Contractor shall obtain the
consent of the Employers representative of such arrangement prior to
proceeding with the work.
5.4
Pipe Laying
The pipeline shall be generally buried except for bridge if any and rocky
hillocks in alignment. Soil cover shall not be less than 1500 mm and shall not
exceed 3500 mm for alignment along ZP roads. For alignment along NH-8 &
SH the soil cover shall be minimum 2000 mm and maximum 3500 mm.
Minimum cover specified is obligatory.
The tenderer depending on his
methodology may vary maximum cover to 4500 mm.

The trench width shall be equal to pipeline outside diameter +600 mm. The
pipeline shall be laid in proper slope without any kink or dip in profile so as to
PAGE 13 of 30
1988 of 2461
MMRDA
facilitate air flow towards air valve for further release to atmosphere. The
slope shall generally not be less than 1:500 for ascending section and 1:400
for descending section. Where such minimum slope cannot be achieved, the
lesser slope shall be adopted with prior approval of Employers representative
. Spacing between air valves in section with lesser slope shall be less than
general spacing detailed for air valve.
Bedding shall be as specified in standard specifications and tender drawings.
Bedding material shall be as specified for each zone. Compaction of each
layer shall be achieved, tested for proctor density and recorded duly signed by
the Employers representative and contractors representative.
Concrete encasing for 11.6 km long length from chainage NH 475.000 to
493.400 km shall be provided as per tender drawing.
Above ground pipeline shall restricted to minimum where below ground laying
is either not economical or not feasible such as pipeline passing over bridge if
any or rocky hillock. Contractor shall take proper care such as expansion joint
as necessary between two ends and the pipeline shall be on ring girder as
shown in tender drawings. Suitably designed thrust block shall be provided to
restrain pipeline.
The contractor shall prepare working drawings on basis of topographical
survey done by him for final pipeline route and exact locations of fittings and
valve chambers which shall be agreed on site between the Contractor and the
5.5
Valves on Pipeline
The selection of the type of the valve i.e. butterfly valve as line valve, sluice
valve as wash out and air valves, the detailed design, and the precise location
of each valve shall be carried out as follows:
Valves shall be in accordance with the Specification. The Contractor shall use
the uniform types and the single manufacturer for each type of valve,
PAGE 14 of 30
1989 of 2461
MMRDA
throughout the Works.

5.5.1 Air Valve
200 mm diameter of rating PN 1.6 / 16 bar, tamperproof air valve shall be
provided. The location of air valve shall at every peak on pipe section and
peak on hydraulic grade line, on upstream end of pipe section for crossing
river, nallah and other minor crossings and on inlet and outlet shafts of
tunnels. Spacing between two air valves shall be 500m for 2135 to 2335 mm
diameter pipeline whereas 600 mm for 1729 to 1929 mm diameter pipeline.
Above spacing is for pipeline section with minimum slope of 1:500 for
ascending section and 1:400 mm for descending section. If flatter slope is
unavoidable, number of air valves shall be increased. Air valves shall be in
properly designed R.C.C. chamber as shown in tender drawings.
The
drawings also show arrangement of air valves as pipeline without encasing

and with encasing of pipeline.
5.5.2 Line Valve
The line valve shall generally be provided at 5 km interval so as to isolate
pipeline and prevent unnecessary draining of pipeline during repairs and
maintenance.
For pipe diameter range 2135 to 2335 mm and 1729 to 1929 mm diameter of
line valves shall be 2000 mm and 1600 mm respectively. Line valves shall be
long body butterfly valve and of rating PN1.6. Flange adapter of adequate
pressure rating shall be provided in combination with BFV to facilitate repairs,
seal replacement and maintenance of BFV. The line valve shall be in R.C.C
.chamber. The reducer and enlarger shall be eccentric type so as to allow air
movement.
Manhole shall be provided at one end of BFV as approved by the Employers
representative and blank flange with dish shaped flange .
5.5.3 Wash Out
PAGE 15 of 30
1990 of 2461
MMRDA
Wash outs are required to drain the pipeline for repairs and maintenance.
Location of wash out shall be at dippest point and near natural stream so as
to dispose drained quantity. For wash out, sluice valve of rating PN1.6 shall
be used in conjunction with flange adapter. Size of washout for higher slope
and flatter slope shall be 300 mm and 400 mm respectively. Due to very
small width available between pipeline and edge of ROW, the wash out need
to be located very close to the pipeline. In view of above, RCC chamber need
to accommodate both pipeline and wash out as shown in tender drawings.
The exact location for each chamber shall be determined on site between the
Employers representative and Contractor. Unless indicated otherwise the
manhole shall be of a uniform type and manufactured by the single
manufacturer throughout the Works.
Access steps shall be of specially designed CI rungs in accordance with the
Drawings and Specification. No improvised units shall be installed.
Where washouts have their outfalls to ditches, it will be necessary to install an
outfall as indicated in tender Drawings. The Contractor shall design and get
approval for the outfall to account for local variations in the size and layout of
the ditch.
The Contractor shall review all the washout locations during the initial route
survey and shall agree with the Employers representative including the type
of outfall to be used at each location.
5.6
Thrust Block and Anchor Blocks

The Contractor shall submit detailed design proposal on thrust blocks at
bends, tees and dead ends and anchor blocks. The design pressures
including uncontrolled surge pressures and available restrained lengths shall
be clearly stated in the detailed design report by the Contractor. The Design
Report shall be submitted by the Contractor with the remedial measures and
detailed drawings for thrust blocks and anchor blocks at specific locations in
PAGE 16 of 30
1991 of 2461
MMRDA
order to obtain the approval from the Employers representative.

5.7
Culvert, Small River and Nallah Crossings

4 major river / creek crossings are encountered.
i)
Vandri river
width 115 m
ii)
Vaitarna river
width 240 m
iii)
Tansa river
width 170 m
iv)
Kaman creek
width 85 m
The methodology for crossing is discussed in subsection 6C.8: other works

For other culvert, small river and nallah crossings, the crossings shall be done
by laying the pipeline at least 300 mm below the bed level as shown in tender
drawings. The length of the pipeline under full water course shall be encased
in concrete encasing with minimum 1000 mm encasing extending beyond
maximum width of water course. Detailed work specifications are given in
Subsection 6C.8.
5.8
Internal Protection Lining
5.8.1 Cement Mortar Lining

The interior of pipe shall be coated with cement mortar lining as per
stipulations in annexure of IS 3589 and AWWA C205. The cement mortar
lining shall be applied by centrifuge spinning or method known to provide
equivalent results. The lining shall be factory applied or lining in situ. The
thickness of cement mortar lining shall be 12 mm. Tolerance +3 mm and 0
mm shall be applicable.
5.8.2 Other Internal Coating
PAGE 17 of 30
1992 of 2461
MMRDA
Other internal coating system such as liquid epoxy coating, fusion bonded
epoxy coating, nylonbased epoxy coating are not acceptable.
5.9
External Protection
5.9.1 Tape Coating System

The buried Mild Steel pipeline shall be protected with cold applied tape
protective coating conforming to IS 3589 Annex D and AWWA C214 (Cold
Applied Tape Coating Systems for Exterior of Steel Water Pipelines). The
coating system shall be applied in shop. The materials provided shall meet
the provisions of AWWA C214. Work or material that fails to conform to this
standard may be rejected at any time before final acceptance.
The prefabricated polyolefin tape coating system shall be at least three layers
consisting of the following:
A liquid adhesive layer
An inner-layer tape for corrosion protection
An outer-layer tape for mechanical protection
The inner-layer tape and outer-layer tape shall be made of prefabricated

tapes in rolls.
Liquid Adhesive
The liquid adhesive shall consist of a mixture of suitable rubber and synthetic
compounds and a solvent. The liquid adhesive shall be applied to the properly
prepared pipe surface as specified below before application of the inner-layer
tape. The function of the liquid adhesive is to provide a bonding medium
between the pipe surface and the inner-layer tape.
PAGE 18 of 30
1993 of 2461
MMRDA
Cleaning
Prior to adbrasive blast cleaning, surfaces shall be inspected and, if required,
cleaned according to remove oil, grease, or other foreign matter. Only
approved solvents that do not leave a residue shall be used. Preheating to
remove oil, grease, mill scale, water and ice may be used provided all pipe is
preheated in a uniform manner to avoid distorting the pipe.
The exterior pipe surfaces shall be abrasive blast cleaned to achieve a near
white metal surface. The interior pipe surfaces shall be abrasive blast cleaned
to achieve a white metal surface. Abrasive blasting and coating shall only be
performed when the metal temperature is more than 3C above dew point.
Surface Inspection
The exterior and interior pipe surfaces shall be inspected for surface
imperfections, such as slivers, scabs, burrs, weld spatter, and gouges, shall
be removed by grinding.
Inner-layer Tape
The inner-layer tape shall be a two-layer tape consisting of a polyolefin (only)
backing layer with a laminated butyl-based adhesive layer. The inner tape
shall be compatible with the liquid adhesive. The manufacturer shall certify
that the backing material shall be polyolefin only, containing not less than 1.0
percent nor more than 3.5 percent by weight, of non-polyolefinic material
consisting of carbon black and antioxidants. The inner-layer tape shall be
applied after the liquid adhesive and before the outer-layer tape.
Outer-layer Tape
Outer layer shall be laminated butyl adhesive layer. The manufacturer shall
certify that the backing material shall be polyolefin only containing not less
PAGE 19 of 30
1994 of 2461
MMRDA
than 3.0 percent or not more than 7.0 percent, by weight, of non-polyolefinic
material consisting of pigments, antioxidants and stabilizers.
The outer-layer tape shall be compatible with the inner-layer tape. The
primary functions of the outer-layer tape shall be to provide mechanical and
outdoor weathering protection to the tape system, and secondarily, to
contribute to the overall corrosion-protection properties of the system. The
outer-layer tape backing shall be compounded so that it will be resistant to
outdoor weathering. The outer-layer should be of suitable quality for the local
environment, as follows:
Storage Temperature
: 0 to 50C
Over-ground Condition
: 0 to 50C
Under-ground Condition
: 7C to 35C
Underground Water Table : Generally wet and get saturated during monsoon
Ultraviolet-ray Protection
: Required in outer layer
Coating-system Thickness
Depending on operating and installation conditions, more than one application
of inner-layer tape and outer-layer tape can be used. The total thickness and
combination of the various layers used shall be approved by the Employers
represetative, with proper consideration given to the manufacturer's
recommendations. However, in no case the thickness shall be less than 2mm.
Extent of coating for pipeline adjacent to ground level
Where pipeline is partially below ground and partially above ground, the
taping used on buried portion shall be continued 200 mm clear above ground
level.
PAGE 20 of 30
1995 of 2461
MMRDA
Field repairs to damaged coating

Contractor shall be responsible for field repairs to damaged coating during
transportation and handling. Methodology shall be on basis of the
manufacturers recommendations subjected to approval of the Employers
represetative.
5.9.2 Other Exterior Coating
Other coating system such as reinforced cement mortar coating (guiniting),
liquid epoxy coating, and coal tar based coating and wrapping are not
accepted.
5.9.3 Coating of Welded Joints
Heat-shrinkable coatings consist of material fabricated from cross-linked
polyolefin sheet or tubing pre-coated with an adhesive. After they are
installed, the coating shall conform to all surface contours of the pipe.
Heat shrinkable polyolefin material shall conform to AWWA C-216 and the
following requirements.
The Heat Shrinkable polyolefin coating shall be a laminate that consists of a
cross linked polyolefin backing and a homogeneous adhesive layer. The
adhesive may be either a tack, pressure-sensitive amorphous adhesive
(mastic) or a non tacky, semi crystalline adhesive (hot melt).
The prefabricated heat-shrinkable polyolefin coating shall be one of the
following types:
Type I, Tubular-type Coatings: These are installed before joining the pipe
ends by sliding the coating from a free end of the pipe onto the area to be
coated.
Type II, Wraparound-type Coatings: These are wrapped circumferentially
PAGE 21 of 30
1996 of 2461
MMRDA
around the pipe area to be coated. Each wraparound coating is provided with
either a separate or a built-in closure, as supplied by the manufacturer that
secures the overlap during the shrinking process.
The closure shall meet the technical requirements, with the exception of
thickness which shall be a minimum of 1.5 mm as supplied.
5.9.4 Protection for above ground pipeline
Protection as specified in standard specification shall be adopted.
5.10
Cathodic Protection
5.10.1 General
This Part contains requirements which, where relevant to this Contract, shall
apply to the supply, installation and testing of the cathodic protection of MS
pipeline including pipes and fittings where required to be laid in, on or above
ground or to be fixed on or built into other parts of the Works. Protection
system comprising sacrificing anode shall be provided to protect M.S. pipeline
to prevent cathodic corrosion at following locations:
Low soil resistivity, 5000 ohm-cm or lower
Location of pipeline under H.T. Line
Location under railway trench
In this method, electrical potential generated causes current to flow from

sacrificial anode to the pipeline, thereby preventing any corrosion or erosion
of the pipe line.
The above requirements are to be achieved while maintaining safe working
practice and ensuring that the final design is safe, in particular with reference
to stray current or induced current pick-up from foreign buried or overhead
PAGE 22 of 30
1997 of 2461
MMRDA
power lines.
Cathodic protection of the pipelines shall be attained by the use of sacrificial
anodes, whenever it is necessary.
The cathodic protection system shall
conform to requirement of the sacrificial anode cathodic protection system as

per specification.
The Contractor shall employ and appoint a Corrosion Engineer to supervise,
inspect, test and commission the installation of the cathodic protection
system. The Corrosion Engineer shall be an Engineer with certification or
licensing that includes education and experience in cathodic protection of
buried or submerged metal structures, or a person certified by relevant
authority as a cathodic protection specialist. Such a person shall have not
less than five years of experience in the cathodic protection of underground
buried pipelines. The Contractor shall submit evidence to justify the
qualifications of Corrosion Engineer to the Employers representativefor
review and approval.
The Corrosion Engineer shall design the cathodic protection system by taking
into account of the following:
1.
Total surface area of the pipelines;
2.
Type of coating and condition of coating at the pipelines;
3.
Total bare surface area to be protected shall be assumed to be, as a

minimum, 25% of the total surface area of the pipelines;
4.
Minimum current density of 10 mA/m2 to the protected surface area;
5.
Chemical analysis of the treated water and the resistivity expressed in ohmcm;
6.
Minimum anode design life of thirty (30) years; and
PAGE 23 of 30
1998 of 2461
7.
MMRDA
Economic and maintenance convenience consideration.
The design for the cathodic protection system shall be submitted to the
Employers representative for approval and should be the pre-requisite
condition for any pipe laying work to commence.
The design shall be
conforming to specification and requirements stated hereunder.

5.10.2 Investigation Work
The Contractor shall carry out soil resistivity surveys at 1000 m intervals, on
RoW (Right of Way) for buried pipeline under procedure given below to
identify hot spots.
Soil resistivity survey shall be carried out by 4 Pin Wenner technique at

pin spacings of 1.5 m and 2 m
Additional readings shall be taken at following location or positions At

nalla, river, marshy areas etc i.e. where buried pipeline is close to water
bodies
Location/position where initial ERT survey show low value in

proximity of 100 ohm m or drastic change in resistivity value
from adjoining reading.
If the ratios of two consecutive readings is greater than 2 and lower of

the two readings is less than 200 ohm m, additional reading shall be
taken at mid point.
If the ratio of additional reading to reading on either side is also greater

than 2, another reading shall be taken between the midpoint and the
reading which is differing by ratio of 2. This procedure shall be followed,
but minimum gap between readings shall be 100m.
Based on the soil resistivity readings, the length of pipeline [to the
nearest
PAGE 24 of 30
1999 of 2461
MMRDA
100 m] in soil resistivity less than 100 ohm m shall be identified.
Based on the soil resistivity survey, the contractor shall prepare a

detailed report with schematic drawing showing the soil resistivity in
ROW clearly highlighting the locations where the soil resistivity is less
than 100 ohm m.
The results of the survey shall be furnished to the Employers
representative, who shall determine the locations and extents of
sacrificial anodes to be installed. The Contractor shall install all such
anodes in the trenches during laying of the pipeline.
5.10.3 Sacrificial Anodes Cathodic Protection System

The cathodic protection shall be done by using sacrificial anodes in form of
extruded magnesium ribbon anode laid in the pipe trench parallel to pipeline
as shown in the drawing. The length of ribbon at hot spot shall be length of
hot spot pocket + 10.0 m on each side of pocket but not less than 100 m. The
ribbon anode shall be connected to the pipeline by means of tail cable with
thermit welded joint.
Extruded magnesium ribbon anode shall be of the specifications stated below.
Contractor shall furnish test certificate of chemical composition, dimensions
and weight.
Material Composition:
Element
% by Weight
Zinc
0.01 max
Aluminium
0.01 max
Manganese
0.5 1.3
Copper
0.02 max
Iron
0.03 max
Nickel
0.001 max
PAGE 25 of 30
2000 of 2461
Others (metal)
MMRDA
0.05 max each

0.30 max total
Magnesium
Balance
Open circuit Potential
-1.6 V with respect to saturated copper

copper sulphate reference cell
Consumption rate
kg per Amp Year
Size
3/8 x 3/8 cross section
Insert
Continuous 1/8 iron wire core
Weight
0.24 lbs per foot or 0.357 kg per m
Anode tail cable
1C x 25 sq.mm PE insulated PVC

sheathed high conductivity stranded
unarmoured copper conductor cable
Heat shrinkable sleeve
Heat shrinkable sleeve of suitable size

to shrink on anode and anode tail
cable to seal the cable to anode core
joint
Job Description
The
magnesium
ribbon
anodes
wherever required shall be installed

prior to backfilling of trench as follows;
The length of Magnesium ribbon anode equal to length of pipeline in soil

resistivity < 100 ohm m + 20 m shall be cut from spool
The ribbon anode shall be laid in cable trench starting 10 m before and
ending 10 m after chainage of pipeline to be provided with cathodic
protection at each location as shown in tender Drawing
PAGE 26 of 30
2001 of 2461
MMRDA
The core at extreme ends of the ribbon anode shall be exposed and
cleaned thoroughly.
1 C x 6 sq.mm copper conductor each 5 m long shall be soldered to the

core at both ends using silver solder (EUTEC ROD 157)
The soldered cable to anode core shall be directly thermit welded to the
pipeline. The procedure of thermit welding and encapsulation of pipe to
cable joint is given in the tender Drawing
Soft soil shall be backfilled around anode before pipeline trench is

backfilled
5.10.4 Special Requirements

Cathodic protection shall be provided locally, on basis of soil resistivity, effect of
crossing below HV and EHV electric line and railway track.
Possible locations are, for example, Railway pipeline crossing location, pipeline
on possible water depression location, pipeline near to Grid Line. Because of
limited cathodic protection locations, the Contractor should prepare necessary
procedure for following items:
a.
Foreign service crossings

At all locations where the pipeline crosses other metallic services, one
cable shall be attached to the pipeline and one to the Foreign Service. It
shall be the Contractors responsibility to arrange for the owners of
services to be notified so that the test lead may be attached to his
service while the trench is open.
The
Contractor must establish
whether the service owner wishes to make the connection himself or

have his representative present during the work. The cables shall be
terminated in a potential/marker post.
b.
Pipeline casing and Railway pipeline crossing
PAGE 27 of 30
2002 of 2461
MMRDA
Where the pipeline is protected by a steel casing, such as at Road

crossings or Railway crossing, the casing shall be insulated from the
pipeline and provided with potential test facilities.
c.
Test posts
Test posts and distribution boxes shall be installed above ground and
shall be of rugged construction and protected from external and internal
corrosion. Test points shall be provided at intervals not exceeding 1km
and at each insulation device along the pipeline. Compartments shall be
weatherproof and lockable. The compartments shall have adequate
space for the termination of all test cables, pipeline bonding and
provision of resistors or other facilities as determined by the design.
d.
Parallelism with overhead high tension power lines

In order to prevent voltage peaks due to induction from parallel overhead
high-tension power line on the pipeline, zinc anodes shall be connected
to the pipe or power line crossings with the pipeline and at the ends of
parallelisms. During laying, sections of continuously-welded pipe above
ground shall not be permitted to exceed 400 metres within 100 metres of
overhead high-voltage power lines and shall be earthed.
e.
Pre-commissioning Tests and Commissioning

The Contractor shall carry out all pre-commissioning tests in the
presence of the Employers representative to confirm satisfactory
installation and operation of all equipment. Such tests shall include trial
operation
of
power
sources
to
their
maximum
capacity
and
measurement of cathodic protection circuits to confirm satisfactory

connections.
During Commissioning all pipe to soil potentials shall be measured with
reference to a copper/copper sulphate half-cell using a high-resistance
PAGE 28 of 30
2003 of 2461
MMRDA
voltmeter / potentiometer and recorded as volts negative. The results of

the commissioning tests shall be recorded and included in a
commissioning report to be submitted to the Employers representative.
f.
Interaction testing
The Contractor shall carry out interaction testing.
He shall be
responsible for contacting all the service owners concerned and

arranging for their presence at the tests if they so desire. The Contractor
shall be responsible for confirming the results of interaction testing with
the service owners concerned and obtaining written confirmation from
them that results are acceptable to them and they have no objections to
the operation of the cathodic protection system.
5.11

After completing the installation of pipeline or a section of the line and welding
of joints, a hydrostatic pressure test of the line shall be conducted before giving
the coating to the exposed joints. The hydrostatic pressure equal to or higher
than design pressure shall be maintained for 4 hours as per Clause 11.2 of the
IS:5822. If a drop in pressure occurs the quality of water added in order to reestablish the test pressure, should be carefully measured. This should not
exceed 0.1 litre per mm of pipe diameter per km of pipeline per day for each 30
m head of pressure applied.
Under the test pressure no leakage or sweating shall be visible at all section of
pipes, fittings, valves, hydrant and welded joints. Any defective pipes, fittings,
valves or hydrants discovered in consequences of this pressure test shall be
removed and replaced by sound material and the test shall be repeated until
satisfactory to the authority.
If the pressure measurements are not observed at the lowest section, an
allowance should be made for the static head between the lowest point and the
point of measurement to ensure that the pressure at the lowest point is as per
required test pressure.
Any defective joint or part shall be repaired and
PAGE 29 of 30
2004 of 2461
MMRDA
retested in the presence of the Employers representative. The contractor shall

make his own arrangements for water and all equipment and instruments.
Water used for testing shall be free from contaminants for field testing. The
pressure gauge used shall got tested and calibrated from laboratory approved
by Engineer. The pipeline shall be tested in stretches of not exceeding 2 km in
length. The hydraulic testing is mandatory.
PAGE 30 of 30
2005 of 2461
SUB-SECTION 6C.6
SURGE CONTROL AND BREAK PRESSURE
TANK
2006 of 2461
MMRDA
Table of Contents
SUB-SECTION 6C.6: SURGE CONTROL AND BREAK PRESSURE TANK ....................... 1
6.1
General ...................................................................................................................... 1
6.2
Surge Analysis and Water Hammer Control Devices ........................................... 2
6.2.1
Surge Analysis .................................................................................................... 2
6.2.2
Acceptable Water Hammer Control Solution ....................................................... 2
6.2.3
Unacceptable Control devices ............................................................................ 3
6.2.4
Surge Tank / Surge Shaft .................................................................................... 3
6.2.5
One Way Surge Tank ....................................................................................... 4
6.2.6
Stand Pipe........................................................................................................... 4
6.3
Conceptual Designs ................................................................................................. 5
6.3.1
Surge Tank as Control Device for Raw Water Pumping Main .............................. 5
6.3.2
One- way Surge Tank as Control Device for Clear Water Pumping Main ........... 5
6.4
Break Pressure Tank ................................................................................................ 6
6.4.1
Design Basis ....................................................................................................... 6
6.4.2
Design Data ........................................................................................................ 6
6.4.3
Design Methodology for Numerical Analysis ........................................................ 7
6.4.4
Further Optimization Aspects .............................................................................. 9
6.4.5
Conceptual Design ............................................................................................ 10
6.4.6
Contractors Option for Tank Construction.......................................................... 10
6.4.7
Design Parameters for BPT in Steel Tank Construction .................................... 10
6.4.8
RCC Tank /Shaft at BPT ................................................................................... 13
6.4.9
Termination of inlet and outlet pipes .................................................................. 13
2007 of 2461
MMRDA
SUB-SECTION 6C.6: SURGE CONTROL AND BREAK PRESSURE TANK

6.1
General
Unsteady flow phenomenon takes place in three transmission Pipe
systems as under:
(i)
Raw water pumping main from intake to Water Treatment Plant

Length 2025 m
(ii)
Clear water pumping main from Clear water pumping station to

Break Pressure Tank
(iii)
Gravity Main from Break pressure tank to Kashidkopar Junction

and further Chene.
The pumping mains at (i) and (ii) encounter on power failure to pumpmotor set transient pressures both negative and positive
of
objectionable magnitude causing water column separation and

consequent high pressure when separated water column rejoin. Water
hammer control device is necessary to restrict low pressure and high
pressure to safe limits.
As regards BPT, unsteady phenomenon is experienced when pumps
are restarted from No-flow condition in gravity main downstream of
BPT .As seen from Hydraulic flow diagram in tender drawing, entire 84
km long gravity main from BPT to Chene MBR shall be full except for
few stretches of small lengths above 52.5 m RL (TWL of MBR). On
restarting the pumps very high acceleration head is imposed
very long length
due to
causing WL rise initially in empty high level sections
and further WL rise shall takes place in BPT which shall depend on
cross sectional area of BPT.
The BPT needs to be designed considering this unsteady flow.
SECTION 6C.6: SURGE CONTROL & BPT
PAGE 1 of 14
2008 of 2461
MMRDA
6.2
Surge Analysis and Water Hammer Control Devices
6.2.1
Surge Analysis
Surge analysis shall be carried out for sudden power failure condition
using recognized software developed by Indian Institute of Science,
Banglore or Kentucky University or any other recognized software.
Design flow rate for surge analysis shall be as under:
Raw Water Pumping main for Q = 27083 m3/hr which is

corresponding to future Q after augmentation by 150 MLd
Clear water pumping main for Q = 19040 m3/hr which is present Q
Complete analysis with output of software shall be furnished. If results

of analysis show low pressure below -3.0 m or water column
separation, suitable water hammer control device shall be proposed for
individual pumping main to meet following pressure limits
Negative pressure over any pipe section of the pumping main

not permissible
Positive pressure shall not exceed 1.5 times normal working
pressure
6.2.2
Acceptable Water Hammer Control Solution

Methods / solutions as under are acceptable to restrict water hammer
pressure within acceptable limits stated above
(i)
Surge Tank or Surge Shaft
(ii)
One Way Surge Tank
(iii)
Stand Pipe
PAGE 2 of 14
2009 of 2461
6.2.3
MMRDA
Unacceptable Control devices

Following control devices are not acceptable
6.2.4
(i)
Air Vessel
(ii)
Zero Velocity Valve and Air Cushion Valves
(iii)
Pressure relief Valve
(iv)
Surge Anticipation valve / Surge suppressor
(v)
Hydraulically operated valve
Surge Tank / Surge Shaft

Surge Tank as elevated tank in RCC or surge shaft either in RCC
construction or steel construction can be accepted. TWL and overflow
level shall be on following basis
(i)
TWL of surge tank for raw water pumping main

= HGL at pumping station (at C=120 and Q=27083 m3/h )
(ii)
TWL for surge tank for clear water pumping main

= HGL at pumping station (at C=120 on basis of TWL of
BPT and
Q = 19040 m3/h)
The diameter of the tank / shaft shall be such that amplitude of

downsurge is controlled to prevent any negative pressure on pumping
main.
Provision as under shall be included
(i)
Connecting pipe between pumping main and surge tank / shaft

shall not be less than half of diameter of pumping main.
(ii)
Full diameter butterfly valve on connecting pipe
with flange
adaptor shall be provided . Class of BFV shall be minimum PN

PAGE 3 of 14
2010 of 2461
MMRDA
1.0 rating. The valve shall be located in Chamber.

(iii)
Overflow system with weir above TWL comprising overflow weir

of adequate length, launder for collection of overflowing quantity
and
pipeline laid upto disposed point, diameters of overflow
conveyance pipeline shall be adequate so as to surcharge

launders.
(iv)
Drain valve of 200 mm diameter with pipe work shall be laid to

dispose of drained water.
(v)
Top of the tank shall be with dome. Top shall be covered if shaft
is provided.
6.2.5
(vi)
Staircase upto the top of tank / shaft.
(vii)
Lightning protection.
One Way Surge Tank

If one-way surge tank is offered, the design details shall be furnished to
demonstrate that quantity discharged is adequate to prevent negative
pressure. Capacity of one-way surge tank shall be at least two times
the quantity discharged. The filling arrangement shall incorporate float
valve to ensure that inflow to one way surge tank stops when Water
level in tank reaches TWL. The filling shall be automatic.
The tank shall be in RCC construction. All provisions specified for
surge tank shall be provided. In addition a non-return valve / dual plate
check valve with chamber shall be provided. Direction of NRV / DPCV
shall be such that flow through this valve into one way surge tank is
disallowed. All valves shall be located in chambers. Diameter of pipe
shall be minimum half of diameter of pumping main.
6.2.6
Stand Pipe
PAGE 4 of 14
2011 of 2461
MMRDA
Stand pipe in MS construction with ground level RCC foundation is

acceptable subject to demonstrating that surge pressures are within
limit.
Top of stand pipe shall be above maximum HGL encountered at C =
120 and as specified for surge tank.
Suitable stays at appropriate level shall be provided to withstand wind
load as well as any misalignment from vertical.
6.3
Conceptual Designs
6.3.1
Surge Tank as Control Device for Raw Water Pumping Main

A surge tank as per design details is incorporated in conceptual design
Flow
19629 m3/h
Type
RCC Elevated tank
TWL
88.70 m RL
LWL
85.00 m RL
Overflow level
89.20 m RL
Diameter
18000 mm
Connecting pipe
6.3.2
1100 mm diameter
One- way Surge Tank as Control Device for Clear Water Pumping
Main
Surge analysis with one way surge tank shows that very small capacity
i.e. 24 m3 is required which eliminates negative pressure and as
consequent positive pressure is controlled. Hence one way surge tank
is suitable and proposed.
Since chlorine contact tank shall always be full, the same tank can be
used as one way surge tank by adopting arrangement as under:
PAGE 5 of 14
2012 of 2461
i)
MMRDA
Interconnection between Inlet pipe to CCT and clear water

pumping. Diameter of interconnection shall be half of diameter
of pumping main.
ii)
A non-return valve and BFV shall be provided in the

interconnecting pipe with flange adopter.
iii)
With above arrangement the chlorine contact tank shall function

as a one way surge tank to control and eliminate transient low
pressure in pumping main. Analysis is carried out for capacity of
one way surge tank. Required capacity is 24 m3 which is very
small as compared to capacity of 9500 m3 of chlorine contact
tank.
6.4
Break Pressure Tank
6.4.1
Design Basis
Hydraulic analysis
shall be based on guidelines given in paper
Development of Guidelines for sizing of BPT written by Dr. R.N. Ingle,

Retired Professor Visvevaraya Regional College of Engineering,
Nagpur and published in IWWA Journal. The hydraulic analysis shall
include unsteady flow analysis in BPT during startup of pumps from no
flow condition.
6.4.2
Design Data
Qdesign = 19040 m3/h (418.88 ML/d in 22 hrs)
(i)
LWL - based on steady state HGL @ C = 145 pipeline and

C=120 ( tunnel); No residual head
(ii)
TWL -
based on steady state HGL @ C = 120 (pipeline and
tunnel) + 5.0 m; (Residual head )

PAGE 6 of 14
2013 of 2461
(iii)
MMRDA
Overflow Level - based on max WL attained during unsteady

flow + 1.0 m or TWL whichever is higher
(iv)
Kashidkopar (KK) Junction

Q(Kashidkopar MBR)
8413 m3/h (185.09
ML/d)
Q (Chene MBR)
(v)
6.4.3
10045 m3/h (220.99 ML/d)
MBRs
TWL(Chene MBR)
- 52.50 m RL
TWL (Kashidkopar MBR) - 70.0 m RL
Design Methodology for Numerical Analysis

Design methodology and equations stated below are based on Dr.
Ingles paper on BPT design
(i)
Start point is No flow condition attained in entire downstream

transmission system
(ii)
from BPT to MBRs
From Hydraulic flow-diagram enclosed as tender drawing it is

obvious that following sections of pipeline are nearly full under
No-flow condition and only small lengths are drained
Entire pipeline and tunnels from Kashidkopar junction to

Chene MBR shall be full
Major length of 2.0 km pipeline from Kashidkopar junction to

Kashidkopar MBR below
52.5 m RL is full except for short
length of about 200 m above 52.5 m RL which shall drain

PAGE 7 of 14
2014 of 2461
MMRDA
Major length of 40 km long downstream pipeline from

Mendhawankhind tunnel outlet to Kashidkopar junction below
52.5 m RL shall be full except for small length about 1 km
from tunnel outlet shall drain
The Mendhawankhind tunnel shall be full except from vertical

Inlet shaft which shall be partly full and partly empty
The pipeline from BPT to Mendhawankhind tunnel shall be

nearly full except for very short length adjacent to BPT
(iii)
The computation shall be based on numerical analysis for

unsteady flow on basis of following two equations which are
based on Dr. Ingles paper.
Continuity of flow
Qpump
= QBPT + Qpipe
Equation 1
Where
QBPT
= Qaccumulated in BPT at any instance
Qpipe
= Flowrate in pipeline at any instance
Unsteady HGL equation

ZBPT
= Zend + Hf + Ha
Equation 2
Where
PAGE 8 of 14
2015 of 2461
ZBPT
MMRDA
= WL in BPT or transmission pipeline as

applicable at any instance
Zend
= TWL in Chene MBR
Hf
= Friction loss for Qpipe at any instance [ The

Hf shall be based on C=120 ]
Ha
= Acceleration head at any instance caused

due to increase / decrease in Qpipe
(iv)
All duty pumps are assumed to start at starting point. Qpump is

assumed to remain constant
(v)
Computations using above equation are continued till maximum

WL is attained in BPT for given BPT area
(vi)
Further computations
are continued till
Qpipe becomes
practically equal to design Q. HGL in BPT for the Q should be

practically as steady state HGL which is check to ensure that
numerical analysis is correctly done
(vii)
C value for computation of friction shall be C = 120 being the

worst design parameter
and
Minor losses @ 10% above
friction loss
(viii)
Volume of BPT for given area shall be calculated on basis of

maximum WL attained
(ix)
The analysis is done for 3-4 BPT areas to determine optimum

and feasible BPT volume
6.4.4
Further Optimization Aspects

It may be possible to optimize capacity of BPT if provided in steel
PAGE 9 of 14
2016 of 2461
MMRDA
construction by providing large tank area for lower part and small tank
area or riser pipe in upper part
6.4.5
Conceptual Design
Conceptual design based on C=145 for LWL and C = 120 for TWL + 5
m residual head envisages following hydraulic levels
Tank area
58.0 m2 (8.6 m diameter of circular BPT or 7.6 m X

7.6 m if square)
6.4.6
LWL
102.50 m RL
TWL
120.80 m RL
Water Depth
18.30 m
Contractors Option for Tank Construction

The contractor can opt for any of the following:
6.4.7
Low level elevated RCC tank
Ground level RCC shaft
Steel tank on RCC foundation or elevated foundation
Design Parameters for BPT in Steel Tank Construction

(a)
Determination of Plate Thickness, Inlet and Outlet

If BPT is in steel tank, parameters are as under:
Design of Steel tank shall conform to IS 2025- Code for

unfired pressure vessels
PAGE 10 of 14
2017 of 2461
MMRDA
Design pressure
1.5 x maximum water depth

(upto max. WL
attained
during unsteady flow after

pumps start)
Configuration
Vertical
Type
Class II
Weld joint efficiency
0.8
Carbon steel, grade 2A or 2B
factor
Material of construction
as per IS 2002
Corrosion allowance
3 mm
Dished ends shall be provided at upper and lower ends and

shall be designed as per above IS. Thinning allowance 3 mm
and corrosion allowance 3 mm shall be considered for plate
thickness of dished end
Inlet pipe shall be at bottom and shall be of diameter and

shell thickness similar to clear water pumping main. The Inlet
shall terminate in bellmouth with lip at least 500 mm above
bottom
(b)
Outlet pipe shall be taken from side wall and shall be at LWL
Riser pipe
Riser pipe shall be provided on the top of the tank.
(c)
Overflow
Riser pipe shall be provided on top of tank and shall be part of
PAGE 11 of 14
2018 of 2461
MMRDA
BPT for hydraulic and numerical analysis.

Invert level @ top shall be at TWL and shall be of configuration
of inverted U-tube. The horizontal leg and downstream vertical
leg shall function as overflow which shall be laid to pass
overflow to clear water sump.
The exit end of pipe shall be at least 600 mm above TWL of
clear water sump to prevent any back up in overflow system of
sump and to keep exit freely open to atmosphere so as to
prevent any siphonic reserve flow.
Downstream leg functioning as overflow can be reduced to
render overflow velocity to maximum 5.0 m/s.
(d)
Foundation
The tank shall be founded on RCC platform designed suitably to
mount the tank on platform and provide entry of Inlet pipe from
bottom and outlet from side.
(e)
Supporting and Access Arrangement
Spiral ladder shall be provided for access to top of tank and

further ladder for access to top of riser-cum-overflow pipe
The overflow pipe may be supported by duck-foot bend at

ground level.
In addition,
purpose-designed
RCC
or
structural steel supports shall be provided to keep the piping

systems stable for vertical load and lateral load including
wind load
(f)
Appurtenances and Fittings on BPT
600 mm diameter manhole at bottom part of tank
PAGE 12 of 14
2019 of 2461
MMRDA
Pressure gauge at bottom
Level gauge
Air vent of 100 mm
x 500 mm height at top of riser cum
overflow pipe.
6.4.8
RCC Tank /Shaft at BPT

If RCC tank or RCC shaft is proposed , provision as under shall be
incorporated
(i)
Access staircase
(ii)
Overflow arrangement including drain pipe for disposal
(iii)
Tank drain arrangement including drain valve of 200 mm

diameter.
(iv)
6.4.9
Lightening protection
Termination of inlet and outlet pipes

The inlet pipe shall be at the bottom of tank with flanged bellmouth .
Outlet pipe may be bottom or side. Lip of the bellmouth shall be 200
mm above the bottom of the tank.
PAGE 13 of 14
2020 of 2461
MMRDA
For Reference only
PAGE 14 of 14
2021 of 2461
SUB-SECTION 6C.7
TUNNELS
2022 of 2461
MMRDA
Table of Contents
SUB-SECTION 6C.7: TUNNELS
7.1
SCOPE AND EXTENT OF WORKS
7.2
THE SITE
7.3
TUNNEL BORING MACHINE
7.4
TUNNEL CONSTRUCTIONAL DETAILS
7.5
HYDRAULIC DESIGN REQUIREMENTS
7.6
CONTRACTORS SUBMISSION OF DESIGN & METHODOLOGY
7.7
SAFETY MEASURES
7.8
SPECIFIC PRECAUTIONS
10
2023 of 2461
MMRDA
SUB-SECTION 6C.7: TUNNELS

7.1
Scope and Extent of Works

This subsection covers particular requirements applicable to the
Construction of Tunnels and associated works including shafts and MS
end pieces.
Three tunnels as follows are included in the project components:
i. 3.6 m bore x 3.0 m finished diameter x 1.7 km long tunnel for
crossing of NH-8 at Mendhawankhind.
ii. 2.6 m bore x 2.0 m finished diameter x 4.435 km long tunnel for
crossing Tungareshwar Wild Life Sanctuary.
iii. 2.6 m bore x 2.0 m finished diameter x 0.9 km long tunnel for
crossing under Vasai creek having deep water column.
Major items of work covered are:
Construction of Tunnels about 7.035 kilometres long by TBM and

Concrete Lining and or steel liners;
Installation of all related permanent electrical and mechanical

equipment for operation of the System;
All related incidental works, such as pipe specials, Valves and Valve
Chambers, shaft, etc. specified in accompanying drawings and/or
Specifications
All the works are located very close to existing NH8 and one tunnel is
located in Tungareshwar Wild Life Sanctuary. Stringent rules and
regulations for working are applicable. The contractor shall familiarise
with all existing situations, rules, regulations and limitations etc. The
SECTION 6C.7: TUNNELS
PAGE 1 of 11
2024 of 2461
MMRDA
contractor shall be fully responsible for all works in the areas and failure
if any. It is important and vital that the methodology and construction
sequence has to ensure that existing facilities are not damaged,
disturbed or dislocated during construction.
7.2
The Site
The Contractor shall carry out a detailed survey of the tunnel route,
conduct Geo-tech investigation and draw up plans in consultation with
The plans shall be submitted to the Employers representative for use
by the Employer in obtaining permissions from the authorities. The
plans shall be submitted well in advance of the date scheduled for
commencement of construction of Tunnels as specified in the
Specifications and Employers requirements.
For inlet and outlet shafts of each tunnel, 50 x 50 m plot is earmarked.
The Contractor shall make his own arrangements and pay all expenses
for any additional area that he may require outside the site locations as
shown in the Drawing, in order to carry out the Tunnel work. The
Contractor shall obtain the consent of the Employers representative and
Employers representative of such arrangement prior to proceeding with
the work.
7.3
Tunnel Boring Machine

The tunnels shall be excavated using modern full face TBM suitable for
excavation of rock of all types encountered in the geotechnical
investigation. Outline details of the TBMs and mode of transport to the
Sites shall be submitted by the Tenderer along with the Tender.
The TBM shall include provision for forward probing at the face or on
the sides of the excavated tunnels to check rock quality and location of
likely places where water ingress could occur. They shall also include
provision for pre-grouting of rock in advance of excavating the tunnels
to seal water bearing fissures or to improve the strength of the rock
PAGE 2 of 11
2025 of 2461
MMRDA
mass and provision for installing rock bolts or dowels within 10 m of the
excavated face or along the periphery of excavated tunnel. Tunnel
excavation without forward probing shall not be permitted to be carried
out.
The Contractor shall submit full details of the TBM, the backup train
and all ancillary equipment to the Employers representative at least 6
weeks before the same is ready for shipping. The Contractor shall be
solely responsible for ensuring that all equipment provided by him is
suitable for the purpose of carrying out the Works. The TBM shall be
capable of excavating the tunnels of the required size to the line and
levels shown on the Specification Drawings at the rate of minimum 450
metres per month. All the equipment shall be capable of dealing with
poor ground conditions over local areas and water inflow at the face.
7.4
Tunnel Constructional Details
The tunnel shall be drilled with Tunnel Boring Machine in straight line
with ascending slope 1:500 from upstream to downstream
Bore diameter shall be 3.6 m and 2.6 m as per conceptual data
MS shaft of suitable diameter at both ends shall be provided for

lowering of TBM and handling of muck and water during drilling. Top
of MS shaft shall be at least 1000 mm above surrounding ground
The tunnel at Mendhawankhind and Tungareshwar shall be internally

lined by concrete with reinforcement both at outer section and inner
section of lining. The thickness of lining shall be minimum 300 mm
and shall be designed to withstand design pressure equal to 1.5 time
maximum static head encountered above lowest invert level of tunnel
Steel liners of adequate thickness and suitable design shall be

inserted and grouted to stop percolation of ground water into the
tunnel and pressurized water into surrounding rock in case of tunnel
PAGE 3 of 11
2026 of 2461
MMRDA
at Mendhawankhind and Tungareshwar wherever required. The

tunnel under the creek shall have both RCC lining and steel liners
over full length as per specifications given above
Both ends of tunnel shall be closed by providing and inserting mild

steel end pieces having puddle flanges at tunnel end, dished end at
outer end and shall also incorporate a square tee of diameter equal
to and for connecting vertical pipe for further connection to MS
transmission main below GL and mounting of two numbers air valves
at top end of each vertical pipe
Adequate designed thrust block shall be provided on above end

pieces to counter very high horizontal thrust encountered at dished
end of end pieces. Preliminary calculation shows that thrust at design
pressure is of following magnitudes:
Thrust @ Design Pressure
Tunnel
3m tunnel @
587 metric tonne
Mendhawankhind
2m tunnel @
692 metric tonne
Tungareshwar WLS
2m tunnel @ Vasai Creek
796 metric tonne
Stability of the thrust block is of paramount importance. All possible

methods and measures shall be adopted to ensure stability and zero
displacement of thrust blocks. Some of the desirable methods &
measures are:
Providing locking pins under the thrust block so that the pins are
locked in the rock
Making founding surface under the blocks undulating, uneven or

stepped so as to increase resistance to horizontal movement
Weight of gravity block shall be adequate to ensure that resultant
PAGE 4 of 11
2027 of 2461
MMRDA
of thrust and weight of block intersects base in middle third
Providing concrete packing between dished end and rock face on

alignment of end pieces
The contractor shall submit his proposed method or combination of

methods for restraining thrust for approval
Vertical pipe in M.S laid in the shaft as connecting pipework between

tunnel end piece and pipeline.
The vertical pipe shall have two
square tee branches of diameter equal to main pipeline diameter,

one branch shall be connected to main pipeline and second branch
shall be blind flanged
with dish shaped blind flange design
to
withstand field test pressure
Dished end with 2 numbers x 200 mm flanged tee shall be provided

at top of vertical pipe for mounting of air valves
The vertical pipe shall incorporate 600 mm manhole below dished

end
The connection of vertical pipe and jointing to MS pipeline below

ground level shall be by means of 90o square tee
200 mm diameter x 2 numbers kinetic air valves shall be mounted on

two 200 mm diameter tee on top of dished end of vertical pipe
Annular space between MS shaft and vertical pipe shall be filled with
lean concrete upto ground level
7.5
Hydraulic Design requirements
The tunnel, concrete lining of tunnel with reinforcement, liner and

associated pipework shall be designed for 150% of maximum static
head encountered on tunnel. Maximum static head is equal to
PAGE 5 of 11
2028 of 2461
MMRDA
elevation difference between design TWL at BPT and lowest invest

level of tunnel section
Corrosion and other allowance as under shall be considered for

design wall thickness of pipework
3 mm corrosion allowance for all pipework and liner
In addition 3 mm thinning allowance for dished end
MOC of pipe shall be of grade Fe 410 or superior conforming to IS

3589
7.6
Contractors Submission of Design & Methodology

The contractor shall submit detailed design and methodology for
approval
of
the
Employers
representative
and
Employers
representative. The submission shall include the following:

i.
Bore log data for each tunnel in compliance of requirement for

geotechnical investigation specified in Employers requirements.
ii.
Justification with reference rock profile, that proposed tunnel levels

are technically most suitable.
Full justification will be required that no leakage or seepage from rock
surface into the empty tunnel or from pressurised tunnel to rock
surface can occur.
iii.
The Tenderer shall furnish complete information about the method,

he proposes for sinking the wells, sinking the shafts within the wells,
drilling and excavation including in rock for shafts and tunnels where
applicable, supporting system for tunnels and procedure for
dismantling TBMs inside the tunnel and for withdrawing from
respective shafts.
PAGE 6 of 11
2029 of 2461
MMRDA
The Tenderer shall also give details of mucking arrangement for the
tunnels duly considering the high rate of production of muck by TBMs
and its final disposal expeditiously. In this connection, the Tenderer
shall note that due to limited availability of area at the shafts head,
intermediate dumping of muck within the plots will not be permitted.
The Tenderer shall further furnish details of full circle shuttering to be
used by him and the arrangement for concrete hauling and
placement of concrete for lining.
iv.
Detailed design for RCC internal lining including reinforcement to

ensure that it can withstand design pressure.
v.
Justification for use of grade of cement or sulphate resisting Portland

cement based on investigation of composition of rock and subsoil
water at boring level.
vi.
Composition of concrete and outer & inner reinforcement and

methodology for conveying lining material and lining placement.
vii.
7.7
Details of steel liners and methodology for construction.

Safety Measures
a) All operations inside the tunnels or shafts shall be carried out under
the immediate charge of a properly qualified and competent safety
engineer. The Contractor shall also depute experienced safety
supervisors in all three shifts under the overall command of the
safety engineer.
b) An effective and workable safety programme shall be planned in
advance in consultation with the Employers representative and
adhered to. Workmen shall be thoroughly instructed in safety rules
and shall be required to follow them at all times. They shall be
required to report immediately, to the safety engineer, any unsafe
conditions observed, who in turn will bring the same to the notice of
PAGE 7 of 11
2030 of 2461
MMRDA
the Employers representative and take necessary immediate actions

as required to ensure safety.
c) The safety engineer appointed to look after the tunnelling work may
also take guidance from geologists about the bad reaches expected
to be met in the tunnels so that necessary additional safety
measures could be adopted.
d) The occurrence of any accident involving injury to personnel or of any
dangerous incident, such as serious breakdown of or damage to any
apparatus / equipment and temporary works shall be reported to the
Employers representative and adequate precautions shall be taken
by the Contractor to prevent recurrence. An accurate record of such
accidents shall be properly maintained. Probable reasons of accident
shall be investigated and precautionary measures taken to avoid
farther recurrence.
e) All persons entering the tunnels or shafts shall be provided with
protective wear such as helmets, hand torches, and also safety belts
if required. Gumboots or similar types of protective footwear shall
also be provided. Ladies and children shall normally be not allowed
entry in the underground works, except in rare cases when they shall
be accompanied by responsible persons and escorted by the safety
engineer or a safety supervisor.
f) Signboards 1 m x 1.5 m in size with the following wording shall be
erected at the access to the shafts "CONSTRUCTION AREA.
HELMETS REQUIRED BEYOND THIS POINT".
g) No loose garments or ragged clothing shall be worn by personnel
engaged in the tunnelling operations.
h) Effective artificial respiration arrangements shall be provided, with
trained men capable of providing artificia1 respiration.
PAGE 8 of 11
2031 of 2461
MMRDA
i) First aid arrangements commensurate with the degree of hazard and

the number of workers employed shall be maintained in a readily
accessible place throughout the whole working hours of the
tunnelling job. At least one experienced first aid attendant shall be
available in each shift to take care of injured persons. Stretchers and
other equipment necessary to remove injured persons shall be
provided at shaft exits. The Contractor shall also make necessary
arrangement to remove the injured persons to the nearest qualified
medical practitioner / hospital as required.
j) Only the materials required for work in progress shall be kept inside
the tunnels. All other materials shall be removed from inside the
tunnels and at least 1.5 m width of the .formation shall be as even as
possible and without any obstacles to enable the workers to escape
out of the tunnels quickly in case there is any collapse or any other
mishap inside the tunnel.
k) All storage, handling and use of inflammable liquids shall be under
the supervision of qualified persons. All sources of ignition shall be
prohibited in areas where inflammable liquids / gases are stored,
handled and processed. Suitable warning and 'No Smoking' signs
shall be pasted at all such places. Receptacles containing
inflammable liquids / gases shall be stacked in such a manner as to
permit free passage of air. All combustible materials like rubbish shall
be continuously removed from such areas where inflammable liquids
/ gases are stored, handled and processed. All spills of inflammable
liquids shall be cleared up immediately. Containers of inflammable
liquids / gases shall be tightly capped.
l) Fire extinguishers and fire buckets appropriate to hazards should be
conveniently located and identified.
m) All cranes, winches, hoists, lifts etc. used for working in the shafts
shall be periodically (at least once a week) inspected by the safety
engineer jointly with the Employers representative. Any deficiency
PAGE 9 of 11
2032 of 2461
MMRDA
noticed shall be immediately rectified by the Contractor so that the

equipment satisfies requirements of the respective codes.
7.8
Specific Precautions
a) Specified safety precautions shall be taken for execution of tunnels,
shafts and sundry excavations.
b) Wet drilling shall be adopted to ensure dust free conditions in shafts.
c)
Blasting shall be controlled to ensure that the peak particle velocity

at any adjacent/nearby structure is within safe limits as determined
by the seismologist. The information on drilling and blasting pattern
requires to be furnished to the Employers representative. For this
purpose, the Contractor may conduct trial blast in the shafts/ tunnels
proper and arrive at a blasting pattern in line with the
recommendations of Central Water & Power Research Station
(CWPRS) according to which the peak particle velocity shall not
exceed 5 mm per second.
d) Strict safety measures shall be followed to ensure safe haulage of

men, materials and other equipment as per rules laid down in Indian
Mines Regulations.
e) Heavy duty pumps of adequate capacities shall be available at all
times at the Sites to control the seepage of water in the shafts and
tunnels.
f) Immediate arrangements shall be made for grouting the rock
(including chemical grouting) to control the seepage whenever
required.
g) The Contractor shall supply and erect head frames including hoists,
cables, pulleys, shackles and other accessories which shall be of
steel construction properly designed, with sufficient head room and
PAGE 10 of 11
2033 of 2461
MMRDA
safety against possible overload and impact due to sudden drops.

h) Hoisting equipment shall be thoroughly inspected at least once a
week. Suitable stand-by power supply arrangement or alternate
means of working the hoists mechanically as specified in I.S. 807:
Code of practice for design, manufacture, erection and testing
(structural portions) of cranes and hoists, shall be provided. A limit
switch or automatic brake shall be provided on every hoist to control
speed.
i) A masonry parapet wall of suitable height shall be constructed
around the well opening at ground level as well as around the shaft
openings to prevent entry of water or any other material falling into
the shafts.
j) Personnel shall be lowered in the shafts by passenger lifts from
ground level to the bottom of the shafts.
k) Reliable means of communication such as walkie-Talkie, bells or
whistles, shall be maintained at all times between the bottom of the
shafts and the surface and telephones used, whenever possible. Any
code of signal used shall be kept conspicuously pasted near work
place and entrance.
l) In case rail mounted equipment is deployed, the rail track shall be
properly earthed at suitable intervals.
m) A diesel generator set for lighting and power shall be available.
n) Suitable portable ventilation system shall be provided.
PAGE 11 of 11
2034 of 2461
SUB-SECTION 6C.8
TAPPINGS FOR 27 VILLAGES AND
CROSSINGS
2035 of 2461
MMRDA
Table of Contents
SUB-SECTION 6C.8: TAPPINGS FOR 27 VILLAGES AND CROSSINGS
8.1
TAPPING FOR 27 VILLAGES
8.2
RAILWAY CROSSING
8.2.1
8.2.2
8.2.3
Location and Magnitude of Crossing.................................................................. 4

Methodology ...................................................................................................... 5
GA Drawing ........................................................................................................ 6
8.3
CROSSINGS OF WATER COURSES
8.3.1
8.3.2
8.3.3
Minor Nallah/ Stream Crossings ....................................................................... 6

Canal Crossing................................................................................................... 6
River Crossings .................................................................................................. 7
8.4
CROSSING OF KAMAN CREEK - MICROTUNNEL WITH STAINLESS STEEL

PIPE
8
8.5
NH CROSSING AT GHODBUNDER JUNCTION
8.6
THANE GHODBUNDER ROAD CROSSING
8.7
EPOXY COATING SYSTEM FOR INTERIOR AND EXTERIOR OF PIPELINE

UNDER CROSSING
10
8.7.1
8.7.2
8.7.3
8.7.4
8.7.5
8.7.6
Coating and Lining Systems ............................................................................ 10

Pipe Preparation .............................................................................................. 11
Cure ................................................................................................................. 12
Electrical Inspection for Continuity ................................................................... 13
Coating Repair ................................................................................................. 13
Welded Field Joints .......................................................................................... 13
2036 of 2461
MMRDA
SUB-SECTION 6C.8: TAPPINGS FOR 27 VILLAGES AND CROSSINGS

8.1
Tapping for 27 Villages

27 villages in vicinity of VVCMC area are not merged in the city
corporation. Population of 27 villages as per census 2011 is 60,560.
The Surya RWSS incorporates provision of 15 ML/d bulk water supply
to all 27 villages.
Considering geographical aspects, these 27 villages are divided in
seven (7) groups. Branch tapping shall be provided for each group at
appropriate location.
Further transmission and distribution shall be
responsibility of the villages.

Table 8.1 below shows the details. The diameter of tapping is based
on 16 hrs. per day water supply.
The pipe material for tapping shall be mild steel Fe 410 grade and shall
be as square tee from main pipeline. The branch tee shall with flanged
end.
The general arrangement of tapping shall be with electromagnetic flow
meter, bypass with three valve arrangement as shown in tender
drawing.
Out of 27 village 12 villages on east & 15 villages on west of NH
Minimum diameter of tapping pipe is 100mm and
maximum
diameter is 400 mm
Size of chamber will be 1400 mm x 4300 mm
Existing RoW is adequate, No need to acquire fresh land for

chamber
SECTION 6C.8: TAPPINGS FOR 27 VILLAGES & CROSSINGS
2037 of 2461
PAGE 1 of 14
MMRDA
One flow meter & one sluice valve shall be provided in chamber as
shown in drawing
Locations of Tappings:
The pipeline along entire stretch is on west of Nh-8. However three
groups i.e. group 2, 6 and 7 are on east of NH-8. Remaining four
groups are on west of NH-8.
Thus for three groups i.e. 2,6 & 7, NH-8 is required to be crossed. The
location of tapping for these three groups shall be adjacent to nearby
flyover or culvert so as to facilitate NH crossing.
Table 8.1: Water Demand of 27 Villages Groups & Tapping
Diameters
Grou
Village
p No.
Name
Populatio Populatio
Locatio
Allocate
Group
Diamet
n of
Deman
er of
(Census
(Census
villages
Quantit
Tappin
2011)
2011)
w.r.t.
y (MLd)
(MLd)
g (mm)
(group
NH-8
0.78
150
3.80
350
5.95
400
wise)
1
Dolivpada
790
3148
WEST
Tokare
1,369
0.34
Khairpada
989
0.24
Depivali
1,083
Karanjon
768
0.19
Majivali
770
0.19
Parol
1,912
0.47
Saiwan
2,185
0.54
Shirvali
1,406
0.35
Shivansai
1,246
0.31
Tilher
3,606
0.89
Usgaon
2,374
0.59
Arnala
13,170
15,350
24,029
EAST
WEST
2038 of 2461
0.20
0.27
3.26
PAGE 2 of 14
Grou
Village
p No.
Name
MMRDA
Populatio Populatio
Locatio
Allocate
Group
Diamet
n of
Deman
er of
(Census
(Census
villages
Quantit
Tappin
2011)
2011)
w.r.t.
y (MLd)
(MLd)
g (mm)
(group
NH-8
2.23
250
1.25
200
0.64
150
0.35
100
wise)
Arnala
2,262
0.56
Kalamb
4,976
1.23
Satpale
3,621
0.90
Shilottar
326
Rangaon
3,640
0.90
Tivari
1,265
0.31
Vasali
3,765
0.93
Killa
Khochivad 2,604
8996
WEST
5,054
WEST
0.08
0.64
Pali
739
0.18
Panju
1,362
0.34
Sarjamori
349
0.09
Poman
1,669
Mori
910
Nagale
1,404
2,579
EAST
0.41
0.23
1,404
EAST
2039 of 2461
0.35
PAGE 3 of 14
MMRDA
8.2
Railway Crossing
8.2.1
Location and Magnitude of Crossing

Vasai-Panvel railway crossing is encountered at village Juchandra.
Railway over bridge above NH is provided for NH crossing with high
embankment about 6 m high. Width of crossing is 100m within railway
boundary. As per guideline of railway authority, crossing needs to be
10m from railway boundary on each side. Thus the total length of
crossing is 120m.
2040 of 2461
PAGE 4 of 14
8.2.2
MMRDA
Methodology
a)
RCC Box
Approval of Railway Authority is obtained for crossing. As per
approval letter RCC box of dimension 2500mm x 2500 mm with
300 mm thickness is required to be pushed under the
embankment. As per approval letter, this work i.e. RCC box will
be carried out by railway.
b)
Conveyance / carrier pipe and concrete fill

Pipeline of diameter 1829 mm and shell thickness not less than
22 mm in mild steel Fe 410 shall be laid in the box with suitable
saddle at the bottom. Anti-corrosive paint shall be provided on
outside. Space between pipeline and RCC box shall be filled with
concrete. The inside of pipe will be coated with the primer and
two coats of epoxy paint as per specification given hereunder on
basis of Annex B of IS 3589. This work shall be done by the
contractor under this contract and shall be supervised by Railway
authority.
c)
Pushing and receiving pit

Pushing and Receiving pits will be provided at two ends of
crossing. Pushing pit size will be 8000mm x 5000mm x 5000 mm
and Receiving pit size will be 6000mm x 5000mm x 5000mm
approximately.
d)
Inspection chamber and valve arrangement

Butterfly valve long body of PN 1.6 with flange adopter and
inspection chamber will be provided outside railway boundary to
facilitate the closure of flow of water supply whenever required.
2041 of 2461
PAGE 5 of 14
MMRDA
After completion of work pushing and receiving pits will be filled.

Valves chambers will be at both pushing and receiving pits. Vent
pipe & sign board shall be provided.
8.2.3
GA Drawing
GA drawing is enclosed as tender drawing.
8.3
Crossings of Water Courses
8.3.1
Minor Nallah/ Stream Crossings

Pipeline shall be laid at least 300 mm below the bed level by doing
open excavation which will be feasible and economical as these
Nallahs and streams are not perennial. The pipe sections shall be
encased in RCC in all such crossings section as shown in tender
drawing. The encasing shall be extended at least 1000mm on both
sides over maximum width of crossing. Concrete used for this shall be
of M15 grade. Before placing concrete the pipes shall be supported at
every 500 mm spacing with a padding of compressive material on a
pre-cast concrete block. Concrete shall not be placed until the pipes
have been jointed, inspected and tested. The concrete shall be placed
to ensure full contact with the pipe barrel throughout its length.
Necessary reinforcement steel shall be provided as per the approved
design and site conditions. No concrete shall be placed around joints of
a welded steel pipe until that length of pipe has passed a sectional
hydraulic test.
8.3.2
Canal Crossing
The crossing of irrigation canals is to be executed as per the approved
L-section, after obtaining necessary permission from the Irrigation
Department or as directed by Employers Representative. The
Contractor has the full responsibility in case of damage to the canal
embankment or lining. All costs for reinstatement of the canal to its
2042 of 2461
PAGE 6 of 14
MMRDA
original status shall be borne by the Contractor.

The pipe shall be laid at least 300 mm below the canal bed level. The
entire length of pipeline under canal plus 10,000 mm on each side shall
be encased. Concrete used for this shall be of M15 grade. Before
placing concrete the pipes shall be supported at every 500 mm spacing
with a padding of compressive material on a pre-cast concrete block.
Concrete shall not be placed until the pipes have been jointed,
inspected and tested. The concrete shall be placed to ensure full
contact with the pipe barrel throughout its length. Necessary
reinforcement steel shall be provided as per the approved design and
site conditions. No concrete shall be placed around joints of a welded
steel pipe until that length of pipe has passed a sectional hydraulic test.
The Contractor shall provide concrete lining of the canal section for a
length of at least 15 m on each side of the crossing after the excavated
portions of the canal embankment have been properly reconstructed
with required compaction. Construction of the concrete lining must not
result in any hump in the canal and must be graded to the requirements
of the Irrigation Department.
8.3.3
River Crossings
There are three major river crossing encountered throughout pipeline
alignment
Vaitarna River
Tansa River -
170 m
Vandri River -
115 m
240 m
Pipeline should be 3 m below the bed level / scour level of river by

open excavation in rocky bed. Pipe will be encased in RCC in river
section.
Open excavation is feasible and economical option as
2043 of 2461
PAGE 7 of 14
MMRDA
discussed below.
a)
For Vaitarna and Tansa Rivers working is to be restricted during

low tide period and fair season when there is hardly flow in the
river or by construction of coffer dam, if necessary.
b)
Vandri River is diverted in two streams near existing road

crossing bridge. Pipeline shall be laid by closing one stream with
coffer dam and diverting flow in other stream. Next coffer dam
shall be constructed on second stream , flow stopped and
pipeline shall be laid.
The pipe sections shall be encased in RCC in all such crossings

section as shown in tender drawing. The encasing shall be extended at
least 10,000 mm on both sides over maximum width of crossing.
Concrete used for this shall be of M15 grade. Before placing concrete
the pipes shall be supported at every 500 mm spacing with a padding
of compressive material on a pre-cast concrete block. Concrete shall
not be placed until the pipes have been jointed, inspected and tested.
The concrete shall be placed to ensure full contact with the pipe barrel
throughout its length. Necessary reinforcement steel shall be provided
as per the approved design and site conditions. No concrete shall be
placed around joints of a welded steel pipe until that length of pipe has
passed a sectional hydraulic test.
8.4
Crossing of Kaman Creek - Microtunnel with Stainless Steel Pipe

The water in Kaman creek is highly polluted. Total length of crossing in
Kaman creek is 85 m. The creek falls in CRZ area and mangroves are
on both sides.
In view of large mangroves, crossing by pipeline bridge will be costlier as
length increases enormously. Crossing below bed level by conventional
open excavation is not feasible due to mangroves.
2044 of 2461
PAGE 8 of 14
MMRDA
In view of above aspects, the crossing by Microtunnelling is proposed. In

view of possibility of ingress of polluted water, the material of
construction should be highly corrosion resistant. Hence pipe of
stainless steel grade 316 is proposed to be inserted in Microtunnel. The
material is resistant to very high polluted water. The diameter shall be
same as M.S. pipeline and shell thickness of SS 316 pipe shall be 20
mm. Flanged ends shall be provided at both ends for connecting to M.S.
Pipeline.
8.5
NH Crossing at Ghodbunder Junction

The pipeline route is on west of NH8 whereas MBR at Chene is on East
of NH.
Hence crossing at Ghodbunder junction is encountered
immediately downstream of Vasai creek. NHAI has proposed trumped

with flyovers at the junction. Crossing of NH shall be through RCC box.
NHAI has agreed to construct RCC box during construction of trumpet.
Pipeline of diameter 1829 mm and higher thickness of 22mm shall be
laid in the box with suitable saddle at the bottom. Interior and exterior of
pipeline shall be coated with epoxy as per specification given hereunder.
Space between pipeline and RCC box shall be kept open. The inside of
pipe will be coated with the primer and two coats of epoxy paint as per
IS 3589. This work shall be done by the contractor.
8.6
Thane Ghodbunder Road Crossing

Thane Ghodbunder Road crossing shall be done by providing micro
tunnelling or RCC box as per approval of MSRDC.
Pipeline shall be of 1829 mm diameter and higher thickness of 22 mm.
Pipelines crossing Thane Ghodbunder roads shall be encased in M15
concrete, including necessary reinforcement. The Contractor shall
program the Works so as to reduce disruption to road traffic to a
minimum. Before any work commences, the Contractor shall obtain
2045 of 2461
PAGE 9 of 14
MMRDA
permission and approval of all concerned authorities, serve notices of

intent to start the work as may be necessary, and observe all local Laws
and Regulations. The Contractor shall submit details of his proposals,
obtain approval from the Employers Representative and local highway
authority, and construct any required temporary diversion roads before
starting the work.
The exterior of pipeline shall be coated with epoxy as per specification
given hereunder.
8.7
Epoxy Coating System for Interior and Exterior of Pipeline under

Crossing
The specification shall be applicable for interior of following pipeline
under crossing:
i.
Exposed pipeline on pipeline bridge across Kaman creek (Exterior

only)
8.7.1
ii.
Railway crossing (Interior coating)
iii.
NH crossing at Ghodbunder (Interior and Exterior)
iv.
Crossing of Thane- Ghodbunder road (Interior coating)
Coating and Lining Systems

The coating and lining systems shall consist of two-part, chemically
cured epoxy primer and two coatings of a different two-part, chemically
cured epoxy topcoat.
8.7.1.1
Liquid-Epoxy Coatings
The coatings used shall be based on liquid, chemically cured epoxies.
The curing agent may be an amine, amine-adduct, or polyamide; and
2046 of 2461
PAGE 10 of 14
MMRDA
the epoxy may be modified with the coal rat, phenolic, or other modifiers.
Materials used in both the primer and finish coat(s) shall be products of
one manufacturer.
8.7.1.2
Coating Thickness
Unless otherwise specified by the purchaser, the minimum dry film
thickness DFT provided shall be at least 406 m.
After curing but prior to burial, the coating system shall be a continuous
film, free of thin spots and other imperfections as defined and shall pass
electrical inspection.
8.7.1.3
Coating Application
The pipe coating shall be applied in accordance with the manufacturers
recommendations. Application by airless spray or centrifugal wheel
equipment is preferred.
8.7.2
Pipe Preparation
8.7.2.1
Cleaning
Prior to adbrasive blast cleaning, surfaces shall be inspected and, if
required, cleaned according to remove oil, grease, or other foreign
matter. Only approved solvents that do not leave a residue shall be
used. Preheating to remove oil, grease, mill scale, water and ice may be
used provided all pipe is preheated in a uniform manner to avoid
distorting the pipe.
8.7.2.2

The exterior pipe surfaces shall be abrasive blast cleaned to achieve a
near white metal surface. The interior pipe surfaces shall be abrasive
blast cleaned to achieve a white metal surface. Abrasive blasting and
2047 of 2461
PAGE 11 of 14
MMRDA
coating shall only be performed when the metal temperature is more

than 3C above dew point.
8.7.2.3
Surface Inspection
The exterior and interior pipe surfaces shall be inspected for surface
imperfections, such as slivers, scabs, burrs, weld spatter, and gouges,
shall be removed by grinding.
8.7.2.4
Interior Cleaning
If abrasives or other loose foreign matter has entered the interior of the
pipe, then clean, dry oil free compressed air shall be used to remove the
loose foreign matter in a manner that does not adversely affect the
cleaned surface. Alternatively, vacuum cleaning or other methods may
be used in place of compressed air.
8.7.2.5
Application Temperature
The temperature of the mixed coating material and of the pipe at the
time of application shall not be lower than 10C. Preheating of the
coating material, the use of in line heaters to heat the coating material;
or heating of the pipe, fittings or specials may be used to facilitate the
application. Heating shall conform to the recommendations of the
coating manufacturer.
8.7.2.6
Application of Epoxy Coating System

If more than one coat is applied, the second coat shall be applied within
the time limits, surface conditions, and temperature recommended by
the manufacturer, if the period between coats is exceeded, then a repair
procedure shall be obtained from the coating manufacturer and its
recommendations followed.
8.7.3
Cure
2048 of 2461
PAGE 12 of 14
MMRDA
After application, the coating system shall be tested for cure.

8.7.4

After curing, but prior to installation, the coating system applied to the
pipe shall be tested for holidays according to the procedures and using
the voltage settings. Any holidays indicated by the detector shall be
marked with chalk or felt-tip marker to identify the area to be repaired.
8.7.5
Coating Repair
Accessible areas of pipe requiring coating repairs shall be cleaned to
remove debris and damaged coating using surface grinders or other
means acceptable to the purchaser. The adjacent coating shall be
feathered by sanding, grinding, or other methods approved by the
purchaser. Accumulated debris shall be removed by vacuum, blowing,
or wiping with clean rags.
8.7.6
Welded Field Joints
8.7.6.1
Preparation
The weld joint shall be cleaned so as to be free from mud, oil, grease,
welding flux, weld spatter, and other foreign contaminants. The cleaned
metal surfaces of the weld joint shall then be abrasive blasted, vacuum
blasted, or abraded using rotary abrading pads. The adjacent liquid
epoxy coating shall be feathered by adbrading the coating surface for a
distance of 25 mm.
8.7.6.2
Electrical Inspection
After curing, the coating system applied to the welded joints shall be
holiday tested. Any holidays indicated by the detector shall be marked
with chalk or felt-tip marker to identify the area for repair.
2049 of 2461
PAGE 13 of 14
8.7.6.3
MMRDA
Bedding and Trench Backfill

Where the trench traverses rocky ground containing hard objects that
could penetrate the protective coating, a layer of screened earth, sand,
or rounded river run gravel not less than 150 mm thick with a maximum
particle size of 20 mm shall be placed in the bottom of the trench prior to
installation of the coated article.
2050 of 2461
PAGE 14 of 14
SUB-SECTION 6C.9
MASTER BALANCING RESERVOIRS
2051 of 2461
MMRDA
Table of Contents
SUB-SECTION 6C.9: MASTER BALANCING RESERVOIRS
9.1
GENERAL
9.2
PERMISSIBLE VARIATION
9.3
DESIGN CONSIDERATIONS
9.4
GENERAL FEATURES OF THE TANK
9.4.1
9.4.2
9.4.3
9.4.4
9.4.5
9.4.6
9.4.7
9.4.8
9.4.9
Roof / Dome above Tank ................................................................................... 4

Overflow Arrangement ....................................................................................... 4
Tank Drain Arrangement .................................................................................... 5
Inlet and Outlet Pipes ......................................................................................... 5
Pipes and Specials............................................................................................. 5
All Flanged Specials........................................................................................... 6
Puddle Collar...................................................................................................... 6
Railing ................................................................................................................ 6
Staircase and Ladders ....................................................................................... 7
9.5
MATERIAL
9.6
CONSTRUCTIONAL REQUIREMENT
9.6.1
9.6.2
9.6.3
9.6.4
9.6.5
9.6.6
Concrete............................................................................................................. 8
Check of Reinforcement and Concreting ........................................................... 8
Minimum Requirement for all reinforced or plain concrete structures ................ 8
Construction joints.............................................................................................. 9
Final Finishing .................................................................................................... 9
Precautions to Keep MBR Free From Contamination ........................................ 9
9.7
TESTING FOR WATER TIGHTNESS
2052 of 2461
10
MMRDA
SUB-SECTION 6C.9: MASTER BALANCING RESERVOIRS

9.1
General
Two MBRs are proposed in scheme. Kashidkopar MBR is about 57 km
and Chene MBR near Ghodbunder about 84 Km from WTP. The scope
of work for construction of MBR includes survey, geo-tech investigation,
design, construction, testing and commissioning of clear water RCC
reservoir having effective storage capacity of 38 ML at Kashidkopar for
Vasai Virar City Municipal Corporation and 45 ML at Chene for Mira
Bhayander Municipal Corporation along with all associated works i.e.
supply, installation, of M.S pipes, specials, valves etc. for Inlet / Outlet /
Overflow / Interconnection with existing system as described. Other
facilities such as manholes, ladders, staircase, re-chlorination etc. shall
be provided.
The MBR at Kashidkopar is partly on deep cutting of
hillock and partly elevated on sloping ground. The MBR at Chenne

shall be ground level tank.
Conceptual design parameters are as under:
Parameter
Kashidkopar MBR
Chene MBR
Capacity
38 ML
45 ML
TWL
70 m RL
52.5 m RL
LWL
65.0 m RL
47.5 m RL
Compartment wall is provided in each MBR to achieve compartments of

equal capacities.
9.2
Permissible Variation
The positions shapes and water depth can be changed. TWL and
capacity remains fixed. LWL and water depth can be varied subject to
furnishing and approval of design by the Employers representative.
Instead of single large tank, multiple tanks can be offered with following
conditions:
SECTION 6C.9: MASTER BALANCING RESERVOIS
PAGE 1 of 10
2053 of 2461
MMRDA
Shape can be changed; even irregular shapes can be accepted
Compartment wall is not necessary in multiple tanks
Hydraulic interconnections between compartments or multiple tanks

with isolation valve are to be provided. The diameter of
interconnection shall be minimum 500 mm
Each tank or each compartment shall have individual inlet and outlet
and overflow arrangement
Cumulative overflow capacity of the tanks or compartments should

be such that when any one tank or compartment is taken out of
service /operation, all remaining tank(s) or compartment should be
suitable to handle full overflow without exceeding free board for
head rise for passing full overflow
9.3
Design Considerations
The Contractor shall be responsible for the safety of structures,
correctness of design and drawings, even after the approval of the
same by the Employers representative. Complete detailed design
calculations of foundations and superstructure together with general
arrangement of drawings and explanatory sketches of reservoir shall be
submitted to the Employers representative for approval. Separate
calculations for foundations or superstructures submitted independent
of each other shall be deemed to be incomplete and will not be
accepted by the Employers representative.
The design considerations described under General Specifications are
the minimum basic requirement that the Contractor shall consider under
this contract. However, any particular structure shall be designed for the
satisfactory performance of the functions for which the same is being
PAGE 2 of 10
2054 of 2461
MMRDA
All designs shall be based on the latest Indian Standard (I.S.)

Specifications or Codes of Practice unless otherwise specified in the
standard Specification. The design standards adopted shall follow the
best modern engineering practice in the field based on any other
international standard or specialist literature subject to such standard
reference or extract of such literature in the English language being
supplied to and approved by the Employers representative. In case of
any variation or contradiction between the provisions of the I.S.
Standards or Codes and the specifications given along with the
submitted tender document, the provision given in this specification
shall be followed.
All Design Considerations as described in the General Specification for
Civil Works namely Design Submission, Design Life, Design Loading,
Dead Load, Live Load, Wind Load, Earthquake Load, Joints, Design
Condition for ground level or Partly elevated Liquid Retaining
Structures, Foundations. Liquid Retaining Structures, Concrete Mixes
are applied unless otherwise stated in elsewhere of the Tender
Document.
The Contractor shall provide all items, materials, required pipes, fittings,
valves, specials, etc. for interconnecting to the water mains and
reservoirs, as specified in this Specification and tender drawings in bid
document. In order to determine the final locations, the detailed design
report, and the drawings shall be submitted by the Contractor for prior
approval of the Employers representative to proceed for the
Construction Stage Drawings including the shop drawings. The
Contractor shall store materials and equipment at places on the site
agreed with the Employers representative. No materials or equipment
shall be left in a way that the reservoir structure is supporting it.
The Contractor shall submit method statement to advise the work
sequence of their work and to justify that they have taken into account
all necessary protection provision to protect sites, structures, etc. The
method statement and MSP Gant Chart have to be submitted to the
Employers representative for approval. Interface between, civil works,
PAGE 3 of 10
2055 of 2461
MMRDA
mechanical works, electrical works and other works shall be furnished

in MSP Gant Chart. The aggregates and cement shall be proportioned
by weight only. No hand mixing of concrete will be allowed. Standby
Concrete Mixer and Vibrator shall be available at Site.
The ground water available in this area may not be potable and not fit
for concreting. Therefore transporting water from nearby safe and
acceptable water source has to be made. For the purpose of concreting
and curing only potable water conforming to provisions of IS: 456 is to
be used. For this purpose the Contractor shall make a temporary
masonry/RCC underground water reservoir at least for 3 days average
water consumption storage capacity. He shall provide a diesel pump set
and necessary piping arrangement to ensure proper curing.
9.4
General Features of the Tank
9.4.1
Roof / Dome above Tank

Flat Roof or dome shall be provided with adequate freeboard.
Freeboard should be of adequate magnitude and such that even after
head rise over overflow weir or pipe, minimum 250 mm clearances
between lowest part/soffit of roof/dome and raised WL while passing
overflow is available. Adequate number of air vents shall be provided
over roof. Minimum one manhole for each compartment/ tank shall be
provided.
9.4.2
Overflow Arrangement
In view of large flow rates, piped overflow is not accepted. Weir length
of tank or compartment shall be adequate to pass higher flow rate when
one tank or compartment is out of service.
Overflow shall be collected in launder and disposed by providing drain
pipe in launder. Drain pipe shall be sized to restrict velocity to 5.0 m/s.
Total friction losses in drain pipes shall be such that no surcharging in
launder occurs. Overflow shall be let into outfall for final discharge into
PAGE 4 of 10
2056 of 2461
MMRDA
lake /stream. Purpose designed outfall shall be provided to protect

banks of lake or nallah from erosion.
9.4.3
Tank Drain Arrangement

Drain arrangement with 300 mm diameter pipe and isolating valve shall
be provided. The drain pipe shall flush with bottom of tank. The drain
may be connected to overflow drain arrangement.
9.4.4
Inlet and Outlet Pipes

Inlet and outlet pipes shall be sized by using following relationship:
Required inlet/outlet diameter (pipeline diameter x (Capacity of

tank/compartment Total capacity.
Isolation BFV with flanged adaptor shall be provided on inlet and outlet.
Both inlet and outlet shall be terminated in flanged bellmouth ends.
Flared bellmouth ends shall be designed for velocity 0.9 m/s. Inlet to
MBR tank or compartment shall terminate at TWL. Outlet of MBR tank
or compartment shall terminate at 200 mm above bottom of tank.
9.4.5
Pipes and Specials

The MS/DI/CI double flanged Pipes shall conform to relevant IS and
MS/DI/CI double flanged fitting specials shall be in accordance with
relevant IS code.
Sizes of different pipes for Inlet, Outlet, and Overflow and wash out
pipes for different locations shall be as per scope of work or General
Arrangement (GA) Drawing for MBRs.
Double flanged flange adaptor shall be installed in such a manner that
valves can be dismantled without stress to the joints. These shall be for
minimum working pressures of 10 kg/cm2 (1 MPa) and shall be
PAGE 5 of 10
2057 of 2461
MMRDA
completely leak proof with proper gasket arrangement. Flange

dimensions shall conform to latest relevant IS code. Flanged specials
shall be supplied with required nuts, bolts, rubber gaskets, lubricants
and paints with excess quantities for wastage and maintenances. The
flange adopter / dismantling joint shall be internally and externally
coated with epoxy primer and two coats as per latest edition of IS 3589.
9.4.6
All Flanged Specials

The MS flanged specials (all flanged tee, flanged tapers, bends, blank
flanges and puddle collar) shall conform to standards in General
specifications.
MS specials shall be internally and externally coated with epoxy primer
and two coats as per latest edition of IS 3589.
Flanged specials shall be supplied with the galvanised bolts, nuts,
rubber gaskets, lubricants and paints with excess quantities for wastage
and maintenances. The galvanised nut & bolts shall be supplied in jute
bag; rubber gasket shall be supplied in polyethylene bags. The rubber
gaskets shall conform to IS 5382.
The length and size of the puddle collars to be fixed at different places
of the structures shall be decided as per approval of Employers
representative.
9.4.7
Puddle Collar
All puddle collars shall be of D.I. /MS. The length and size of the puddle
collars shall be as per the General Specifications of the tender.
9.4.8
Railing
Hand railing around the stairs shall be consisting of 25mm diameter
medium B class GI pipes in two rows (one at the top and other at
middle level) and 1000mm high vertical post 65x65x6 mm angle iron @
PAGE 6 of 10
2058 of 2461
MMRDA
1500mm centre to centre (At least two vertical angles are to be

provided wherever distance is less) with all accessories like elbows,
tees etc. including welding, threading and embedding in cement
concrete floor. Railing shall be protected against corrosion after
welding. The pipe shall pass through hole in the vertical angle.
9.4.9
Staircase and Ladders

RCC staircase shall be provided for access from ground level to top of
each tank. Stainless steel ladder shall be provided for access to bottom
of each compartment/tank. The stainless steel shall be chlorine
resistance.
9.5
Material
The Contractor shall submit to the Employers representative, samples
of the materials which will form part of the permanent works, sufficiently
in advance of the start of the work, so that necessary tests can be
carried out for the approval of the Employers representative, before
using any such material on site. Contractor shall arrange for testing of
all the material supplied in separate lot, from recognized government
institution as approved by the Employers representative as per
Standard Specification of work. All testing charges shall be borne by the
Contractor. The necessary tests shall be carried out as per latest Indian
Standards.
If necessary, the Employers representative may request any other test
to be carried out from time to time as per the Indian Standards at
Contractors cost. The sampling shall be done from each lot of supply
and as per relevant IS.
The aggregates and cement shall be proportioned by using weight
batch mixer only. No hand mixing of concrete will be allowed. Standby
Concrete Mixer and all type of vibrators shall be available at Site.
PAGE 7 of 10
2059 of 2461
MMRDA
9.6
Constructional Requirement
9.6.1
Concrete
During the progress of construction sampling, preparation of test
specimens, curing and testing of concrete shall be conducted in
accordance with IS 1199 and IS 516 as mentioned in the General
Specification. However, if concrete is tested in accordance with Testing
of Concrete and the result of crushing strength of the 7 days test of
concrete shows too low, then the Employers representative may direct
for another concrete sampling and testing, without waiting for the
results of the 28 days tests.
Failure to Meet Strength Requirements
In case concrete tested fails to meet the test requirements, the
Employers representative shall have the right to ask for additional tests
as required. These shall be carried out by Contractor at his own
expense.
9.6.2
Check of Reinforcement and Concreting

All reinforcement shall be checked by the Employers representative of
the Employer section and recorded prior to pouring of concrete.
Similarly, the entire concrete pouring work shall be done in the
presence of the Employers representative at the site. The Contractor
shall therefore, give a notice of a minimum three days to the Employers
representative. No work shall be covered before inspection and
9.6.3
Minimum Requirement for all reinforced or plain concrete structures

a)
The minimum grade of concrete for water retaining structures

shall be M30 having minimum cement content of 360 kg/m3 with
maximum 20mm size downgraded coarse aggregates.
PAGE 8 of 10
2060 of 2461
b)
MMRDA
Approved quality water proofing compound (chloride free) shall

be added during concreting of all water retaining structure, in the
proportion specified by the manufacturer/as per design mix or up
to 2% (percent) by weight of cement.
9.6.4
Construction joints
As construction joints are weaker in the places where the shear stress
is critical, the Contractor shall locate the construction joints where shear
stress is minimum. The locations of the construction joints shall be
shown in the Contractors Method Statement and shall obtain the
approval
from
the
Employers
representative,
prior
to
the
commencement of concrete works of the MBR. In the event the

Contractor solely requires construction joints for his convenience,
construction joints at bottom slab and/or vertical construction joints in
the wall of the water retaining structures, then the Contractor shall
provide approved PVC water-stop of 230mm width and 8 mm thick in all
such joints. For the convenience of construction and to avoid
segregation of concrete, horizontal construction joints shall be provided
in a height not more than 1.5 m.
9.6.5
Final Finishing
The Contractor shall ensure that the entire structures along with all its
installations are in a finished and in new and fully operative condition
when handed over at end of the Defect Liability Period. Even during the
construction period, he shall repair and remove all signs of damages
that would may happen during the course of installation and fixing of
equipment. This shall be done to the satisfaction of the Employers
representative.
9.6.6
Precautions to Keep MBR Free From Contamination

As soon as possible after completion of MBR and after all pipes are
laid, the Contractor shall remove all dirt, debris, materials, tools etc.
from the reservoir and shall wash and brush with water the whole of the
PAGE 9 of 10
2061 of 2461
MMRDA
interior. He shall also if required by the Employers representative

incorporate a mixture of chloride of lime in the water to be used for
washing.
Due care shall be taken to keep the entire reservoir free from any
contamination. Strict supervision shall be maintained over the workmen
entering after first washing. Provision shall be made to enable workmen
to wash their feet or footwear clean and sterilize them before entering.
9.7
Testing for Water Tightness

The contractor shall carry out a water tightness test for the maximum
water head condition i.e. with the water standing at full supply level. All
cost of testing shall be borne by the contractor. This test shall be
carried out as per IS: 3370 and per latest IS as stated in the General
Specification.
If the test results are unsatisfactory, the Contractor shall ascertain the
cause and make all necessary repairs and repeat the water retaining
structure test procedures, at his own cost. Should the re-test results still
be unsatisfactory after the repairs, the structure will be rejected and the
Contractor will dismantle and reconstruct the structure, to the original
specification, at his own cost.
PAGE 10 of 10
2062 of 2461
SUB-SECTION 6C.10
RECHLORINATION
2063 of 2461
MMRDA
Table of Contents
SUB-SECTION 6C.10: RECHLORINATION .................................................................................. 1
10.1
Introduction ............................................................................................................................. 1
10.2
Rechlorination......................................................................................................................... 1
10.3
Equipment and Plant ............................................................................................................. 2
10.4
Operation of Rechlorination Plant ..................................................................................... 2
10.5
Safety......................................................................................................................................... 3
10.6
Control Philosophy ................................................................................................................ 3
10.7
Important Instructions .......................................................................................................... 4
2064 of 2461
MMRDA
SUB-SECTION 6C.10: RECHLORINATION

10.1
Introduction
Chlorine will be used as disinfection of Water Treatment Plant at two
stages i.e. pre-chlorination and post-chlorination. However, the treated
water transmission main is approx. 90 km and at two locations the
water will be withdrawn, further re-chlorination is required at MBR
levels. During the course of long transmission of water chlorine is
normally consumed and it is necessary to add booster dose at the end
point, so as to give minimum 0.2 PPM at longest consumer end. In
addition to this it also help keeping safe potable water even if minor
contamination takes place enroute to the consumers.
10.2
Rechlorination
For large plant such as 403 MLd, Surya Project, break point
chlorination will be carried out a treatment plant. Thereafter whatever
chlorine added will remain as free residual. It is essential to bring this
state as it is more effective within short period of span. However,
during transportation of water the free chlorine gets consumed.
In view of this it is necessary to dose minimum 1 PPM dose at MBR
level from where water is supplied to various service reservoir.
Taking into account the disbursement of water at MBR level, MBRVVCMC will get 185 MLd and MBR-MBMC will get 218 MLd.
Therefore, chlorine dose required at MBR-VVCMC is 185 kg/day and at
MBR-MBMC it is 218 kg/day i.e. 7.7 kg/hr at MBR-VVCMC and 9.09
kg/hr at MBR-MBMC.
SECTION 6C.10: RECHLORINATION
PAGE 1 of 4
2065 of 2461
MMRDA
The chlorination tonner gives 7 kg/hr at 20C gaseous withdrawal

continuously. Therefore, it is recommended to connect 1 no. of tonner
at Kashidkopar installation and 2 Nos. of tonners at Chene installation.
10.3
Equipment and Plant

Both the installation will have sufficient space to install 2 Nos. of wall
mounting vacuum chlorinators (1W + 1S), 2 Nos. of booster water
pumps and 5 Nos. of tonners. It is essential to provide scrubbing
system with half hood to each connected tonner in the system. One
monorail crane manually operated shall be provided at each
installation. The capacity of the crane shall be 2.5 tons.
In scrubbing system NaOH solution with caustic pumps (1W + 1S), 1
No. of blower shall be used in order to neutralize 930 kg of chlorine
leakage.
10.4
Operation of Rechlorination Plant

The contractor shall find out the residual chlorine in received water at
MBR and accordingly chlorine shall be dose subject to maximum 1
PPM.
For changing over tonners automatic switch over panels shall be
provided for chlorinators. The chlorinators rating will be 0 to 10 kg/hr for
vacuum operated water solution type. Though the capacities of the
chlorinators are same at both the sites, at Chene two tonners shall be
connected in parallel for withdrawal beyond 7 kg/hr per tonner.
The total storage of chlorine tonners shall be not be beyond 5 Nos.
The plant shall be operated 24x7 pattern.
PAGE 2 of 4
2066 of 2461
10.5
MMRDA
Safety
The safety requirement according to all statutory Rules & Regulations
for hazardous chlorine shall be observed.
Following safety measures but not limited to be provided at each site.
i.
ii.
10.6
Safety emergency kit
1 No.
Breathing apparatus, self-
1 No.
contained
iii.
Emergency showers
1 No.
iv.
Eye fountain
1 No.
v.
Weather cock
1 No.
vi.
First Aid Box
1 No.
vii.
Safety signs
viii.
Scrubbing system NaOH Type
1 No.
ix.
Chlorine leak detector sensor
Online
x.
Chlorine residual testing kit
4 Nos.
xi.
Safety shoes as per requirement
xii.
Ammonia torch
1 No.
Control Philosophy
Whenever leakage of chlorine takes place the ventilation system
(normal) will stop with giving alarm to the staff present on duty.
Immediately neutralization i.e. scrubber will start. The blower will take
the chlorine mixed air and circulate into the NaOH solution content
tank. At the same time caustic soda circulating pump will circulate the
NaOH solution into the tank. The tank shall be FRP with inner lining of
poly propylene.
The system of scrubbing is only temporary measures of neutralization
of leaking chlorine.
During the process of neutralization it shall be
essential to take action to control the leaking container-tonner as early

as possible.
This action is essential because during the course of
PAGE 3 of 4
2067 of 2461
MMRDA
neutralization the temperature of caustic soda increases and beyond

certain temperature it may not neutralize the chlorine.
10.7
Important Instructions
All the statutory approval required for re-chlorination shall be obtained
by the contractor.
PAGE 4 of 4
2068 of 2461
SUB-SECTION 6C.11
ELECTRICAL WORKS
2069 of 2461
MMRDA
Table of Contents
SUB-SECTION 6C.11: ELECTRICAL WORKS ......................................................................... 1
11.1
Scope of Work ...................................................................................................... 1
11.2
MSETCLs requirement for Switching Station at 132 kV substations
at Kawdas &
Suryanagar up to point of Supply are as under........................................... 1
11.3
General Electrical Requirements ......................................................................... 4
11.3.1
Design Consideration .............................................................................................. 4
11.3.2
Environmental Conditions ....................................................................................... 5
11.3.3
Estimated Power Requirements .............................................................................. 5
11.3.4
Electrical Distribution System .................................................................................. 5
11.3.5
MSETCL Electricity Supply Switchgear ................................................................... 6
11.3.6
MSETCL Supply System Data ................................................................................ 6
11.3.7
Liaison with MSETCL .............................................................................................. 7
11.3.8
Liaison with Electrical Inspectorate ......................................................................... 8
11.3.9
Utilization Voltages .................................................................................................. 8
11.3.10 132 / 6.6 kV Substations ......................................................................................... 8
11.3.11 415 V & 6.6kV System Neutral Earthing .................................................................. 9
11.3.12 6.6 kV/ 415 V System Voltage Drop ........................................................................ 9
11.3.13 Protection Co-ordination........................................................................................ 10
11.3.14 Electrical Safety .................................................................................................... 10
11.4
132 kV Outdoor Substation ................................................................................ 11
11.5
High Voltage Switchboard and Motor Control Centre ..................................... 12
11.6
6.6 kV Induction Motors ..................................................................................... 20
11.7
Transformer ........................................................................................................ 22
11.7.1
Main Transformer .................................................................................................. 22
11.7.2
Transformer Compounds ...................................................................................... 24
11.8
415 V Switchboard and Motor Control Centre .................................................. 25
11.9
Electrical Ancillary Equipment .......................................................................... 31
11.9.1
Power Factor Correction ....................................................................................... 31
11.9.2
Uninterruptible Power Supplies ............................................................................. 32
11.9.3
Emergency Stop Push-Buttons ............................................................................. 32
11.9.4
Local Control Units (LCU) ..................................................................................... 32
11.10
Cabling ................................................................................................................ 33
11.11
Earthing ............................................................................................................... 35
11.12
Lightning Protection........................................................................................... 41
11.13
Diesel Generator Sets Diesel Engine ............................................................. 42
11.13.1 General Requirements .......................................................................................... 42
11.14
Diesel Generator Sets Generator....................................................................43
11.14.1 General Requirements .......................................................................................... 43
11.15
Water Treatment Works with CWPH Suryanagar ............................................. 44
11.15.1 Scope of Works .................................................................................................... 44
11.15.2 Incoming Power Supply......................................................................................... 44
11.15.3 132 kV Metering Panel .......................................................................................... 45
11.15.4 132 kV Outdoor Sub-station .................................................................................. 45
11.15.5 Power Transformers.............................................................................................. 46
11.15.6 High Voltage Switchboard and Motor Control Centre ............................................46
11.15.7 6.6 kV Induction Motors at CWPS ......................................................................... 54
Power Factor correction at 6.6kV Motor at CWPS:............................................................... 56
11.15.8 Capacitor shall be APP or Mixed Di electric type ................................................... 56
11.15.9 110V Battery and Battery Charger ........................................................................ 56
11.15.10 Low Voltage Switchboard / Motor Control Centre .................................................. 57
2070 of 2461
11.15.11
11.15.12
11.16
11.17
11.18
11.18.1
11.19
11.19.1
11.20
11.20.1
11.21
11.21.1
11.21.2
11.21.3
11.21.4
11.22
11.23
11.24
11.25
11.26
11.27
11.28
MMRDA
Emergency Stop Push-Buttons ............................................................................. 64

Local Control Units (LCU) ..................................................................................... 64
Cabling ................................................................................................................ 64
Earthing ............................................................................................................... 67
Diesel Generator Sets Diesel Engine ............................................................. 73
General Requirements .......................................................................................... 73
Diesel Generator Sets Generator....................................................................75
General Requirements .......................................................................................... 75
Building Services at Kawdas & Suryanagar ..................................................... 76
Scope.................................................................................................................... 76
Lighting ............................................................................................................... 76
Internal Main Lighting ............................................................................................ 76
Internal Emergency Lighting.................................................................................. 77
External Walkway Areas ....................................................................................... 78
Floodlighting .......................................................................................................... 78
Small Power ........................................................................................................ 79
Ventilation ........................................................................................................... 79
Ceiling Fans ........................................................................................................ 80
Air Conditioning.................................................................................................. 80
Telephone Facilities ........................................................................................... 80
Distribution Boards ............................................................................................ 81
Wiring .................................................................................................................. 81
2071 of 2461
MMRDA
SUB-SECTION 6C.11: ELECTRICAL WORKS
11.1
Scope of Work
This section covers the particular requirements for the provision of all
necessary electrical site works for the 132 kV outdoor substations Raw
Water Pumping Station at Kawadas and Water Treatment Plant with
Clear Water Pumping Station at Suryanagar including MSETCL
switching Station at Both Substation.
11.2
MSETCLs
requirement
for
substations at Kawdas &
Switching
Station
at
132
kV
Suryanagar up to point of Supply are
as under
Establishment of 132 kV substations as per MSETCL requirements,

supervision and Technical specification up to point of supply comprising
Incoming bay steel structure for two lines
Lightning arresters
Coupling capacitor
Wave traps
Isolator with earth blade
Current transformer for metering and protection
SF6 Circuit breakers
Isolators
SECTION 6C.11: ELECTRICAL WORKS
PAGE 1 of 82
2072 of 2461
MMRDA
Single bus bar system with 3 isolator and Bus P.T complete with
bay steel structures, insulator ACSR Conductor etc.,
Earthing and lightning protection
Control and relay panels. Control and power cable etc.
All civil works including metering room
Metering C.T., P.T (main & check), insulator, support structure,

conductors etc.
ABT metering with connectivity and allied equipments
PLCC terminal (Twin channel carried set) at Suryanagar

substation and Kawdas substation
SCADA System for remote monitoring of switchyard to be installed at

existing 132 kV Dahanu substation
All equipments materials etc., required for above works shall be as per
supply companies specifications and requirements. Supervision,
companies representatives. Contractor shall be responsible for
O & M of above works shall be done by MSETCL.

supervision).
PAGE 2 of 82
2073 of 2461
MMRDA
The Contract shall include the design, manufacture, testing at

manufacturers' works, delivery to Site, off-loading, storage, erection,
testing, commissioning and setting to work the complete electrical site
works for all sites including but not limited to:
(a)
132 kV outdoor substation Equipments after point of supply with

transformers;
(b)
High voltage switchboards, motor control centres and motor

starters;
(c)
HT motors
(d)
Low voltage switchboards and motor control centres, motor

starters;
(e)
Power factor correction equipments
(f)
Emergency
stop
push-buttons/local
start/stop
push-button
stations;
(g)
Battery units for switchgear operation;
(h)
Battery and Battery charger Panel;
(i)
Power,
control,
instrumentation
and
telephone
cabling
installations;
(j)
Interface with electrical & ICA plant to be provided;
(k)
Earthing and lightning protection installations;
(l)
All Cabling, termination and cable containment works;
PAGE 3 of 82
2074 of 2461
(m)
MMRDA
Ventilation systems, firefighting and alarm system, DG sets etc.
The electrical Plant, cabling and earthing installations shall comply with
Standard Specifications and the following clauses herein. Where there
are discrepancies among the Standard Specification, the Particular
Specification and the Drawings, the latter shall take precedence.
11.3
General Electrical Requirements
11.3.1
Design Consideration
The Contractor shall design the electrical installation taking into

consideration the following:
(a)
Location and power demand of all loads;
(b)
Security of supply;
(c)
Prospective short-circuit current;
(d)
Environment in which electrical plant is located;
(e)
Ambient temperature, humidity and its effect on the rating of

switchgear, transformers, cables and generating plant;
(f)
Method of cable installation;
(g)
Cable transient and steady state volt-drop on motor starting;
(h)
Transient volt-dip on motor starting at point of supply;
(i)
Electrical protection discrimination;
PAGE 4 of 82
2075 of 2461
11.3.2
MMRDA
(j)
Ground earth resistivity;
(k)
Overall system power factor shall be minimum 0.99.
Environmental Conditions
All Plant shall be designed and manufactured for continuous operation

under the specified climatic and environmental conditions as detailed
elsewhere within the Specification.
11.3.3
Estimated Power Requirements
The Contractor shall submit estimated installed and running loads for
each load centres and calculate the estimated available load required to
corroborate transformers, generators, switchgears and power factor
correction capacitor ratings given herein, for the approval of the
Employers representative. In the sites of this Contract where there will
be equipments and installation to be provided by other contractors, the
Contractor shall take into account the electrical power requirements of
the loads of these contractors to determine the power rating of the
electrical installation.
Load estimates for sizing all equipment/cables shall consider present

load, future expansion for 75 MLD-02 Nos pumps and 20% design
margin on the total value.
11.3.4
Electrical Distribution System
The electrical distribution systems design at each site of the Raw Water
pumping station and Water Treatment Plant and Clear Water Pump
House shall be as follow including 132 kV outdoor substations:
a)
Mains derived supply of 132 kV Overhead line to Raw Water

Pumping Station and Clear Water pumping station with WTP at
PAGE 5 of 82
2076 of 2461
MMRDA
Kawdas and Suryanagar respectively;
b)
132 kV receiving substations to step down supply voltages to

6.6 kV and 433 Volts
c)
Operational flexibility;
d)
Ease of maintenance with minimum operational disruption to the

operation of the works.
The final configuration of the switchboard and the sub-distribution

system shall be determined by the Contractor.
The design shall be
submitted to the Employers representative for approval.
11.3.5
MSETCL Electricity Supply Switchgear
The high Voltage electricity supplies to the Clear Water pumping

stations with WTP and RWPH works will be provided by extension of
existing 220 kV Substation at Dahanu by 132 kV overhead lines by
MSETCL.
The supply Cos contract interface shall be the 132 kV tower near site
boundary / metering boxes or termination chambers to cater the
additional power requirement of proposed RWPH and WTP with CWPH.
The cost for the provision of the MSETCL power supplies to meet
demand at each site including any registration fees/charges shall be
paid by the Employer.
All liaison works for the procurement of the
MSETCL supplies shall be included within the Contract Price.
11.3.6
MSETCL Supply System Data
(a)
Voltage
132 kV
PAGE 6 of 82
2077 of 2461
11.3.7
MMRDA
(b)
Frequency
50Hz
(c)
Voltage tolerance
10%
(d)
Frequency tolerance
2.5%
(e)
Neutral earthing
direct
(f)
Three phase symmetrical short-circuit current: -
- Maximum
(To be determined by the MSETCL) kA
- Minimum
(To be determined by the MSETCL) kA
Liaison with MSETCL
The Contractor shall be responsible for:-
(a)
Confirming maximum short-circuit and maximum earth fault

current data;
(b)
Confirming minimum short-circuit current data (for use in the

calculation of voltage dip);
(c)
Finalising supply capacity;
(d)
Establishing any special MSETCL requirements;
(e)
Finalizing protection relay characteristics, settings and coordination. Make submission of protection setting grading of the
relays at the motor control centre under the Contract with the
relay at MSETCL switchgear and obtain their approval;
PAGE 7 of 82
2078 of 2461
(f)
MMRDA
Agreeing procedures and responsibility for connection of 132 kV

feeder and cables to the metering panel and pre-commissioning
testing.
(g)
Responsibility of co-ordination with MSETCL for overhead line

work and Substation works;
(h)
Calculation of the voltage dip during starting of motors at the

coupling point with MSETCL and obtain their approval
Liaison with the MSETCL shall be done by contractor through MMRDA.
11.3.8
Liaison with Electrical Inspectorate
The Contractor shall be responsible for obtaining all design approvals

necessary from the local Electrical Inspectorates Chief Officer as well as
obtaining a sanction for energising the new supplies. All liaisons with
the Electrical Inspectorate shall be done by contractor through MMRDA
11.3.9
11.3.10
Utilization Voltages
(a)
High voltage
132 kV/6.6 kV
(b)
Low voltage
415 V
(c)
Control
a.c. - 230V
(d)
d.c - 24V for SCADA and instrumentation
(e)
d.c.- 110V/220V for Battery charging & other circuits
132 / 6.6 kV Substations
Two power transformers & two auxiliary Transformers each capable

PAGE 8 of 82
2079 of 2461
MMRDA
of meeting the full maximum demand of the project shall be provided

at CWPS with WTP at Suryanagar and RWPS at Kawdas
11.3.11
415 V & 6.6kV System Neutral Earthing
The 6.6 kV / 415 V transformer secondary winding neutrals shall

be solidly earthed
The 132 / 6.6 kV Main transformer secondary neutral shall be

through NGR (Neutral Grounding Resistor)
11.3.12
6.6 kV/ 415 V System Voltage Drop
(a)
Steady State
Under normal service conditions the volt-drop at the terminals of

the fixed current-using equipment shall not be greater than 2.5%
of the nominal voltage of the supply except where a lower value
is necessary for the:
satisfactory operation of the equipment;
compliance with the volt-drop criteria for motors during the

starting period;
a)
Transient
During motor starting periods the following criteria shall apply:-
Under minimum supply voltage conditions specified earlier,

the voltage at the motor terminals shall not be lower than
85% of the motor rated voltage;
the voltage dip at the point of supply shall not be greater than
PAGE 9 of 82
2080 of 2461
MMRDA
limitation percentage of the rated voltage allowable by power

supply Co.;
11.3.13
Protection Co-ordination
The high and low voltage protection devices provided as part of this
Contract shall be capable of co-ordination so that on the occurrence of a
fault only the affected section is disconnected from the system.
The Contractor shall carry out a protection co-ordination design study for
the different types of faults occurring at different points in the system
under maximum and minimum fault conditions.
The proposed relay
characteristics shall be submitted to the Employers representative and

MSETCL for approval.
11.3.14
Electrical Safety
The Contractor shall provide adequate safety labels for the safe
operation and maintenance of all electrical equipment.
An A1 laminated single line diagram shall be provided on each switch

room wall.
Each electrical switchboard shall be provided with all necessary safety

equipment including operating gloves, full length rubber safety mat, a
minimum of 2 No CO2 portable fire extinguishers, fire bucket and any
other equipment deemed necessary by the Contractor.
HV and EHV outdoor substation shall have safety precautions,

clearances between live parts and ground, firefighting protection, safety
factors, etc. conforming to Indian Electricity Rules.
An emergency first aid kit and safety procedure shall be provided in

PAGE 10 of 82
2081 of 2461
MMRDA
each switch room.
11.4
132 kV Outdoor Substation
The contractor shall design the 132 kV outdoor substations at

a) Intake raw water pumping station at Kawadas and
b) Water Treatment Plant with clear water pumping station at

Surya Nagar to meet the requirements of the proposed plants.
Sizing of power transformers capacity Two power transformers

each capable of meeting the full maximum demand of the plant shall
be provided
The outdoor switchyard shall have H layout with 5 Nos., 132 kVSF6 circuit breakers arranged in a H formation of bus with 2 circuit
breakers for line control, 2 circuit breakers for the transformers and
a fifth circuit breaker for bus coupler as per single line diagram
Two 132 kV overhead lines shall be provided by MSETCL forming

ring main between 132 kV substation at Kawdas and 132 kV
substation at Surya Nagar. Interlocks to avoid parallel operation of
132 kV lines shall be provided
Two auxiliary transformers, each capable of meeting the full

maximum demand of LV auxiliary load shall be provided
The feasibility of starting the largest HV motor with only one power
transformer in service with all other loads already in operation shall
be established by calculations
All substation equipments after point of supply i.e. LAs, Isolators,

CBs, CTs, PTs etc. shall be designed to meet the normal and short
PAGE 11 of 82
2082 of 2461
MMRDA
circuit conditions
Separate Metering before transformer shall be provided with same

class of accuracy as ABT metering at relay and metering panel
132kV SF6 CB both transformer feeder
11.5
Single line diagram and substation layout are enclosed for reference
High Voltage Switchboard and Motor Control Centre
The Contractor shall design the high voltage power distribution to meet
the requirements of the proposed plant.
The high voltage switchboard/motor control centres shall be of the floor

mounting metal-clad cubicle type equipped with VCBs, vacuum
contactors and motor starters as appropriate. All compartments shall be
provided with and designed for withdrawable type switchgear.
The
switchboard shall be provided with the protection and metering as

shown on the single line diagram.
Cable entry shall be located at the bottom with suitable gland plates.
Cable openings in the base of switchboards and motor control centres
shall be fitted with plates to prevent the entry of vermin.
Switchboards and motor control centres shall be extensible to cater for

the future designed development. The Contractor shall take this
requirement into account when designing switch rooms and control
rooms.
Rubber insulation floor mat of 9mm thickness shall be provided at the

front of each switchboard and motor control centre.
The mat shall
extend over the full length of switchboards and motor control centre plus
800mm minimum at each end.
PAGE 12 of 82
2083 of 2461
MMRDA
Test plugs and tools shall be provided to facilitate switchboard testing.
(a)
Technical requirements
Rated voltage: 6.6/7.2kV
Rated short circuit: Shall be coordinated with supply fault

level breaking current subject to a minimum 25 kA for 3 sec.
Rated short-circuit - current withstand time: Not less than 1

second.
Incoming circuit breakers and bus-couplers shall be

motorized to allow automatic operation of the circuit
breakers on loss of power on any incomer;
Switch-disconnector,
earth
switch
and
circuit-breaker
operating mechanisms shall be of the independent manual

type and shall have positively driven position indicators;
Operating mechanisms shall be pad lockable in all

positions;
Control functions shall be centralized on the module front;
Busbar shall be insulated;
(b)
Incomer units
All incomer units shall be 3 poles.
Circuit-breaker type incomer units shall be equipped with the

following minimum facilities:-
PAGE 13 of 82
2084 of 2461
MMRDA
Voltage transformer and voltmeter with phase to phase

selector switch;
Indicator lights shall be provided to indicate voltage

presence;
Power meter/load manager shall be provided to monitor kVA,

kW, kWh, power factor, voltage and current with provisions for
RS485 communication port. The outputs shall be wired to the
ICA system;
Overcurrent and earth fault protection relays. The relay

characteristics shall be selected to co-ordinate with upstream
and downstream protection devices;
Auxiliary relay with hand reset operation indicators for

transformer winding temperature high alarm, transformer oil
temperature high alarm and circuit-breaker trip initiation (for
incomers derived from transformers only);
Phase failure and under voltage relay/release for circuitbreaker trip
initiation,
alarm
annunciation and remote
indication. The relay shall be connected on the busbar side of

the circuit-breaker;
High voltage inter-trip receive relay (for incomers derived from

transformers only);
Combined Restricted Earth Fault relay and Differential

Protection;
Current transformers of appropriate accuracy class and limit

factor and output for instrumentation and protection;
PAGE 14 of 82
2085 of 2461
MMRDA
Status Indicator lights for:
Circuit-breaker open
Circuit-breaker closed
Circuit-breaker trip supply healthy
Push-buttons for:
(c)
Circuit-breaker close
Circuit-breaker trip supply test
Lamp test
Control and operation
A local control panel shall be provided adjacent to each pump set

for accommodating pump set instrument transmitters and pump
status indicators for effective monitoring of the pump set.
(d)
Outgoing units for Motor Feeders 6.6kV

following minimum facilities:

selector switch;

presence;
Power meter/load manager shall be provided to monitor

kVA, kW, kWh, power factor, voltage and current with
provisions for RS485 communication port. The outputs
shall be wired to the ICA system;
PAGE 15 of 82
2086 of 2461
MMRDA

characteristics shall be selected to co-ordinate with
upstream
and
downstream
protection
devices
as
mentioned in SLD;
Auxiliary relay with hand reset operation indicators for Motor

feeders with following protections:
\Composite Motor Protection Relay consisting of following

minimum features
Earth Fault
Instantaneous over current protection
Thermal overload with memory feature
Locked rotor
Phase currents out of Balanced
Motor Winding & bearing temperature alarm & trip relays
Negative Sequence
Overload Alarm.
Instantaneous Short circuit protection


PAGE 16 of 82
2087 of 2461
MMRDA
Push-buttons for:
(e)
Lamp test
Interlocking
The switchboards/motor control centers with incomers derived

from two separate sources shall have circuit breakers for the two
incomers and bus-coupler. The switchboard shall be provided
with an electrical and mechanical interlocking scheme to allow
only two out of three circuit breakers to be closed at any one time.
The normal operation of the switchboard will have the two
incomers closed and the bus-coupler open, with the load equally
distributed between the two incomers. On power failure of one
incomer, the bus-coupler will be closed automatically and the
complete plant operating from one supply.
Interlock shall be provided to prevent access to cable termination

enclosure unless the associated earth switch is closed.
Alternative interlocking arrangements, which are standard to a
particular switchgear manufacturer, shall be submitted to the
Employers representative for approval.
(f)
Feeder units
Feeder units shall be provided as required on each switchboard

PAGE 17 of 82
2088 of 2461
MMRDA
and motor control centre.
(g)
Lamp test
Each switchboard and motor control centre compartment shall be

provided with a lamp test facility when fitted with indicating lamps.
(h)
Anti-condensation heaters
Anti-condensation heaters shall be provided for each panel.
(i)
Auxiliary contacts
Voltage-free changeover type contacts shall be provided for

remote status and alarm indications as follows:-
Each incomer (mains/generator)

Circuit-breaker/switch open;
Circuit-breaker/switch closed;
Circuit-breaker tripped on fault;
Transformer winding temperature high;
Transformer oil temperature high;

Supply healthy;
Each bus-coupler
Each motor starter
Motor available
Motor running
Motor fault (common)
PAGE 18 of 82
2089 of 2461
MMRDA
The contacts shall be wired to a common marshalling terminal in

the associated LCP.
(j)
Switch room design considerations
Switch room floor flatness and concrete insert shall be provided

to the requirements of switchboard manufacturer. Space shall be
provided within the switch room to permit two circuit-breaker
panels to be added to one end of the switchboard. Front
clearance shall be not less than 2500mm.
For switchboards and motor control centers designed for rear

access, a clear space of not less than 1500mm shall be provided
at the rear of the panel.
Where floor trenches for cabling is provided it shall extend over

the full depth of switchboards and motor control centers plus
800mm minimum at each end. Trench depth shall be not less
than 1000mm. A galvanized steel supporting framework shall be
provided for switchboards and motor control centers.
Galvanized steel or aluminum chequer plate cable trench covers

shall be provided.
Doorways shall be dimensioned to permit the entry of the largest

section of switchboards and motor control centers in its upright
position.
An identification label shall be fitted to the outside of the building

adjacent to the access door. The label shall identify voltage and
substation location. The label material shall be plastic laminate or
other material approved by the Employers representative and the
size of characters and numerals shall be not less than 50mm.
The label description shall be subject to the approval of the
PAGE 19 of 82
2090 of 2461
MMRDA
Employers representative. The label shall be fixed to the building

using non-ferrous screws.
Mechanical ventilation shall be provided for the switch room.

Ventilation fan sizing calculation taking into account of equipment
heat
dissipation
rate
shall
be
provided
for
Employers
representative approval. The minimum air change rate for switch

room shall be 10 air change per hour.
11.6
6.6 kV Induction Motors
1)
Site
and
Operating
Conditions
2)
a)
Altitude
- Not exceeding 1000 meters
b)
Temperature
- Max. ambient temperature 45C
Reference standard
- IS325,
IS4029,
IS4722:1992,
IS12824:1989, IS12802:1989
3)
Degree
of
protection - IP55
provided by enclosure
4)
Type of duty
- S1
5)
Method of cooling
- IC411 / IC611
6)
Type of construction and - TEFC/TETV/CACA, Mounting as

mounting
per pump requirement
7)
Frequency in Hz
- 50 Hz
8)
Number of phases
- 3-Phase
PAGE 20 of 82
2091 of 2461
MMRDA
9)
Mechanical output in kW
- As per pump requirement
10)
Rated voltage
- 6.6/7.2 kV
11)
Class of insulation
- Class
with
Class-B
temperature limits
12)
Speed in R.P.M
13)
Direction of rotation, viewing - As per pump requirement

from the driving end
14)
Particulars of tests
- As per Standards specified
15)
Rotor
- Squirrel cage
16)
Method of starting
- Suitable for Direct On Line

starting
17)
Method of starting
- Direct online
18)
Nature of load
- Pump for water
19)
Method of drive
- Direct coupled
20)
Breakaway torque and the
- Adequate
21)
for
smooth
corresponding breakaway
acceleration during starting as
starting current
per specifications
Cable termination boxes
- Phase segregated
Power Factor correction at 6.6kV
The capacitor shall be connected to the motor terminals. The size of

6.6kVcapacitor shall be limited in this instance to a kVAr value
PAGE 21 of 82
2092 of 2461
MMRDA
numerically not greater than the 90% of the motor magnetizing kVAr.
This is to ensure that the motor does not have a tendency to run on
(self-excited) when the motor is switched off. Capacitor of fixed type
connected across 6.6kV motor shall improve power factor from 0.78 to
0.96
Capacitor shall be APP or Mixed Di electric type
APFC
Capacitor switching and automatic power factor correction panel shall

be designed in such a way that power factor of 0.99 can be obtained.
Timings to cut in capacitor shall be provided in such a manner to
facilitate capacitor discharging before next switching and shall also
avoid hunting due to temporary fluctuations of load. The timer shall be
11.7
Transformer
11.7.1
Main Transformer
Main transformers shall be oil filled and naturally air cooled outdoor type
with winding temperature indicator incorporating alarm and trip contacts
for remote indications, pressure relief device with trip contacts and
primary/secondary cable boxes.
The transformers shall be sized for total duty loads of the Works plus
the following additional capacities:
future expansion works based on 2 Nos., 75 MLD additional pumps

working
20% working margin
PAGE 22 of 82
2093 of 2461
MMRDA
Check the feasibility of starting the largest HV motor with only one
power transformer in service with all other loads already in
operation.
Establish by calculations that the voltage at motor
terminals at the instant of start should not drop below 85% of the
rated voltage
Main transformers shall be provided with a +5% to -15% On-load tap

changing (OLTC) facility. All other auxiliary transformers shall be
provided with off-load tap changing facilities.
The transformers shall be fitted with a removable link to connect the low
voltage winding neutral point to earth. The link shall be accommodated
in the low voltage cable box and shall be fitted with a label inscribed LV
WINDING NEUTRAL EARTH LINK.
Outdoor type copper wound transformer continuously rated for 3 Ph, 50

Hz, at full load and temp. rise not exceeding 45 C by thermometer in oil
and 50C by the resistance in winding after continuous run at full load
rating, the transformer should have oil immersed winding having vector
group DY 11, HT side connected in Delta and LT side connected in Star
with neutral brought out connected to provided separate earthing. The
transformer shall have power terminal arrangement, bushings on HT
side and cable end box on LT side. 2 Nos. channels with stoppers shall
be provided and fixed on the provided plinth for mounting the
transformer. The transformer should have following standard fittings.
Transformer shall be of latest manufacturing standards as per amended
IS specifications and the Load & No Load losses shall be limited to the
values given below or as per IS.
1)
Oil conservator with filling hole with cap and plain oil level gauge
2)
Silica gel dehydrating breather charged with Silica Gel
3)
Oil drain valve
PAGE 23 of 82
2094 of 2461
MMRDA
4)
Oil filter valve
5)
Lifting eyes / hooks
6)
Two earthing terminals
7)
Diagram and rating plate
8)
Air Vent
9)
Explosion Vent
10) 100 mm dia. thermometer with thermometer pocket
11) Four bi directional plain roller
The tap position shall be clearly marked.
11.7.2
Transformer Compounds
The transformers shall be housed in a compound surrounded by 2.4m

high chain link fencing or similar approved. Each transformer shall be
provided with a double leaf gate not less than 2.4m wide.
The
transformers shall be shaded from direct sunlight.
A minimum clearance of 1500mm shall be provided to all sides of the

transformer.
Transformers shall stand on reinforced concrete plinths surrounded by

an oil retaining sump. The sump shall be filled with suitable single size
(nominally 40mm) rounded stones. The capacity of the sump when filled
with stones shall be suitable to hold the total oil content of the
transformer plus 15%. The sumps shall be connected to a separate
PAGE 24 of 82
2095 of 2461
MMRDA
chamber to permit the removal of standing water and oil.
Trenches and ducts entering the oil-retention area shall be sealed after
the cable installation.
The compound shall be provided with a name plate identifying the

transformer number and rating. The name plate shall be plastic laminate
or other material approved by the Employers representative and the
size of characters and numerals shall be not less than 50mm. The name
plate shall be fixed to the access gate using stainless steel fixings.
Each transformer compound shall be provided with adequate portable

firefighting equipment accordingly to Statutory Requirements.
11.8
415 V Switchboard and Motor Control Centre
The 415 V switchboard shall be of the floor mounting metal-clad cubicle

type equipped with MCCBs and fuse-switches as appropriate. Cable
entry may be top or bottom with panel access to the front or rear to suit
the requirements of the site layout drawings.

shall be fitted with plates and all cables shall be terminated at cable
glands, to prevent the entry of vermin.
Provision shall be made on switchboards for supplying building and

external services.
Supplies to process plant and instrumentation shall be derived from a

separate process/ instrumentation services distribution board and not
derived from building services distribution boards.
Switchboards shall be extensible to cater for the future designed

development. The Contractor shall take this requirement into account
PAGE 25 of 82
2096 of 2461
MMRDA
when designing switch and control rooms.
(a)
Rated voltage: 415 V
Three phase symmetrical short-circuit current: The maximum

let-through current of the supply transformer or feeder
protective device but not less than 36kA
Rated short-circuit current withstand time: Not less than 1

second.
(b)
Incomer units
Incoming
supplies
and
associated
bus-couplers
rated at
250Amps and above derived from transformer secondary circuit

shall be controlled by withdrawable type air-break circuit
breakers. All other incoming supplies of similar case shall be
controlled by fixed type MCCBs.

Voltmeter with phase to phase and phase to neutral selector

switch

provisions for RS485 communication ports.
shall
be
wired
to
the
ICA
The outputs
compartment
of
the
switchboard/motor control centre

PAGE 26 of 82
2097 of 2461
MMRDA

and downstream protection devices

transformer winding temperature high alarm and circuitbreaker trip initiation (for incomers derived from transformers
only)
Phase failure and under voltage relay/release for circuitbreaker trip initiation, alarm annunciation and remote
indication. The relay shall be connected on the busbar side
of the circuit-breaker.
High voltage inter-trip receive relay (for incomers derived

from transformers only)

factor and output for instrumentation and protection
Push-buttons for:
Lamp test
PAGE 27 of 82
2098 of 2461
MMRDA
Switch-disconnector type incomer units shall be equipped with

the following minimum facilities:-
Voltmeter with phase to phase and phase to neutral selector

switch
Ammeter with phase selector switch
Phase failure and under voltage relay for alarm annunciation

and remote indication. The relay shall be connected on the
busbar side of the switch-disconnector

factor and output for instrumentation.
(c)
Interlocking
The main switchboards/Power control centres with incomers shall

have ACB/MCCBs for the two incomers and bus-coupler. The
switchboard shall be provided with an electrical interlocking and
mechanical linkage (not using Castell key) interlocking scheme to
allow only two out of three circuit breakers to be closed at any
one time. The normal operation of the switchboard will have the
two incomers closed and the bus-coupler open, with the load
equally distributed between the two incomers. On power failure
of one incomer, the bus-coupler will be closed automatically and
the complete plant operating from one supply.
Main switchboards/motor control centers with incomers derived

from a generator and a MSETCL supply shall be provided with
two incomers electrically and mechanical linkage interlocked to
prevent the paralleling of the incoming supplies or an automatic
(with manual over-ride) changeover switch.
PAGE 28 of 82
2099 of 2461
(d)
MMRDA
Feeder units
Feeder units shall be provided as required. As a minimum, a 63

Amp TPN MCCB shall be provided on each switchboard and
motor control centre.
(e)
Lamp test

(f)
Anti-condensation heaters shall be provided.
(g)
Auxiliary contacts

Each incomer
Transformer winding temperature high (where fitted);
Supply healthy;
Each bus-coupler
PAGE 29 of 82
2100 of 2461
MMRDA

the associated switchboard.
(h)
Socket outlet
A 230V 5A single phase socket outlet shall be provided within the

ICA compartment of each switchboard and motor control centre.
(i)
Location
The switchboards and motor control centers shall be located at

suitable location.
(j)
A minimum clearance of 1000mm shall be provided at each end

of switchboards. Front clearance shall be not less than 1500mm.

at the rear of the panel. For front access switchboards a nominal
150mm clear space shall be provided at the rear of the panel.
Where floor trenches for cabling is provided it shall extend under

the full depth of switchboards and motor control centers and shall
be not less than 1000mm deep. For switchboards and motor
control centers designed for front cable access the trench shall
extend not less than 600mm from the front face. A steel
supporting framework shall be provided for switchboards and
motor control centers.
Hot dip galvanized steel or aluminum chequer plate cable trench

covers shall be provided.
PAGE 30 of 82
2101 of 2461
MMRDA

position.
415V supply for MSETCL Control room and 132kV Relay and
Control Room Lighting, Ventilation, etc. shall be taken from
Power Distribution Board.
11.9
Electrical Ancillary Equipment
11.9.1
Power Factor Correction
The power factor at each load centre shall be corrected to no less than
0.99 lagging. The correction may be by means of capacitors connected
to individual items of plant or by automatically controlled multistage
capacitors connected to busbar sections.
For multistage power factor correction, capacitor ratings shall be

selected to ensure that motors are not subjected to leading power factor
conditions or abnormal operating conditions due to the effect of selfexcitation when switched off.
Multistage capacitors shall be controlled by contactors via an automatic

capacitor controller with target power factor setting adjustment and
manual override facilities. The contactors shall be de-rated to
compensate for zero power factor switching duty, the permitted
capacitor positive tolerance and the presence of harmonic currents.
Capacitors shall incorporate a discharge circuit and shall not contain

polychlorinated bi phenols.
Calculations corroborating capacitor kVAr ratings shall be submitted to

the Employers representative for approval.
PAGE 31 of 82
2102 of 2461
11.9.2
MMRDA
Uninterruptible Power Supplies
An uninterruptible power supply (UPS) unit or units shall be provided

where it is necessary to maintain a no-break supply to instrumentation,
control and alarm systems as detailed in the ICA section of the site
works specifications.
The UPS system with fully charged batteries shall, on loss of mains
supply, be capable of supplying the connected loads for a minimum
period of 60 minutes.
Battery capacity calculations shall be submitted to the Employers

11.9.3
Emergency Stop Push-Buttons
An emergency stop push-button shall be installed adjacent to all motors.
11.9.4
Local Control Units (LCU)
Each motor shall be capable of being manually operated from a local

operating position.
Where motor starters are provided at remote
locations, the Contractor shall provide a local control unit (LCU) in a safe
and accessible operating position adjacent to the motor.
Each LCU
shall be of robust construction suitable for the environmental conditions.

The LCU shall be provided with a start/stop or open/close pushbutton.
Local control units installed externally shall be protected from the sun
with sun covers and constructed with an IP rating of IP65.
The Contractor shall submit drawings identifying the locations of the

LCUs for the Employers representative approval.
PAGE 32 of 82
2103 of 2461
11.10
MMRDA
Cabling
(a)
General
The Contractor shall provide a complete cabling installation

comprising power, control, instrumentation, communications and
telephone cables (if applicable) and all accessories including
cable glands, terminations, cable markers, support systems, clips,
fittings and fixtures to:
Interconnect all Plant provided under the Contract;
Interconnect ICA signals to the Local Control Panels of the

contractor;
Interconnect existing plant (if applicable) with the Plant

provided under the Contract
All calculations to corroborate current carrying capacity and

compliance with the volt-drop criteria specified herein shall be
The power, control and instrumentation cabling shall interconnect

the entire Plant including but not limited to:
Valves actuators, pump sets, etc.;

Switchgear and distribution boards;
Motor control centers;
Local Control Panels;
Local control units;
Measuring instruments and sensors; and
(b)
Cable grouping
PAGE 33 of 82
2104 of 2461
MMRDA
The cables shall be grouped as follows:
(c)
HV power cables
6.6 kv grade (E) XPLE
Power cables
1.1 kv grade LV
Control cables
110 V d.c. / 660 V a.c
Cable types
High voltage power cables shall be of the XLPE/SWA/PVC type

with a conductor size appropriate to the short-circuit current and
short-time requirements. The cable shall be suitable for prolonged
operation at plus 10% rated voltage.
415V power cables and control cables shall be 600/1100V grade

PVC or XLPE/SWA/PVC unless otherwise approved to by the
(d)
Installation
External below ground
Unless otherwise approved by the Employers representative

all cables shall be installed in ducts and concrete trenches.
Duct systems shall be provided with draw chambers at the

point of entry into buildings, at changes in direction and at
suitable intervals in straight runs to permit the installation of
cables without exceeding the manufacturers' recommended
maximum tensile stress. Draw chambers shall be generously
dimensioned to enable cables to be pulled without damage or
excessive stress due to bending.
Where high voltage and low voltage cables are installed in a

PAGE 34 of 82
2105 of 2461
MMRDA
common trench, they shall be on opposite faces, and have a

distance clearance of as a minimum 300mm. Cables in
trenches shall be installed on tray and/or ladder systems.
External above ground
Cables on structural surfaces shall be installed on tray and

ladder systems or in trunking and conduit as appropriate.
Cable tray on structural surfaces shall be fitted with covers.
Internal
Cables on structural surfaces shall be installed on tray and

ladder systems or in trunking and conduit as appropriate.
Cables in trenches shall be installed on tray and/or ladder
systems.
Cable tray, ladder and trunking systems
Cable tray, ladder and trunking systems shall be heavy duty

hot dip galvanised steel with return flange at the upstand.
Cable tray on external structural surfaces shall be fitted with
covers.
Installations in the chemical and chlorine buildings shall be

heavy duty GRP systems.
Conduit systems
Conduit shall be heavy duty galvanized steel. Installations in

the chemical and chlorine buildings shall be heavy duty GRP
systems.
11.11
Earthing
PAGE 35 of 82
2106 of 2461
(a)
MMRDA
General
A complete and fully interconnected low voltage earthing

installation comprising earth electrodes, earthing terminals and all
earthing, protective and equipotential bonding conductors shall be
provided by the Contractor at each of the sites of reservoirs,
sumps, tapping points from trunk mains, Chlorination stations and
booster pumping stations.
(b)
Earth electrode system
The Contractor shall carry out a ground resistivity survey for each
site and design and install the earth electrode systems to provide
an overall resistance to earth not greater than 1 ohm.
The earth electrode system shall comprise at least two separate

groups of rods located at agreed locations to allow for testing of
one earth electrode system whilst the other is connected to the
system.
The main earth bar shall be provided with test links to enable
independent testing of each group of earth electrodes.
Design calculations for the earth electrode system shall be

(c)
Earthing terminals
Earthing terminals shall be located adjacent to the associated

switchboard or motor control centre. The earth terminals shall be
interconnected. The earthing terminal shall be used to connect
the following conductors to the earth electrode system:
PAGE 36 of 82
2107 of 2461
MMRDA
(a)
The circuit protective conductors;
(b)
The main bonding conductors; and
(c)
The functional earthing conductors (if required).
The size of bonding conductor connecting the main earthing

terminals at the sites of this Contract and the electricity suppliers
transformer earth or metallic sheaths of service cable, should not
2
be less than 150 mm copper equivalent. Provisions should be
made for disconnection of the bonding conductor for testing

purposes.
A warning notice bearing the words SAFETY ELECTRICAL

CONNECTIONDO NOT REMOVE and in equivalent Indian
language should be displayed in a conspicuous position at or
near the main earthing terminal.
At the booster pumping station sites, the main earth terminal with
test link shall be located inside the booster pumping station
switch room. An auxiliary earth terminal with test link shall be
provided under this Contract and is to be located at the telemetry
room inside the booster pumping station for the installation of the
Local Control Panels. At the tapping point from the trunk mains
sites, the main earth terminal with test link shall be located inside
the enclosures for the installation of the Local Control Panels. At
the union reservoir sites, the main earth terminal with test link
shall be located inside the switch room at the Chlorination Station
Building.
An auxiliary earth terminal with test link shall be

room inside the Chlorination Station Building for the installation of
the Local Control Panels.
(d)
Bonding to structural steelwork
PAGE 37 of 82
2108 of 2461
MMRDA
Structural steelwork including concrete reinforcement bars shall

be bonded to the earthing system. The method of connection to
reinforcement bars shall be subject to the approval of the
(e)
Equipotential bonding
All metallic pipework and other extraneous conductive parts shall

be provided with positive earthing terminals and provided with
equi-potential bonding.
In each installation, main equipotential bonding conductors

should be connected to the main earthing terminal for all
extraneous conductive parts to create an equipotential zone; such
conductive parts include:
(i) all water pipes;
(ii) all gas installation pipes;
(iii) other service pipes and ducting;
(iv) cable trays, cable ladders, conduits, trunkings etc.;
(v) exposed metallic parts of structural framework; and
(vi) the lightning protection system.
In a large installation, where there are a number of equipotential

zones, these zones should be bonded together to form one
equipotential zone.
Aluminum or copper clad aluminum conductors should not be

PAGE 38 of 82
2109 of 2461
MMRDA
used for bonding connections to water pipes likely to be subjected

to condensation in normal use.
Main equipotential bonding conductors should have crosssectional areas not less than half the cross-sectional area of the
earthing conductor of the installation, subject to a minimum of 6
2
2
mm copper equivalent, and need not exceed 25 mm copper
equivalent.
Main equipotential bonding connections to any gas or water pipes

should be made as near as practicable to the point of entry of
those services into buildings; provided that where there is an
insulating section or insert at that point, the connection should be
made to the metalwork on the consumers side of that section or
insert.
In particular, for gas services, the bonding connection should be

made on the consumers side of the meter (i.e. between the
meter outlet union and any branch pipework). This connection is
recommended to be made within 600 mm of the gas meter.
Within the zone formed by the main equipotential bonding, local

supplementary bonding connections should be made to metal
parts, to maintain the equipotential zone, where those parts are:
(i) Extraneous conductive parts,
(ii) Simultaneously accessible with exposed conductive parts or

other extraneous conductive parts, and
(iii) Not electrically connected to the main equipotential bonding

by permanent and reliable metal-to-metal joints of negligible
impedance.
PAGE 39 of 82
2110 of 2461
MMRDA
Metalwork which may be required to be bonded includes service

pipes or substantial parts which are at a distance not exceeding 2
m from exposed conductive parts. Examples are water pipes
adjacent to electric heater or window frame supporting a
ventilation fan or air-conditioner or adjacent to a socket outlet.

The minimum cross-sectional area of a supplementary bonding

conductor should comply with the following table, subject to the
conditions following:
Installation
method
PVC insulated (mm2)

Copper
Aluminu
Bare (mm2)
Copper
Aluminum
16
>6
16
16
1.0
16
m
Surface
wiring
2.5
(sheathed)
4 (nonsheathed)
In
conduits
1.0
or trunkings
(i) The bonding conductor connecting two exposed conductive

parts should have a cross-sectional area not less than that of
the smaller protective conductor connected to the exposed
conductive parts;
(ii) The bonding conductor connecting exposed conductive parts

to extraneous conductive parts should have a cross-sectional
area not less than half that of the protective conductor
connected to the exposed conductive part;
PAGE 40 of 82
2111 of 2461
(iii) The
MMRDA
bonding
conductor
connecting
two
extraneous
conductive parts, where one of the extraneous part is

connected to an exposed conductive part, should have a
cross-sectional area not less than half that of the protective
conductor connected to the exposed conductive part
(f)
Instrumentation earthing
The Contractor shall provide a separate earthing terminal for the

Local Control Panels and all the instrumentation in each telemetry
housing/room.
Each separate earthing terminal shall be
connected to the station earth system through the earth terminal

inside the same housing/room, as mentioned in Instrumentation
Section.
Insulated earth cables shall be used to connect the
instrumentation
to
these
separate
instrumentation
earth
terminals. The instrumentation signal earth cables shall have

different outside insulation colour to the power earth cables in
order to make them easily detectable. Earthing system design
shall comply with local regulations.
11.12
A lightning protection system shall be provided on all main structures,

complying to the requirements entered in BS 6651. Air terminations
and down conductors shall be copper.
The Contractor shall also provide all terminating equipment for all I/O
and communications signals transmitted between buildings on a
copper cable with lightning protection barriers. The barrier shall be
installed in a barrier panel which shall be located adjacent to the main
cable entry point into the building or in a small enclosure adjacent to
the transmitter. The barriers shall be earth bonded in accordance with
manufacturers recommendations and the standard specification.
PAGE 41 of 82
2112 of 2461
MMRDA
11.13
Diesel Generator Sets Diesel Engine
11.13.1
The engine type shall have been in commercial operation for a period
of not less than 3 years.
The engine shall be of the 4-stroke, water-cooled direct-injection

compression-ignition type with an in-line or vee-cylinder configuration.
The engine may be naturally aspirated or turbo-charged. The nominal
speed shall not exceed 1500rpm for 50Hz operation.
The engine shall be rated in accordance with ISO 3046-1:2002 and

shall be capable of continuous operation at rated output plus a 10%
overload for 1 hour in any 12 consecutive hours running.
Unless otherwise specified, fuel oil shall be Class A2 to BS 2869:1998.
All chain and gear drives shall be located in oil-tight cases and shall be
pressure-lubricated.
The engine and generator shall be mounted on a common fabricated

steel bedplate with anti-vibration mountings of the multiple neoprene
type impervious to water and oil.
The engine shall accept full-rated load within 20 seconds from initiation
of the starting sequence when starting from cold at the minimum
specified ambient air temperature. The initial step load shall be not
less than 40% of the full-load value unless otherwise specified.
The starting battery shall be of the nickel-cadmium or lead-acid

type and unless otherwise specified, installed on an engine bed
plate mounted non-corrodible tray or rack and shall have a cover of
PAGE 42 of 82
2113 of 2461
MMRDA
insulating material. The battery shall have sufficient capacity for

three consecutive start attempts each of 10 seconds duration. In
addition, the battery shall have sufficient capacity after the three
start attempts to supply the maximum demand of the control panel
for a minimum period of 24 hours
The battery charger shall be of the solid-state design and shall

incorporate float and boost charging facilities. In the float charge
mode, the charger shall automatically maintain the battery in a fullycharged condition whilst supplying standing loads. In the boost
charge mode, the charger shall be capable of fully charging the
battery from a fully-discharged condition in a period not exceeding
7 hours
11.14
Diesel Generator Sets Generator
11.14.1
The generator shall be of the salient pole brushless type complying

with BS 5000-3:2006. The generator shall be flange and foot mounted
or foot mounted with open coupling, with single or twin end-shield
bearings. A single-bearing machine shall be directly coupled to the
engine crankshaft. A two-bearing machine shall be coupled through
an intermediate flexible coupling.
The generator shall be capable of continuous operation at rated output

plus 10% overload for 1 hour in any period of 12 hours without
exceeding the temperature rise limits of the insulation system.
Generator windings shall be of the 2/3 pitch design to eliminate triple

harmonics on the voltage waveform and fully interconnected damper
windings for stable operation during paralleling.
Generator windings shall be star-connected with neutral point brought

PAGE 43 of 82
2114 of 2461
MMRDA
out to the main cable termination facilities and with provisions for
neutral point earthing as specified.
Bearings shall have a minimum life of 40 000 hours and shall have a
re-lubrication interval preferably 8 000 hours and not less than
4 000 hours. The bearing speed rating shall not exceed 80% and the
bearing outer race temperature shall not exceed 70C.The generator
enclosure shall provide a minimum protection classification of IP22 to
BS EN 60529:1992, unless otherwise specified.
DG Set shall be with an acoustic enclosure confirm to sound level of

75dB at 1mtr distance from acoustic enclosure as per specification.
11.15
Water Treatment Works with CWPH Suryanagar
11.15.1
Scope of Works
The electrical scope of works shall include but not be limited to:
132 kV HT metering panel

132 / 6.6 kV sub-station for WTP with CWPS
Power transformers
Low voltage switchboard/motor control centre
Ancillary electrical plant
11.15.2
Incoming Power Supply
Double circuit 132 kV overhead lines will be laid up to the Works site
boundary. The incoming power supply to the Works shall then be
arranged via 132 / 6.6 kV outdoor substation. The MSETCL contract
PAGE 44 of 82
2115 of 2461
MMRDA
interface shall be 132 kV line tower connection and HT metering.
Contractor shall be responsible for co-ordination of 132 kV overhead

line works and should ensure timely completion of incoming supply
infrastructure by MSETCL.
11.15.3
132 kV Metering Panel
The Contractor shall provide 132 kV metering panels as shown in SLD

and provide MSETCL metering for the incomers in accordance with
MSETCL. Metering arrangements shall be approved and agreed by
MSETCL. Panel and the meter shall be sealed by MSETCL after
completion of work. Separate Metering before transformer shall be
provided with same class of accuracy as ABT metering at relay and
metering panel 132kV SF6 CB both transformer feeder.
11.15.4
132 kV Outdoor Sub-station
The Contractor shall provide a 132 kV outdoor substation in

accordance with the single line diagram.
The substation shall be
provided with the following facilities as a minimum:
2 Nos. 132 kV SF6 CBS incomers;

1 No. 132 kV SF6 CB bus-coupler;
2 Nos. 132 kV SF6 CBS for 132 / 6.6 kV main transformers;
Control panels for 2 Nos. -132 kV Incoming line CBs, 1 No. bus
coupler CB and 2 Nos. transformer CBs shall be provided with the
protection and metering as shown in SLD.
Remote OLTC panels, 110 V DC battery with battery chargers, LT

switchboards etc. shall be provided as per requirements.
PAGE 45 of 82
2116 of 2461
MMRDA
The Contractor shall review the layout of the proposed sub-station and
detail changes required to meet the requirements of the proposed
substation.
11.15.5
Power Transformers
The Contractor shall provide the following transformers to meet the

requirements drawings:
2 Nos. 132 / 6.6 kV ONAN outdoor type transformers with OLTC

2 Nos. 6.6/0.433 kV ONAN outdoor type auxiliary transformers
Emergency DG set
The transformers shall be located near the treated water pumping
station. The Contractor shall include for all power and control cabling
necessary. The cable final routes shall be designed by the Contractor.
The final arrangement of transformer slab civil works shall meet the
requirements of the proposed equipment. On-load tap changer control
units shall be provided for transformers in accordance with
specifications.
11.15.6
High Voltage Switchboard and Motor Control Centre
The Contractor shall design the high voltage power distribution to meet
the requirements of the proposed plant.
The high voltage switchboard/motor control centres shall be of the floor

mounting metal-clad cubicle type equipped with VCBs, vacuum
contactors and motor starters as appropriate. All compartments shall be
provided with and designed for withdrawable type switchgear.
The
switchboard shall be provided with the protection and metering as

PAGE 46 of 82
2117 of 2461
MMRDA
shown on the single line diagram.
Cable entry shall be located at the bottom with suitable gland plates.
shall be fitted with plates to prevent the entry of vermin.
Switchboards and motor control centres shall be extensible to cater for

the future designed development. The Contractor shall take this
requirement into account when designing switch rooms and control
rooms.
Rubber insulation floor mat of 9mm thickness shall be provided at the

front of each switchboard and motor control centre.
The mat shall
extend over the full length of switchboards and motor control centre plus
800mm minimum at each end.
Test plugs and tools shall be provided to facilitate switchboard testing.
(a)
Rated voltage: 6.6/7.2kV
Rated short circuit: Shall be coordinated with supply fault

level breaking current subject to a minimum 25kA for 3 sec.
Rated short-circuit - current withstand time: Not less than 1

second
Incoming circuit breakers and bus-couplers shall be

motorized to allow automatic operation of the circuit
breakers on loss of power on any incomer;
Switch-disconnector,
earth
switch
and
circuit-breaker
operating mechanisms shall be of the independent manual

type and shall have positively driven position indicators;
PAGE 47 of 82
2118 of 2461
MMRDA
Operating mechanisms shall be pad lockable in all

positions;
Control functions shall be centralized on the module front;
Busbar shall be insulated;
(b)
Incomer units


selector switch;

presence;
Power meter/load manager shall be provided to monitor kVA,

kW, kWh, power factor, voltage and current with provisions for
RS485 communication port. The outputs shall be wired to the
ICA system;

and downstream protection devices;

transformer winding temperature high alarm, transformer oil
temperature high alarm and circuit-breaker trip initiation (for
incomers derived from transformers only);
PAGE 48 of 82
2119 of 2461
MMRDA
Phase failure and under voltage relay/release for circuitbreaker trip
initiation,
alarm
annunciation and remote
indication. The relay shall be connected on the busbar side of

the circuit-breaker;
High voltage inter-trip receive relay (for incomers derived from

transformers only);
Combined Restricted Earth Fault relay and Differential

Protection;

Push-buttons for:
(c)
Lamp test
Control and operation
A local control panel shall be provided adjacent to each pump set

for accommodating pump set instrument transmitters and pump
status indicators for effective monitoring of the pump set.
PAGE 49 of 82
2120 of 2461
MMRDA
Outgoing units for Motor Feeders 6.6kV

following minimum facilities:

selector switch;

presence;

provisions for RS485 communication port. The outputs shall
be wired to the ICA system;

and downstream protection devices as mentioned in SLD;
Auxiliary relay with hand reset operation indicators for Motor

feeders with following protections:
Composite Motor Protection Relay consisting of following

minimum features
Earth Fault
Instantaneous Over current protection
Thermal overload with memory feature
Locked rotor
PAGE 50 of 82
2121 of 2461
MMRDA
Phase currents out of Balanced
Motor Winding & bearing temperature alarm & trip relays
Negative Sequence
Overload Alarm.
Instantaneous Short circuit protection

Push-buttons for:
(d)
Lamp test
Interlocking
The switchboards/motor control centers with incomers derived

from two separate sources shall have circuit breakers for the two
incomers and bus-coupler. The switchboard shall be provided
with an electrical and mechanical interlocking scheme to allow
only two out of three circuit breakers to be closed at any one time.
PAGE 51 of 82
2122 of 2461
MMRDA
The normal operation of the switchboard will have the two

incomers closed and the bus-coupler open, with the load equally
distributed between the two incomers. On power failure of one
incomer, the bus-coupler will be closed automatically and the
complete plant operating from one supply.
Interlock shall be provided to prevent access to cable termination

enclosure unless the associated earth switch is closed.
Alternative interlocking arrangements, which are standard to a
particular switchgear manufacturer, shall be submitted to the
Employers representative for approval.
(e)
Feeder units
Feeder units shall be provided as required on each switchboard

and motor control centre.
(f)
Lamp test

(g)
Anti-condensation heaters shall be provided for each panel.
(h)
Auxiliary contacts

Each incomer (mains/generator)

-
PAGE 52 of 82
2123 of 2461
MMRDA
Transformer winding temperature high;
Transformer oil temperature high;
Supply healthy;
Each bus-coupler
-
Each motor starter

-
Motor available
Motor running
Motor fault (common)

the associated LCP.
(i)
Switch room floor flatness and concrete insert shall be provided

to the requirements of switchboard manufacturer. Space shall be
provided within the switch room to permit two circuit-breaker
panels to be added to one end of the switchboard. Front
clearance shall be not less than 2500mm.

at the rear of the panel.
Where floor trenches for cabling is provided it shall extend over

the full depth of switchboards and motor control centers plus
800mm minimum at each end. Trench depth shall be not less
than 1000mm. A galvanized steel supporting framework shall be
provided for switchboards and motor control centers.
PAGE 53 of 82
2124 of 2461
MMRDA
Galvanized steel or aluminum chequer plate cable trench covers

shall be provided.

position.
An identification label shall be fitted to the outside of the building

adjacent to the access door. The label shall identify voltage and
substation location. The label material shall be plastic laminate or
other material approved by the Employers representative and the
size of characters and numerals shall be not less than 50mm.
The label description shall be subject to the approval of the
Employers representative. The label shall be fixed to the building
using non-ferrous screws.
Mechanical ventilation shall be provided for the switch room.

Ventilation fan sizing calculation taking into account of equipment
heat
dissipation
rate
shall
be
provided
for
Employers
representative approval. The minimum air change rate for switch

room shall be 10 air change per hour.
11.15.7
6.6 kV Induction Motors at CWPS
1)
Site
and
Operating
Conditions
2)
c)
Altitude
- Not exceeding 1000 meters
d)
Temperature
- Max. ambient temperature 45C
Reference standard
- IS325,
IS4029,
IS4722:1992,
IS12824:1989, IS12802:1989
PAGE 54 of 82
2125 of 2461
3)
MMRDA
Degree of protection - IP55

provided by enclosure
4)
Type of duty
- S1
5)
Method of cooling
- IC411
6)
Type of construction - TEFC/TETV/CACA, Mounting as per

pump requirement
and mounting
7)
Frequency in Hz
- 50 Hz
8)
Number of phases
- 3-Phase
9)
Mechanical output in - As per pump requirement

kW
10)
Rated voltage
- 6.6/7.2 kV
11)
Class of insulation
- Class F with Class-B temperature

limits
12)
Speed in R.P.M
13)
Direction of rotation, - As per pump requirement

viewing
from
the
driving end
14)
Particulars of tests
- As per Standards specified
15)
Rotor
- Squirrel cage
16)
Method of starting
- Suitable for Direct On Line starting
17)
Method of starting
- Direct online
PAGE 55 of 82
2126 of 2461
MMRDA
18)
Nature of load
- Pump for water
19)
Method of drive
- Direct coupled
20)
Breakaway torque and - Adequate

the
corresponding
breakaway
for
smooth
acceleration
during starting as per specifications
starting
current
21)
Cable
termination - Phase segregated
boxes
Power Factor correction at 6.6kV Motor at CWPS:
The capacitor shall be connected to the motor terminals. The size of

6.6kVcapacitor shall be limited in this instance to a kVAr value
numerically not greater than the 90% of the motor magnetizing kVAr.
This is to ensure that the motor does not have a tendency to run on
(self-excited) when the motor is switched off. Capacitor of fixed type
connected across 6.6kV motor shall improve power factor from 0.78 to
0.96
11.15.8
Capacitor shall be APP or Mixed Di electric type
APFC:
Capacitor switching and automatic power factor correction panel shall be

designed in such a way that power factor of 0.99 can be obtained.
Timings to cut in capacitor shall be provided in such a manner to
facilitate capacitor discharging before next switching and shall also avoid
hunting due to temporary fluctuations of load. The timer shall be
11.15.9
110V Battery and Battery Charger
PAGE 56 of 82
2127 of 2461
MMRDA
The Contractor shall provide adequate sized batteries and battery

charger with eight (8) hour battery backup. Two battery supply units
incorporating float and boost chargers shall be provided with auto
changeover facility in case of failure of one. The batteries shall be
adequate to take emergency requirements of 132kV panels, 6.6kV
panels, control and relay system, monitoring devices, OLTC etc. The
sizing calculations shall be submitted to the Employers representative
for approval.
11.15.10
Low Voltage Switchboard / Motor Control Centre
The Contractor shall design the low voltage power distribution to meet
the requirements of the proposed plant. As a minimum, the Contractor
shall provide the following distribution switchboards.
1 No. main 400V switchboard

Chemical building MCC/Switchboard;
Filter building MCC/Switchboard;
Chlorine building MCC/Switchboard;
Clarifier MCC/Switchboard;
Sludge treatment MCC/Switchboard;
Lighting and small power distribution board;
Street lighting switchboard;
Capacitor panels for automatic correction of power factor;
PAGE 57 of 82
2128 of 2461
MMRDA
Starters/push button stations for auxiliary motor;

Adequate no. of small distribution boards for lighting and power;
Clear water pump house switchboard / MCC
The MCCs shall be of Form 4 construction incorporating but not limited
to the following principle requirements:
(a)
Main 400V Switchboard for Treated Water Pump House and
WTP
2 Nos. ACB incomers;

1 No. ACB bus-coupler;
2 Nos. MCCB for clear water pump house;
2 Nos. MCCB with wash water supply pump motor starters;
2 Nos. MCCB chemical building MCC feeders;
2 Nos. MCCB filter building MCC feeders;
2 Nos. MCCB chlorine building MCC feeders;
2 Nos. MCCB sludge treatment MCC feeders;
2 Nos. MCCB clarifier MCC feeders;
1 No. 63A MCCB lighting and small power distribution board feeder;
1 No. 63A MCCB street lighting feeder
PAGE 58 of 82
2129 of 2461
MMRDA
1 No. 125A MCCB distribution board for ancillary services such as

electrically operated treated water pump inlet and delivery valves,
battery chargers, HV equipment supplies and OLTC panels;
2 Nos. spare 400 Amp MCCB feeders;

2 Nos. spare 125 Amp MCCB feeders;
ICA compartment housing the local control panel as per requirement
The main 400V switchboard shall be supplied from the 2 Nos. 6.6 /
0.433 kV auxiliary transformers in 132 kV substation. The MCC shall be
located within a segregated and mechanically ventilated switch room.
Protection and metering shall be in accordance with the single line
diagram.
The incomers and bus-couplers shall be provided with motorized

switches to automatically open/close breakers on loss of power from one
incomer. The switches shall be electrically interlocked for a two out of
three switching arrangement.
The MCC shall be provided with a panel mounted UPS within the ICA
compartment.
(b)
Chemical building MCC
2 Nos. Switch disconnector incomers castell key interlocks to meet

maximum demand;
2 Nos. Chemical waste holding tank drainage pump motor starters;

2 Nos. Saturated alum transfer pump motor starters;
2 Nos. Stock tank mixer starters;
PAGE 59 of 82
2130 of 2461
MMRDA
2 Nos. Alum stock tank pump motor starters;

2 Nos. Lime tank mixer starters;
6 Nos. Lime transfer pump motor starters;
1 No. Chemical house building services distribution board feeder;
2 Nos. Spare 100 Amp TPN MCB;
The MCC shall be provided with a small panel mounted UPS within the
ICA compartment to supply all essential services.
(c)
Filter building MCC
2 Nos. Switch disconnector incomers castell key interlocks to meet

maximum demand;
2 Nos. air scour blower starters;

4 Nos. used wash water pump motor starters;
1 No. filter house building services distribution board feeder;
1 No. raw water sampling pump motors starter;
1 No. dosed water sampling pump motor starter;
1 No. filter water sampling pump motor starter;
1 No. clarified water sampling pump motor starter;
PAGE 60 of 82
2131 of 2461
MMRDA
1 No. control room UPS switched feeder;

2 Nos. pneumatic valve compressor control panel switched feeder;
1 No. works water supply booster control panel switched (if
required);
2 Nos. spare 100 Amp TPN MCCB;

The filter plant distribution board within the filter building MCC shall
provide small power distribution to the filter gallery local control desks,
the various sample pumps and drainage pumps as detailed in water
treatment works particular specification.
The MCC shall be located
within a segregated and mechanically ventilated switch room.
(d)
Chlorine Building MCC
2 Nos. Switch disconnector incomers castell key interlock to meet

maximum demand;
Pre chlorinator motive water pump motor starter;

Post chlorinator motive water pump motor starters;
Chlorine dosing plant feeder;
Ventilation fan control panel feeder;
PAGE 61 of 82
2132 of 2461
MMRDA
Electrically operated travelling crane feeder;

Chlorine house building services feeder;
2 No. Spare 100Amp TPN MCBs;
The chlorine building MCC shall be supplied from the main 400V
switchboard. The MCC shall be located within a segregated and
mechanically ventilated place.
(e)
Clarifier MCC

maximum demand;
Feeders as necessary to feed each clarifier;

Clarifier services distribution board feeder;
1 No. feeder for the cathodic protection transformer rectifier unit;
1 No. Spare 100 Amp TPN MCBs;
The MCC shall be located within a segregated and mechanically
ventilated place.
Subject to the proposed Contractors clarifier design as detailed in the

PAGE 62 of 82
2133 of 2461
MMRDA
water treatment specification, the functional requirements of the motor

control centre/ICA compartment may be combined within an adjacent
MCC. Where more than four motor starters are proposed by the
Contractor a separate MCC shall be provided.
(f)
Starter panels for clarifiers (Pretreatment)
Weather proof suitable for outdoor use, totally enclosed, floor mounted
starter panels shall be provided for clarifier. Each clarifier starter panel
shall be supplied from pretreatment MCC.
(g)
Sludge treatment MCC

maximum demand;
Clarifier sludge balancing tank mixer starters;

Sludge thickener tank feed pump motor starters;
Sludge thickener tank drive motor starters;
Sludge drainage pump motor starters;
1 No. Future polyelectrolyte dosing plant feeder;
1 No. Pressure water system feeder;
1 No. Sludge treatment building services feeder;
1 No. Spare 100Amp TPN MCCBs;
PAGE 63 of 82
2134 of 2461
MMRDA
The sludge treatment MCC shall be supplied from the main 400V
switchboard. The MCC shall be located within a segregated and
mechanically ventilated switch room.
415V supply for MSETCL Control room and 132kV Relay and Control
Room Lighting, Ventilation, etc. shall be taken from Power Distribution
Board.
11.15.11
Emergency Stop Push-Buttons
An emergency stop push-button shall be installed adjacent to all motors.
11.15.12
Local Control Units (LCU)
Each motor shall be capable of being manually operated from a local

operating position.
Where motor starters are provided at remote
locations, the Contractor shall provide a local control unit (LCU) in a safe
and accessible operating position adjacent to the motor.
Each LCU
shall be of robust construction suitable for the environmental conditions.

The LCU shall be provided with a start/stop or open/close pushbutton.
Local control units installed externally shall be protected from the sun
with sun covers and constructed with an IP rating of IP65.
The Contractor shall submit drawings identifying the locations of the

LCUs for the Employers representative approval.
11.16
Cabling
(a)
General
PAGE 64 of 82
2135 of 2461
MMRDA
The Contractor shall provide a complete cabling installation

comprising power, control, instrumentation, communications and
telephone cables (if applicable) and all accessories including
cable glands, terminations, cable markers, support systems, clips,
fittings and fixtures to:
Interconnect all Plant provided under the Contract;
Interconnect ICA signals to the Local Control Panels of the

contractor;
Interconnect existing plant (if applicable) with the Plant

provided under the Contract
All calculations to corroborate current carrying capacity and

compliance with the volt-drop criteria specified herein shall be
The power, control and instrumentation cabling shall interconnect the

entire Plant including but not limited to:
Valves actuators, pump sets, etc.;

Switchgear and distribution boards;
Motor control centers;
Local Control Panels;
Local control units;
Measuring instruments and sensors; and
(b) Cable grouping
The cables shall be grouped as follows:
Power cables HV 6.6 KV

power cables 1.1 kv
PAGE 65 of 82
2136 of 2461
MMRDA
control cables - 110 V d.c. / 660 a.c
(c)
Cable types
High voltage power cables shall be of the XLPE/SWA/PVC type with a

conductor size appropriate to the short-circuit current and short-time
requirements. The cable shall be suitable for prolonged operation at
plus 10% rated voltage.
415V power cables and control cables shall be 600/1000V grade PVC or
XLPE/SWA/PVC unless otherwise approved to by the Employers
representative.
(d) Installation
External below ground
Unless otherwise approved by the Employers representative all

cables shall be installed in ducts and concrete trenches.
Duct systems shall be provided with draw chambers at the point of

entry into buildings, at changes in direction and at suitable intervals in
straight runs to permit the installation of cables without exceeding the
manufacturers'
recommended
maximum
tensile
stress.
Draw
chambers shall be generously dimensioned to enable cables to be

pulled without damage or excessive stress due to bending.
Where high voltage and low voltage cables are installed in a common
trench, they shall be on opposite faces, and have a distance
clearance of as a minimum 300mm.
Cables in trenches shall be
installed on tray and/or ladder systems.
External above ground
PAGE 66 of 82
2137 of 2461
MMRDA
Cables on structural surfaces shall be installed on tray and ladder

systems or in trunking and conduit as appropriate. Cable tray on
structural surfaces shall be fitted with covers.
Internal
Cables on structural surfaces shall be installed on tray and ladder

systems or in trunking and conduit as appropriate. Cables in trenches
shall be installed on tray and/or ladder systems.
Cable tray, ladder and trunking systems
Cable tray, ladder and trunking systems shall be heavy duty hot dip
galvanised steel with return flange at the upstand. Cable tray on
external structural surfaces shall be fitted with covers.
Installations in the chemical and chlorine buildings shall be heavy

duty GRP systems.
Conduit systems
Conduit shall be heavy duty galvanised steel.
Installations in the
chemical and chlorine buildings shall be heavy duty GRP systems.
11.17
Earthing
(a)
General
A complete and fully interconnected low voltage earthing

installation comprising earth electrodes, earthing terminals and all
earthing, protective and equipotential bonding conductors shall be
provided by the Contractor at each of the sites of reservoirs,
sumps, tapping points from trunk mains, Chlorination stations and
booster pumping stations.
PAGE 67 of 82
2138 of 2461
(b)
MMRDA
Earth electrode system
The Contractor shall carry out a ground resistivity survey for each
site and design and install the earth electrode systems to provide
an overall resistance to earth not greater than 1 ohm.
The earth electrode system shall comprise at least two separate

groups of rods located at agreed locations to allow for testing of
one earth electrode system whilst the other is connected to the
system.
The main earth bar shall be provided with test links to enable
independent testing of each group of earth electrodes.
Design calculations for the earth electrode system shall be

(c)
Earthing terminals
Earthing terminals shall be located adjacent to the associated

switchboard or motor control centre. The earth terminals shall be
interconnected. The earthing terminal shall be used to connect
the following conductors to the earth electrode system:
(d)
The circuit protective conductors;
(e)
The main bonding conductors; and
(f)
The functional earthing conductors (if required).
The size of bonding conductor connecting the main earthing

terminals at the sites of this Contract and the electricity suppliers
transformer earth or metallic sheaths of service cable, should not
PAGE 68 of 82
2139 of 2461
MMRDA
be less than 150 mm2 copper equivalent. Provisions should be

made for disconnection of the bonding conductor for testing
purposes.
A warning notice bearing the words SAFETY ELECTRICAL

CONNECTIONDO NOT REMOVE and in equivalent Indian
language should be displayed in a conspicuous position at or
near the main earthing terminal.
At the booster pumping station sites, the main earth terminal with
test link shall be located inside the booster pumping station
switch room. An auxiliary earth terminal with test link shall be
room inside the booster pumping station for the installation of the
Local Control Panels. At the tapping point from the trunk mains
sites, the main earth terminal with test link shall be located inside
the enclosures for the installation of the Local Control Panels. At
the union reservoir sites, the main earth terminal with test link
shall be located inside the switch room at the Chlorination Station
Building.
An auxiliary earth terminal with test link shall be

room inside the Chlorination Station Building for the installation of
the Local Control Panels.
(d)
Bonding to structural steelwork
Structural steelwork including concrete reinforcement bars shall

be bonded to the earthing system. The method of connection to
reinforcement bars shall be subject to the approval of the
(e)
Equipotential bonding
All metallic pipework and other extraneous conductive parts shall

PAGE 69 of 82
2140 of 2461
MMRDA
be provided with positive earthing terminals and provided with

equi-potential bonding.
In each installation, main equipotential bonding conductors

should be connected to the main earthing terminal for all
extraneous conductive parts to create an equipotential zone; such
conductive parts include:
(j) all water pipes;
(ii) all gas installation pipes;
(iii) other service pipes and ducting;
(iv) cable trays, cable ladders, conduits, trunkings etc.;
(v) exposed metallic parts of structural framework; and
(vi) the lightning protection system.
In a large installation, where there are a number of equipotential

zones, these zones should be bonded together to form one
equipotential zone.

Main equipotential bonding conductors should have crosssectional areas not less than half the cross-sectional area of the
earthing conductor of the installation, subject to a minimum of 6
2
2
mm copper equivalent, and need not exceed 25 mm copper
equivalent.
PAGE 70 of 82
2141 of 2461
MMRDA
Main equipotential bonding connections to any gas or water pipes

should be made as near as practicable to the point of entry of
those services into buildings; provided that where there is an
insulating section or insert at that point, the connection should be
made to the metalwork on the consumers side of that section or
insert.
In particular, for gas services, the bonding connection should be

made on the consumers side of the meter (i.e. between the
meter outlet union and any branch pipework). This connection is
recommended to be made within 600 mm of the gas meter.
Within the zone formed by the main equipotential bonding, local

supplementary bonding connections should be made to metal
parts, to maintain the equipotential zone, where those parts are:
(j) Extraneous conductive parts,
(ii) Simultaneously accessible with exposed conductive parts or

other extraneous conductive parts, and
(iii) Not electrically connected to the main equipotential bonding

by permanent and reliable metal-to-metal joints of negligible
impedance.
Metalwork which may be required to be bonded includes service

pipes or substantial parts which are at a distance not exceeding 2
m from exposed conductive parts. Examples are water pipes
adjacent to electric heater or window frame supporting a
ventilation fan or air-conditioner or adjacent to a socket outlet.

PAGE 71 of 82
2142 of 2461
MMRDA
The minimum cross-sectional area of a supplementary bonding

conductor should comply with the following table, subject to the
conditions following:
Installation
PVC insulated (mm2)
method
Copper
Aluminu
Bare (mm2)
Copper
Aluminum
16
>6
16
16
1.0
16
m
Surface
2.5
wiring
(sheathed)
4 (nonsheathed)
In
conduits
1.0
or trunkings
(i) The bonding conductor connecting two exposed conductive

parts should have a cross-sectional area not less than that of
the smaller protective conductor connected to the exposed
conductive parts;
(ii) The bonding conductor connecting exposed conductive parts

to extraneous conductive parts should have a cross-sectional
area not less than half that of the protective conductor
connected to the exposed conductive part;
(iii) The
bonding
conductor
connecting
two
extraneous
conductive parts, where one of the extraneous part is

connected to an exposed conductive part, should have a
cross-sectional area not less than half that of the protective
conductor connected to the exposed conductive part
(f)
Instrumentation earthing
PAGE 72 of 82
2143 of 2461
MMRDA
The Contractor shall provide a separate earthing terminal for the

Local Control Panels and all the instrumentation in each telemetry
housing/room.
Each separate earthing terminal shall be
connected to the station earth system through the earth terminal

inside the same housing/room, as required.
Insulated earth
cables shall be used to connect the instrumentation to these

separate instrumentation earth terminals. The instrumentation
signal earth cables shall have different outside insulation colour to
the power earth cables in order to make them easily detectable.
Earthing system design shall comply with local regulations.
(g)
A lightning protection system shall be provided on all main

structures, complying to the requirements entered in BS 6651.
Air terminations and down conductors shall be copper.
The Contractor shall also provide all terminating equipment for

all I/O and communications signals transmitted between
buildings on a copper cable with lightning protection barriers.
The barrier shall be installed in a barrier panel which shall be
located adjacent to the main cable entry point into the building
or in a small enclosure adjacent to the transmitter. The barriers
shall be earth bonded in accordance with manufacturers
recommendations and the standard specification.
11.18
Diesel Generator Sets Diesel Engine
11.18.1
The engine type shall have been in commercial operation for a period
of not less than 3 years.
The engine shall be of the 4-stroke, water-cooled direct-injection

PAGE 73 of 82
2144 of 2461
MMRDA
compression-ignition type with an in-line or vee-cylinder configuration.

The engine may be naturally aspirated or turbo-charged. The nominal
speed shall not exceed 1500rpm for 50Hz operation.
The engine shall be rated in accordance with ISO 3046-1:2002 and

shall be capable of continuous operation at rated output plus a 10%
overload for 1 hour in any 12 consecutive hours running.
Unless otherwise specified, fuel oil shall be Class A2 to BS 2869:1998.
All chain and gear drives shall be located in oil-tight cases and shall be
pressure-lubricated.
The engine and generator shall be mounted on a common fabricated

steel bedplate with anti-vibration mountings of the multiple neoprene
type impervious to water and oil.
The engine shall accept full-rated load within 20 seconds from initiation
of the starting sequence when starting from cold at the minimum
specified ambient air temperature. The initial step load shall be not
less than 40% of the full-load value unless otherwise specified.
The starting battery shall be of the nickel-cadmium or lead-acid type

and unless otherwise specified, installed on an engine bed plate
mounted non-corrodible tray or rack and shall have a cover of
insulating material. The battery shall have sufficient capacity for
three consecutive start attempts each of 10 seconds duration. In
addition, the battery shall have sufficient capacity after the three
start attempts to supply the maximum demand of the control panel
for a minimum period of 24 hours
The battery charger shall be of the solid-state design and shall

incorporate float and boost charging facilities. In the float charge
mode, the charger shall automatically maintain the battery in a fullySECTION 6C.11: ELECTRICAL WORKS
PAGE 74 of 82
2145 of 2461
MMRDA
charged condition whilst supplying standing loads. In the boost

charge mode, the charger shall be capable of fully charging the
battery from a fully-discharged condition in a period not exceeding
7 hours
11.19
Diesel Generator Sets Generator
11.19.1
The generator shall be of the salient pole brushless type complying

with BS 5000-3:2006. The generator shall be flange and foot mounted
or foot mounted with open coupling, with single or twin end-shield
bearings. A single-bearing machine shall be directly coupled to the
engine crankshaft. A two-bearing machine shall be coupled through
an intermediate flexible coupling.
The generator shall be capable of continuous operation at rated output

plus 10% overload for 1 hour in any period of 12 hours without
exceeding the temperature rise limits of the insulation system.
Generator windings shall be of the 2/3 pitch design to eliminate triple

harmonics on the voltage waveform and fully interconnected damper
windings for stable operation during paralleling.
Generator windings shall be star-connected with neutral point brought

out to the main cable termination facilities and with provisions for
neutral point earthing as specified.
Bearings shall have a minimum life of 40 000 hours and shall have a
re-lubrication interval preferably 8 000 hours and not less than
4 000 hours. The bearing speed rating shall not exceed 80% and the
bearing outer race temperature shall not exceed 70C.The generator
enclosure shall provide a minimum protection classification of IP22 to
BS EN 60529:1992, unless otherwise specified.
PAGE 75 of 82
2146 of 2461
MMRDA
DG Set shall be with an acoustic enclosure confirm to sound level of

75dB at 1mtr distance from acoustic enclosure as per specification.
11.20
Building Services at Kawdas & Suryanagar
11.20.1
Scope
The Contractor shall include for the design, supply, delivery to Site,
off-loading, storage, erection, testing and setting to work the complete
building services installations at the sites of the clear water pump
houses. As a minimum, the Contractor has to provide the following:
(a)
Internal main and emergency lighting;
(b)
External walkways and floodlighting;
(c)
Small power;
(d)
Air conditioning;
(e)
Ventilation and ceiling fans;
(f)
Telephone lines and telephone handsets;
The
building services installation
shall comply with
Standard
Specification and the following clauses herein. Where the standard

specification, particular specification and drawings differ, the latter shall
take precedence.
11.21
Lighting
11.21.1
Internal Main Lighting
Internal lighting shall be designed to provide the following minimum

service illuminance, measured at floor level:
(a)
Pump hall areas
200 lux
PAGE 76 of 82
2147 of 2461
MMRDA
(b)
Switch rooms
300 lux
(c)
Control room/Telemetry room
350 lux
(d)
Workshop areas
300 lux
(e)
Offices
350 lux
(f)
Staff rooms and reception areas
(g)
Toilets, washrooms, mess rooms
(h)
Corridors and staircases
:
:
150 lux
100 lux
:
75 lux
Luminaires shall be fixed directly to, or suspended from, the underside

of roof slabs, ceilings or fixed to walls as appropriate. To attain energy
saving in operation, all fluorescent lightings shall be of T5 type with
electronic ballast.
Pump halls and other high bay areas shall be provided with high or low
bay energy efficient lighting.
The Contractor shall provide all
necessary equipment to ensure lighting maintenance can be

performed in a safe and efficient manner. Where special provision
would have to be made for accessing luminaires supported from the
underside of the roof slab for maintenance, luminaires shall be wall
mounted.
Luminaires for the control room and offices shall be designed to

minimize glare and shall be suitable for VDUs.
Light switches shall be located adjacent to doorways. Multi-way

switching shall be provided for rooms and areas with more than one
point of access. For large area light switching or high/low bay lighting,
contactors shall be provided to switch lighting in blocks from each entry
point.
11.21.2
Internal Emergency Lighting
Emergency lighting shall be provided and shall comprise of exit and

escape route luminaires to facilitate safe movement of personnel in or
PAGE 77 of 82
2148 of 2461
MMRDA
from any building or major dry structure in the event of a mains supply
failure. Exit luminaires shall be provided above all doors leading to or
accessible to an outdoor area.
Emergency lighting shall also be provided in areas where essential

operations may be required during a mains supply failure, for example,
switch room and control rooms. The regional control centre shall be
provided with emergency luminaires to provide an average illuminance
of 50 lux for one hour during a mains/generator power failure.
11.21.3
External Walkway Areas
Luminaires shall be provided to illuminate all external personnel

walkway areas around buildings and structures. The lighting shall be
designed to provide an even minimum service illuminance measured at
ground level of 15 lux.
Lighting shall be switched at personnel access doors. Multi-way

switching shall be provided where there is more than one point of
access.
11.21.4
Floodlighting
Floodlighting shall be provided for the entrance to the site, pumping

station wet wells, loading/unloading areas, the telemetry housing for
the LCP at the tapping point from the trunk mains sites and reservoirs
access/instrument locations. Floodlighting shall also be provided at all
locations requiring inspection.
Floodlights shall be mounted on galvanised steel poles or on structure

walls as appropriate.
Floodlighting shall provide a minimum service illuminance of 50 lux

measured at the working plane.
PAGE 78 of 82
2149 of 2461
MMRDA
Floodlighting shall be switched from the main switchgear for the site.
11.22
Small Power
Industrial switched type 230Vac socket outlets with residual current

devices for the connection of electric tools shall be installed in
convenient places in all plant and workshop areas.
A suitable rated 415Vac/230Vac socket outlet with residual current

device shall be provided for each water retaining structure. The socket
outlets shall be located in an IP65 weatherproof enclosure fixed to the
structure wall.
For process/pumping plant areas, industrial type socket outlets shall be

so spaced so that any location within the area is no greater than 20m
from an outlet. A minimum of two socket outlets shall be provided in
each area.
Commercial type 230V 15A and 5A socket outlets shall be installed

throughout all administrative office areas, the telemetry housing/room
for installation of LCP and also including the associated corridor areas.
A minimum of two socket outlets shall be provided in each room.
11.23
Ventilation
Mechanical ventilation shall be provided as follows:
Location:
Air changes/hour (ACH):
Pump room
Toilets and washrooms
Mess rooms and kitchen
Electrical switch rooms
10
PAGE 79 of 82
2150 of 2461
MMRDA
Chlorination Building
10
For further details of ventilation requirements refer to the mechanical

specification.
11.24
Ceiling Fans
All administrative areas such as the control rooms and offices shall be
2
provided with 100W ceiling fans at a frequency of 1 per 15m of floor
area.
The fans shall be provided with local speed controllers and
switches adjacent to each individual unit.
11.25
Air Conditioning
As a minimum, all the high voltage switch rooms, 415V switchboard

and motor control centre rooms, the telemetry rooms in the
Chlorination House and the booster pumping stations for the
installation of Local Control Panel (for use by the contractor of
Package I) shall be air conditioned. As a minimum, the Contractor
shall provide one 9,000 BTU air conditioners at each of the
rooms/housings.
The Contractor shall submit calculation to the
Employers representative to select the size of the air conditioners

based on the heat generating load that are to be installed.
The air conditioning shall be designed to maintain a dry bulb

0
temperature of 22 C and relative humidity of 50% under the outside
mean monthly maximum shade temperature and humidity specified

elsewhere.
11.26
Telephone Facilities
The Contract shall provide, as a minimum, one telephone landline and

one telephone handset for each booster pumping station and each
Chlorination Station House.
PAGE 80 of 82
2151 of 2461
MMRDA
A provisional sum item is included within the Contract for the provision
of additional telephone lines and handsets.
11.27
Distribution Boards
Each site shall be provided with suitably sized distribution board.

Distribution board shall provide distribution to lighting, socket outlets,
heating, ventilation and air conditioning. Circuits shall be arranged to
provide a balanced load on each phase of the supply. The design of
the distribution boards shall be submitted to the Employers
11.28
Wiring
Internal wiring on concrete and blockwork surfaces shall be carried out

using single core PVC insulated non-sheathed cables installed in
surface mounted heavy duty galvanised steel conduit and/or trunking.
Wiring in plastered and tiled areas shall be installed in concealed steel
conduit.
External wiring shall be carried out using single core PVC insulated
non-sheathed cables installed in heavy duty galvanised steel conduit
or PVC covered mineral insulated copper sheathed cables.
Wiring associated with lighting and ventilation fans in the chlorine and
chemical buildings shall be carried out using heavy duty GRP
conduits/trunking and/or cable tray/ ladder as necessary.
Within the rooms/housings to be provided for use by contractor of

Package I, the Contractor shall provide computer raised floor.
communications,
control,
small
power
services
All
and
telecommunications cabling shall be contained within a three

compartment
cable
management
system
to
allow
adequate
PAGE 81 of 82
2152 of 2461
segregation of cabling.
MMRDA
The cable management system shall be
designed to allow flexibility and future expansion as well as providing

mechanical protection for all cabling.
PAGE 82 of 82
2153 of 2461
SUB-SECTION 6C.12
INSTRUMENTATION, CONTROL &
AUTOMATION (ICA)
2154 of 2461
MMRDA
Table of Contents
SUB-SECTION 6C.12: INSTRUMENTATION, CONTROL & AUTOMATION (ICA) 1
12.1
Instrumentation, Control & Automation systems
1
12.2
Field Instrumentation and Control
3
12.3
12.4
Instrumentation Design Criteria

Process Instruments
4
6
12.4.1
Flow Measurement
12.4.2
12.4.3
12.4.4
Level Measurement
Pressure Measuring System
Temperature Measuring System
15
21
25
12.4.5
12.4.6
Permanent Vibration Monitoring System

Portable Vibration Monitoring
28
28
12.4.7
12.4.8
Alarm Annunciators
Multi-Function Energy Meter (Intelligent type)
29
30
12.4.9 Surge Protection Devices

12.4.10
Online Analytical Field Instruments
12.5
12.6
WTP Plant Laboratory

Approved Vendor List for Instrumentation
33
33
39
52
12.7
Particular Requirements for Programmable Logic Controllers (PLC)
and Supervisory Control and Data Acquisition (SCADA/HMI)
55
12.7.1
12.7.2
55
56
12.7.3
12.7.4
12.7.5
Quality Assurance
Control System
Contractor submittal Procedures
56
56
61
12.7.6
12.7.7
Approved Vendor List for Automation

Particular Specification for PLC & SCADA / HMI
65
67
I. Specifications for Operator Work Stations & Engineering Station:

PTOP- Specifications
12.7.8 Control Room Furniture (System Console)
12.7.9 Spares for PLC and SCADA Component
12.7.10
80
82
106
107
108
12.7.11
12.7.12
Telemetry Equipment Specifications

Intercom system
114
122
12.7.13
12.7.14
Fire Detection & Alarm Requirement In Control Room

131
Requirement for Closed Circuit Television Monitoring (C.C.T.V.M.) System 151
12.8
12.9
12.10
12.11
Functional design specification for PLC and SCADA/HMI

Submissions by the Contractor
Inspection and Testing Requirements
Training
2155 of 2461
165
173
180
194
MMRDA
12.12 The Minimum Requirements for Instrumentation, control &

Automation Equipment.
2156 of 2461
196
MMRDA
SUB-SECTION 6C.12: INSTRUMENTATION, CONTROL & AUTOMATION (ICA)

12.1
Instrumentation, Control & Automation systems
This section outlines the particular requirements for the instrumentation

systems.
Unless
specified
in
this
section
to
the
contrary
instrumentation Plant provided by the Contractor and workmanship

shall comply with the General Chapters of these Requirements.
The scope of instrumentation, control and automation (ICA) works for
RWPS, CWPS, WTP & MBRs shall comprise the design, manufacture,
programming and configuration, off site testing, delivery to site,
installation and erection, testing, commissioning, setting to work and
provision
of
documentation
for
complete
supervisory,
instrumentation, control and automation system including Wireless

Data transmission required to provide remote monitoring for a safe
and efficient operation of
pumping stations, Treatment Plant and
MBRs.
The Contractor shall submit and obtain approval of the instruments
from the Engineer before beginning the detailed control system design.
Refer approved vendor list for instruments.
At the time of bid submission, the contractor has to submit the
completed technical schedule of the proposed instruments as per the
technical schedule. All relevant manuals should be attached. Failure to
adhere to the above would be treated as a non-responsive bid. The
contractor should take note of the importance of this obligation
The minimum scope of work for ICA at RWPS, CWPS, WTP and each
MBR shall include but not limited to:
Design, supply, install, test and commission a dual redundant

control system. PLC, SCADA / HMI shall include but not limited to
SECTION 6C.12: INSTRUMENTATON CONTROL & AUTOMATION
2157 of 2461
PAGE 1 of 200
MMRDA
process controller including its central process units (CPUs),

communication modules,
input-output (I/O)
modules, control
networks, operator workstations, engineering workstation and

printers, Wireless Communication Gateways of VSAT and GSM /
GPRS modems;
Design, supply, install, test and commission field instrumentation for

the entire RWPS, CWPS, WTP & MBRs;
Design, supply, install, test and commission chlorination system

including its instrumentation and chlorination control units and its
interface with SCADA in WTP;
Design, supply, install, test and commission of Filter Units,

Centrifuge system & Chemical dosing system and its chlorination
control units and its interface with SCADA in WTP;
Design, supply, install, test and commission uninterrupted power

supply for back-up supply requirement to Instrumentation and
Control system equipment in each RWPS, CWPS, WTP& MBRs;
The PLC Data of RWPS and CWPS shall be integrated to WTPPLC system by using the Fiber Optic Cable (F.O.C);
Wireless Communication Gateways (VSAT & GSM / GPRS

modems) equipment to enable communication between the SCADA
Rooms of WTP, MMRDA Office and each MBR;
WTP Control room furniture(system console) includes but not

limited to control console for placing dual redundant SCADA
Operator workstations including Historian Operator Work Station,
two printer compartments, desk for one engineering station and
chairs;
Control room furniture(system console) for RWPS, CWPS and each
2158 of 2461
PAGE 2 of 200
MMRDA
MBR shall include but not limited to control console for placing dual
redundant
SCADA
Operator
workstations,
two
printer
compartments, desk for one engineering station and chairs;

Note: The system console design shall be submitted to Engineer for
prior approval.
The Contractor shall be responsible for the design of each
instrumentation and plant monitoring system, including the selection
and design of appropriate transducers(on approval by the clients
representative), transmitters, signal conditioning devices, indicators,
alarm system programmable devices, communications, cable system
etc. The Contractor shall take account in his design of all installation
and environmental conditions prevailing at the site.
12.2
Field Instrumentation and Control
Each field instrument shall be operable in local mode and have display
functions in SCADA. The Contractor shall be responsible for providing
the appropriate signals at the locations required to provide the
specified control and monitoring functions.
The Contractor shall ensure that field measuring systems shall respond
quickly to any changes of the measured process variables.
All field instruments shall, as far as practicable, be mounted in a
location that shall be free of vibration and shall be powered from the
instrument control system.
24V dc power wiring for field instruments shall be individually fused and
provided with a means of disconnecting the power without disturbing
terminated wiring (e.g. knife-switch-type terminal blocks). Visual
indication of a blown fuse condition shall be provided.
2159 of 2461
PAGE 3 of 200
MMRDA
All field instrument components shall be of a proven and reliable design

and shall have a high degree of uniformity and shall, wherever
possible, be interchangeable. The design shall facilitate easy
maintenance and repair, taking into account the availability of access
routes through plant and structures generally.
Field Instruments shall perform sensing, indicating, transmitting and
controlling. The devices shall generally interface with the SCADA,
either directly or indirectly. The materials of those parts of the field
instruments, including piping material, which are exposed to the
measured media shall be compatible with the conditions of the
respective media and of the ambient fluid and atmospheric conditions.
All field instruments shall be mounted within enclosures that are
corrosion proof, dustproof and waterproof to provide a minimum
protection specified in elsewhere in this Specification.
All field instruments, including the components, shall be tropicalised
and designed for the ambient conditions detailed elsewhere in this
Specification. Lighting protection barriers shall be used for protecting
transmitters and receiving instruments from the surge voltage due to
lighting strike. Lighting protection barriers shall be supplied at both
receiving and sending ends for all signals from outside building and
those installed between the buildings.
12.3
Instrumentation Design Criteria
The design criteria to be applied to instrumentation systems shall be as

follows:
-
all instruments shall be suitable for continuous operation;
all transmitting instruments shall have a 4 - 20 mA linear output;
2160 of 2461
PAGE 4 of 200
MMRDA
all digital outputs shall be volt free;
all instruments shall be designed for the ambient conditions of

temperature and humidity;
all wetted parts of instrument sensors shall be non-corrosive and

suitable for use with potable water containing residual chlorine;
all instrumentation systems for use out of doors will be protected to

IP 65 for sensors and transmitters, while enclosures under
submersible conditions will be protected to IP68;
all analogue displays shall be of the digital type with no moving

parts utilising back lit liquid crystal diode technology;
instrumentation shall utilise solid state electronic technology and

avoid the use where practical of any moving parts;
minimum maintenance requirement;
instrumentation shall resume operation automatically on the

application of power following a power failure
All Field Instruments such as Flow meter, DP, level, Pressure

transmitter shall have capability of digital communication with
control room instrument such as HART It shall be possible to
calibrate field instrument remotely using a suitable calibrator.
Contractor shall supply such calibrator with the system. All
Analytical instruments shall have RS-485 port for connectivity with
control room. Electric Actuators shall have RS-485 port for
communication. Contractor may use 4-20mA signal for connecting
field instruments with control room, however digital communication
capability is a must and shall be used as much as possible. All filed
Instruments shall have local indication.
2161 of 2461
PAGE 5 of 200
MMRDA
Field sensor cables are required to be provided with suitable

lightening protection units as mentioned in the tender document. In
addition to this all signal cabling, LAN cabling, PLC network cabling
etc. should be protected from lightening using a suitable protection
method.
The Contractor shall provide Plant to measure any other parameter

required for the efficient and safe operation of the Pumping stations,
treatment plant and Reservoirs.
Digital systems shall be provided as detailed in the Employers
Requirements and as necessary for the efficient and safe operation of
the treatment plant.
The Contractor shall provide Plant to detect any other condition
required for the efficient and safe operation of the treatment works.
12.4
Process Instruments
12.4.1
Flow Measurement
I.
Electromagnetic Flowmeters
(a)
Full bore electromagnetic flow meter shall consist of flow

sensor (i.e. flow tube), flow transmitter/ flow computing unit
and remote flow indicator cum integrator. The electromagnetic
flowmeters shall be manufactured as per BS EN ISO 6817
(Measurement of conductive liquid flow in closed conduits,
method using electromagnetic flow meters) standard.
(b)
The flow tube flanges and transmitter housing shall be

properly earthed.
(c)
The flowmeter design shall permit for the flow tube to be
2162 of 2461
PAGE 6 of 200
MMRDA
buried in the soil directly for installation on underground

pipelines.
(d)
The flowmeter shall be microprocessor based using digital

technology having facilities for Configuration of engineering
units, flow range and features of memory and self-diagnosis.
(e)
The flow transmitter and flow computation/ evaluation unit

shall be suitable for mounting in a field mounted metallic field
enclosure / cabinet.
(f)
The full bore electromagnetic flow meter shall have bidirectional measurement feature and with accuracy better or
equal to + /- 0.5% of measured value inclusive of linearity,
repeatability, pressure effect etc.
(g)
Flow
transmitter/
flow
computing
unit
should
be
microprocessor based having digital display with flow-rate

indications and integrated flow values with the configuration
facility from the front facia.
(h)
The flow tube shall be installed at a location free from flow

turbulence. In order to achieve the same, the flow tubes shall
be installed in the pipe section such that straight lengths of
pipe without bends or tee shall be minimum 5 diameters on
upstream and 3 diameters on downstream side.
(i)
Material of construction of the wetted parts of flow meters

shall be suitable for functioning on treated / raw and
chlorinated water applications.
(j)
The flow meter shall be installed in such a way that it always

remains filled with water.
(k)
The flowmeter output signals shall contain the data for flow-
2163 of 2461
PAGE 7 of 200
MMRDA
rate and integrated flow readings. The output signal of the

flowmeter will be connected to Remote Terminal Unit (RTU) /
panel mounted Flow Indicator & integrator. The Contractor
shall comply with the compatibility requirements of flowmeter
with RTU which will be supplied by the SCADA Contractor by
providing industry standard digital communication protocol.
(l)
Empty Pipe detection feature shall be inbuilt with the Flow

Transmitter.
(m)
Technical Particulars of Electromagnetic Flowmeter:
1.
General
i)
Application
ii)
Service
: Raw
Potable
water
with
chlorine content.
iii)
Accuracy
: +/- 0.5 % of measured value
iv)
Power Supply
: 230 V AC
2.
Flow Tube
i)
Mounting
: In field on horizontal pipe lines
ii)
Material of lining of : Neoprene / Hard rubber

flow tube
iii)
Housing
: Corrosion protected
iv)
Grounding rings
: As required
2164 of 2461
PAGE 8 of 200
MMRDA
v)
Electrodes
: SS 316 L
vi)
Process connection
: Flanged
vii)
Weather protection
: IP-68
for flow tube

3.
Flow Transmitter / Computation Unit
i)
Type
: Microprocessor based
ii)
Weather
: IP-65
protection class
iii)
Output
: 4-20mA DC / pulsed output and

digital
output with RS 232/ RS 485
communication interface.
iv)
Display
on : 4 digit LCD / LED , for flow rate in
transmitter
for
flow
rate
m3/hr.
and
8 digit LCD / LED for totalized flow
totalised flow
v)
Unit of display
in ML.
: Flow rate M3 / hr
Totalised flow- ML
(Programmable)
vi)
Totalised flow
vii) Self-diagnostic
: To be stored in the memory

: Required
feature
2165 of 2461
PAGE 9 of 200
4.
MMRDA
Flow Indicator cum Totalizer
i)
Type
: Microprocessor based (Combined

unit for
flow rate and flow integration).
ii)
Display :
: Digital, back-lit LCD/ LED display
iii)
Digit Height
: 14 mm or higher
iv)
No. of Digits
: Flow Indicator: 4 digits
(Minimum)
v)
Flow Integrator: 6 digits
Input
: 4-20 mA DC (Isolated) from flow

transmitter
vi)
Zero & Span
: Required
Adjustment
vii) Manual Reset
: Required (Shall be key operated
Facility For Flow
with
Integrator
password protection)
viii) Engineering
Units For
Flow
m/hr
Rate
ML
Indicator
(Programmable)
Flow Integrator
ix)
Enclosure
: Non corrosive
material
x)
Enclosure
: IP-52
Protection
xi)
Accuracy
: 0.25% of span
2166 of 2461
PAGE 10 of 200
MMRDA
xii) Memory :
: Required
xiii) Retransmission
: 4-20 mA proportional to flow rate.
output
xiv) Alarm outputs
: For high and low flow alarms
xv) Mounting
: On control panel front facia
Calibration of Electromagnetic Flow Meters
The electromagnetic flow meter shall be calibrated for the full

flow range specified as per BS EN 29104 (Methods of
evaluation of electromagnetic flow meters). The calibration
method shall be either gravimetric method as per ISO 4185
(Measurement of fluid flow in closed conduits weighing
method) or volumetric method as per ISO 8316 (Calibration by
Volumetric Method). The test bed shall be accredited by
national /international certifying authority. The Contractor shall
produce accreditation certificates for the test facility and
calibration certificate for the flow meter for the review by
Employers
representative.
The
Contractor
shall
also
demonstrate complete calibration on the test bed in the flow

meter laboratory. The flow meter shall be acceptable if the
accuracy and repeatability is equal to or better than those
specified.
II.
Ultrasonic Flow Measuring System for Open Channels
a)
Open channel type flow measuring system shall consist of

Parshall flume/ Venturi flume /weir, ultrasonic level
measuring transducer, flow computer and flow transmitter,
flow indicator and flow integrator and any other item
required to complete the flow measuring system.
2167 of 2461
PAGE 11 of 200
b)
MMRDA
The level of the fluid in the flume/weir shall be measured

by the ultrasonic level transducer. The level measured
shall be used along with the physical characteristics of the
flume/ weir to compute the flow rate.
c)
The design and application of ultrasonic level transducers

shall take into account the channel construction, the
material, size, shape, environment, process fluid or
material, the presence of foam, granules, size etc.
d)
The
installation
shall
avoid
any
degradation
of
performance from spurious reflections, absorption, sound

velocity variations, sensor detection area, temperature
fluctuations, specific gravity changes and condensation.
For application where spurious reflections are unavoidable
the control unit shall be provided with facilities for spurious
reflection rejection.
e)
The structure required for supporting the level sensor,

platform, railings etc. shall be in the Contractors scope.
f)
The flow computer shall be microprocessor based and

shall have facilities for on-line diagnosis, entering data like
the type of channel, channel dimensions, engineering
units, measuring span, etc.
1. General:
i.
Type of channel
Parshall flume / Weir
ii.
Measuring Range
As per Process Requirement
iii.
Overall
of
accuracy 3 % of full scale with facility for
measurement range selection
loop
2. Level Measuring Unit:
i.
Type
Ultrasonic
2168 of 2461
PAGE 12 of 200
MMRDA
ii.
Mounting
Top of flow channel
iii.
Output
4-20 mA or pulsed
iv.
Enclosure Material Die Cast aluminium
v.
Enclosure
IP 65 of IS 13947 Part I
Protection
vi.
Integral cable with Required

sensor
3. Flow Computer and Transmitter

i.
Type
Microprocessor based
ii.
Mounting
Field
iii.
Input
From level measuring unit
iv.
Output
4-20 mA DC (Isolated)
v.
Enclosure
Protection
vi.
Programming
facility
Required
with
programmer
vii.
Display
Digital, Seven segment back-lit

LCD/LCD display
viii.
Flow rate -m3 / hr
Unit of display
Totalized flow ML
ix.
Facility
to
feed Required
data like the type

of
channel,
channel
dimensions, engg.
unit,
dead
band
etc.
x.
Enclosure Material Die Cast Aluminium
4. Flow indicator and integrator

Specification shall be as given under 4.of Technical
Particulars of Electro Magnetic Flow Meter.
2169 of 2461
PAGE 13 of 200
III.
MMRDA
Rate of flow measuring system for Filters
a)
In order to assess the filtration rate of individual filter, rate

of flow measuring device shall be installed. This device
consists of weir supported with level gauging on it with
capacitance type level measurements.
b)
This device shall be provided to each filter bed.
c)
The controller shall be installed in the valve gallery and

protected from being damaged.
IV.
Annubar Type Flow Measuring System for Air Flow

Measurement
Annubar
type
flow
meters
shall
be
provided
for
the
measurement of Air Flow measurement wherever applicable at

common discharge of Air Blowers. Annubar type flowmeters
shall be insertion type differential pressure (DP) type flow
meters that function on the average Pitot tube (APT) principle.
The insertion of the annubar type flow tube shall only require a
single pipe penetration.
The annubar tube shall be a single piece which when inserted
extends the full pipe diameter into the pipe. The tube shall tear
drop, T-shaped, or other proprietary design shape as patented
by a particular manufacturer. The side of the tube facing into the
flow stream shall have holes or slots designed to average the
flow distribution (Velocity profile) across the pipe cross-section.
The Annubar tube shall measure the mean velocity (The
weighted average of all flow velocities across the pipe diameter).
The annubar tube in conjunction with the flow transmitter and
integrator shall accurate measure the (i) differential pressure (ii)
static Pressure (iii) process fluid temperature to dynamically
2170 of 2461
PAGE 14 of 200
MMRDA
calculate the fully compensated mass flow. The accuracy of the

flow measurement shall be sized by the manufacturer for the
pipe diameter to be utilized.
The Annubar tube shall be made up of type 316 stainless steel.
12.4.2
Level Measurement
I.
Ultrasonic Level Measuring System
a)
Level measuring system shall be provided for all water

reservoirs.
b)
The Ultrasonic level measuring system shall consist of noncontact type level sensor, level transmitter unit and panel
mounted digital level indicator.
c)
Level measurement system shall consist of level transducer,

level transmitter, digital level indicator and any other items
required to complete the level measuring system. The output
of the level transmitter shall be connected to panel mounted
Digital Level Indicator.
d)
The Contractors scope of work shall consist of supply,

installation and demonstration of functioning of the level
measuring system after installation. The hardware required
for installation is in the Contractor scope.
e)
The level measuring system shall be designed for continuous

operation.
f)
The level transducer shall be installed on the top of reservoir /

tank by providing a suitable flanged nozzle. The Contractor
shall provide the required nozzle and the matching flanges.
2171 of 2461
PAGE 15 of 200
g)
MMRDA
Due care shall be taken in selecting the place of installation of

the level transducer. The location shall be such that the
ultrasonic beam does not get obstructed by the walls or any
structures / equipment in the reservoir.
h)
The level sensor and transmitter shall be properly protected

by providing heavy metallic covers for protection from
tampering.
i)
Temperature compensation shall be provided as necessary.
j)
The instrument performance and accuracy shall not be

affected due to spurious reflections, absorption, temperature
fluctuations, specific gravity changes and condensation.
Facilities shall be provided in the program of level transmitter
commissioning for rejection of spurious reflections.
k)
To reduce the effect of water turbulence in reservoir,

averaging facility shall be provided in the transmitter unit for
providing steady readings. Ultrasonic level measurement
devices shall be used incorporating integral temperature
compensation.
l)
Technical Particulars of Ultrasonic Level Measuring System:
1. General
i)
Service
Water level measurements in

RWPS, CWPS, WTP and each
MBR
ii)
Range
As Per the requirement of

Process
iii) Accuracy
5 mm or better
2. Level Sensor and Transmitter
2172 of 2461
PAGE 16 of 200
i)
MMRDA
Output
4-20mA, DC, 2 wire system

and Digital output with RS 232/
RS
485
communication
Interface.
ii)
Mounting
On the reservoir
iii)
Power Supply
24 VDC
iv)
Programming facility
Required
v)
Weather protection
IP 65
vi)
Local
Level reading in meters
display
3. Panel Mounted Display Unit
i)
Type
ii)
Display
Digital, back-lit LCD/ LED

display
iii)
Digit Height
14 mm or higher
iv) No. of Digits (Minimum)
3 1/2
v)
4-20 mA DC (Isolated) from
Input
level transmitter
vi) Zero & Span
Required
Adjustment
vii)
Engineering Units for
Meters (Programmable)
level
viii) Enclosure material
Non corrosive
ix) Enclosure Protection
IP-52
x) Accuracy
0.25% of span
xi) Retransmission output
4-20 mA proportional to level
xii)
For high and low level alarms
Alarm outputs
xiii) Mounting
II.
On Instrument panel front facia
Radar Type Level Measuring System
The radar type level measuring system shall consist of a radar type
level sensor, a level transmitter, prefabricated integral cable
connecting
the sensor and transmitter, surge protection
2173 of 2461
PAGE 17 of 200
MMRDA
devices and any other item required to complete the level

measurement loop.
The level sensor shall be suitable for flange or bracket mounting as
required. The installation shall avoid any degradation of instrument
performance
due
to
spurious
reflections,
absorption
and
condensation of the radar waves. A means shall be provided for

rejection of spurious reflections. The radar type level instrument
shall have the facility for dampening and averaging the effect of
waves, undulations on the water surface and discriminate the rate
of change of levels to provide steady readings. If required, the
Contractor shall provide a stilling pipe to ensure the provision of
steady readings with the prescribed accuracy.
A lockable enclosure shall be provided for level transmitters
mounted in the field. A metal cantilever platform shall be provided
for mounting of the level sensor and transmitter.
The radar type level measuring system shall have the following
design features:
Details
Description
General:
Accuracy
: 5 mm
Type of transmitter
Indicating type having backlit LCD or
Range
LED display
Output
4-20 mA, DC (Isolated)
Zero and span adjustment Required
Prefabricated integral
Required
cable between sensor

A means for suppressing Required
echoes from
interfering structures
2174 of 2461
PAGE 18 of 200
Integration
with
MMRDA
Local Required
SCADA system
Enclosure Material
Die cast aluminum (Non-corrosive)
connections SS type 316
Process
flange material
Weather
Protection
Class for transmitter

Lockable mild steel
Required
enclosure
class IP 65 of IS 13947 Part I
painted)
(epoxy
for
Accessories
with
weather
protection
sensor
(i) Mounting bracket
(ii) Name plate or Metal tag
Digital Level Indicator / Digital Panel Meter

Please refer above specification of ULT l.3 for DPI / DPM
III.
Level Detection
Conductivity probe type level sensors shall be used for the

detection of high and low values of water level.
a)
Conductivity type level switches shall be provided on all the

MBRs / tanks for generating alarm and control outputs.
b)
The conductivity type level switch shall consist of level probes

mounted on the reservoir / tanks Connected by suitable cable
to the conductivity controller unit for generating control actions
and high / low level alarms.
c)
The controller unit shall be electronic using ICs or

microprocessors. Both the electrode assembly and the
controller unit shall be suitable for field installation.
d)
The conductivity type level switch shall work on the principle

of detecting presence or absence of liquid between two
electrodes based on conductivity.
2175 of 2461
PAGE 19 of 200
e)
MMRDA
The Contractor shall provide extra lengths of electrodes and

adjust the length at site, as necessary.
f)
The level probes shall be installed on a flanged connection on

the reservoir. The Contractor shall provide the required
matching flanges.
g)
Stilling pipe shall be provided for level electrodes in order to

avoid the effect of water turbulence in the reservoir.
h)
The conductivity level switch shall function for normal

conductivity of water.
i)
Technical Particulars of Conductivity Type Level Switches:
A. Level probe
i)
Type
Rod type preferred. Above 3

met
rope
type
probe
is
acceptable.
ii)
Weather protection class IP 65
iii)
Probe material
SS 316
iv)
Probe head material
Non corrosive
v)
Insulation on the probe
Teflon
vi)
Counter weight for Rope Required

type probe to keep it
straight
vii)
Spacers
probes
entangling
between
to
with
the Required
avoid
each
other
viii) No. of electrodes
4 Nos. (very low, high, very

high and reference) for each
level probe.
2176 of 2461
PAGE 20 of 200
MMRDA
ix) Length of the electrodes
Suitable
as
per
the
requirement of process.
x) Stilling pipe
HDPE, Size to suit the level
(perforated)
probe assembly
xi) Working voltage type
230 V A.C
B. Level Controller Unit
i) Mounting
Wall / pedestal / inside control

panel
ii) Weather protection class
IP 65
iii) Alarm contacts
For
high,
very
high,
intermediate and low level.

iv) Contact rating
24 VDC, 2 A
v) Power supply
24 VDC / 230 VAC
vi) Material of enclosure
Non corrosive
vii) Sensitivity adjustment for Required

conductivity
12.4.3
Pressure Measuring System

I.
Pressure Gauges
a)
Pressure gauges and vacuum gauges shall comply with IS

3624 / BS 1780. Glycerine filled dial shall be provided where
the gauge is subjected to pressure pulsation and / or
vibrations.
The internal parts of pressure gauge shall be
stainless steel.
b)
Pressure gauges shall be provided on discharge and on

suction of each pump. Pressure gauges shall be bourdon type
and calibrated for the required range. The gauge shall be
supplied complete with impulse tubing, two valve manifold
with drain cock, fittings etc.
c)
The minimum diameter for pressure gauges shall be 150 mm.
2177 of 2461
PAGE 21 of 200
MMRDA
However, where the pressure gauge forms part of equipment,

the
equipment
manufacturers
standard
sizes
will
be
acceptable.
i)
Accuracy
+ 1% of full scale
ii)
Dial size
150 mm
iii)
Glass
Shatterproof
iv)
Measuring Range
v)
Over
range 125% of maximum pressure
Protection
vi)
Housing Material
Die Cast Aluminium
vii) Material of sensor SS 316

and
other
wetted
parts
viii) Accessories
2-valve manifold with drain cock,

impulse tubing, snubbers and all
installation hardware
II.
Pressure Transmitter
a)
Pressure measurement system shall consist of pressure

transmitter to be installed close to the water transfer line
and connected by impulse pipe. The output signal of the
pressure transmitter shall be connected to panel mounted
Digital Pressure Indicator.
b)
The Contractors scope of work shall consist of supply,

installation and demonstration of functioning of the
pressure
measuring
systems
2178 of 2461
after
installation.
The
PAGE 22 of 200
MMRDA
hardware required for Installation is in the Contractors

scope.
c)
The pressure measurement system shall be designed for

continuous operation and capable of operating in the
range of line pressures. The pressure transmitter shall be
suitable for field mounting.
d)
The pressure transmitter shall be of the diaphragm type. It

shall be provided complete with isolation valve, impulse
tube and two valve manifold.
1.
General
i)
Service
ii)
Accuracy
Pump discharge
of 0.5% of reading or better
measuring loop
2. Pressure Transmitter
i)
Sensor
Diaphragm Sensor
ii)
Material of sensing SS 316

diaphragm
and
other wetted parts

iii)
Range adjustment
iv)
Zero
and
Adjustable over full span
span Required
adjustment
v)
Output
4-20mA, DC, 2 wire system and

digital output with RS 232/ RS
485 communication interface.
vi)
Enclosure
IP 68
Protection
vii) Enclosure material
Die cast aluminium
viii) Accessories
Isolation valves, Impulse tubing

and all installation hardware
ix)
Over
range 2 times the full range
protection
2179 of 2461
PAGE 23 of 200
MMRDA
3. Panel Mounted Digital Pressure Indicator

i)
Type
ii)
Display
Digital, back-lit LCD/ LED display
iii)
Digit Height
14 mm or higher
iv)
No.
of
Digits 3 1/2
(Minimum)
v)
Input
4-20
mA
DC
(Isolated)
from
pressure transmitter
vi)
Zero & Span
Required
Adjustment
vii) Engineering Units
Meters of water column
for pressure
(Programmable)
viii) Enclosure material
Non corrosive
ix)
IP-52
Enclosure
Protection
x)
Accuracy
0.25% of span
xi)
Retransmission
4-20 mA proportional to pressure
output
xii) Alarm outputs
Mounting
III.
For high and low pressure alarms

On control panel front facia
Differential Pressure Measuring System
a)
Differential Pressure Measuring system shall consist of a

differential pressure transmitter and digital differential
pressure
indicator
and
any
other
items
required
completing the differential pressure measuring system.

b)
Differential Pressure Transmitter shall be rugged in

construction
and
shall
be
suitable
for
continuous
operation. Differential pressure transmitters shall be

designed for operation over 130% of full range.
c)
Differential Pressure Transmitters shall be suitable for field
2180 of 2461
PAGE 24 of 200
MMRDA
mounting. They shall provide 4-20 mA DC output

proportional to differential pressure. Transmitter output
shall be isolated and shall be suitable for transmitting over
long distance. Differential pressure transmitters shall have
high degree of weatherproof protection as specified in
technical particular.
1.
General
a)
Overall accuracy of 0.5% of measured value

measurement loop
b)
Measuring Range
2.
Differential Pressure Sensor and Transmitter
a)
Sensor
Diaphragm sensor
b)
Transmitter type
2-wire, Indicating type having

back-lit LCD/LCD display
c)
Material
Non corrosive
d)
Mounting
Field
e)
Range
Adjustable over full span.
f)
Zero and span
Required
Adjustment
g)
Output
h)
Accessories
Impulse tubing, fittings, valve

manifold with drain cock shall be
provided.
i)
Enclosure
IP-65 of IS 13947 Part I
protection
12.4.4
Temperature Measuring System

I.
Temperature Sensors
Unless otherwise specified, platinum resistance elements shall be

used for measuring spans of up to 200C and chromel-alumel
thermocouples for spans exceeding 200C.
2181 of 2461
PAGE 25 of 200
MMRDA
The accuracy for temperature meters shall be 0.03% of span.

In critical and important application, the temperature sensors shall
be of a dual type (Duplex) arrangement for easy replacement. Each
temperature sensor, unless otherwise specified, shall have a
stainless steel thermowell, or pocket-and- extension assembly,
non-corrodible metal sheath and waterproof terminal head. Pockets
for steam, oil and pressurized-water lines shall be welded; pockets
for other duties shall be screwed. The sensor assembly shall be
designed to permit removal of the temperature element without
twisting the leads.
Platinum resistance thermometers shall comply with BS 1041 and
BS EN 60751 or equivalent Indian Standards on the approval of the
Engineer. Sensors shall have a resistance of 100 ohms at 0C and
shall conform to the European standard curve (DIN 43720), where
Alpha = 0.00385. Each element shall be artificially aged during
manufacture. Terminal heads and amplifiers shall be designed for
four-wire connections between head and amplifier. Platinum
resistance elements shall be spring-loaded and fully encapsulated
in ceramic material and the elements and high-temperatureresistant lead wires shall be hermetically sealed. The associated
resistance-to-current
converters
shall
have
zero
and
span
adjustments and input-output circuit isolation.

II.
Temperature
Monitoring
for
Pump
&
Motor
by
Using
Temperature Scanners
Twelve (12) channel Temperature Scanners shall be provided to

measure high winding and bearing temperatures for each pump.
The high temperature signal shall be used for annunciation of
alarms and the very high temperature signal shall be used for
generating tripping (shutdown) signals. The input signals to the
temperature scanner shall be provided by industrial type PT100
2182 of 2461
PAGE 26 of 200
MMRDA
platinum resistance temperature detectors provided in the windings

and bearings. The temperature scanners shall have the following
design features:
Details
Description
Service
Motor winding and bearing and pump bearing

temperature measurements for each pump
motor in the raw water and clear water
pumping stations and for the backwash water
pumps
o
Range
0 to 200 C
Type
Mounting
On respective Instrument Control Panel
Accuracy
0.2% of range
Resolution
0.1 C
Input Signal
From RTDs for each pump motor set
Display
LCD / LED display, 4 digit for data and 2 digit
for channel Nos.

Scanning rate
Selectable
Communication
RS-485 (With Modbus protocol)
port for interfacing

Set point
2 set points (high and very high) for each

group of channels. A minimum of 3 groups of
channels shall be provided. A separate relay
shall be required for each set-point
Type of contacts
2 change-over contacts for each set-point
No. of channels
12 (6 for pump winding temperatures, 2 for

motor bearing temperatures, 2 for pump
bearing temperatures and 2 spares).
Programming
Through keyboard mounted on the front facia
Password facility
Required
Integration
Local
with Required
SCADA
system
2183 of 2461
PAGE 27 of 200
12.4.5
MMRDA
Permanent Vibration Monitoring System

Two (2) vibration switches, one on the pump casing and one on motor
casing of each pump, shall be provided for protecting the pumps from
costly destructive failure by initiating an alarm or shut-down when
excessive vibration of the machinery is detected. Vibration switches
can be either Electronic AC or DC powered switches or mechanical
switches, the main criteria shall be its durability and reliability. The
Contractor shall offer a complete vibration monitoring system using
these vibration switches as the primary sensors in addition to the
temperature scanners for monitoring the bearing and winding
temperatures of the pumps and motors. A suitable interface shall be
provided for transferring the data and alarms to the PLC and Local
SCADA system.
12.4.6
Portable Vibration Monitoring

A Portable vibration measuring equipment shall also be furnished for
measurement of pump and motor vibrations.
Details
Description
Type
Portable vibration meter
Range
Selectable
from
0-1
mm/sec,
0-10
mm/sec and 0-100 mm/sec

Frequency range
10hz to 10 khz
Display
LED/ LCD type, displaying instantaneous,

true peak, with m/s and mm/s2scales
Sensor (Accelerometer)
Piezo-electric type
Mounting Magnet
Required
PTFE Self-adhesive tape
Required
Power supply
Rechargeable battery operated
Memory for previous data
The instrument shall be capable of storing
storage and processing
records of measurement results
2184 of 2461
PAGE 28 of 200
MMRDA
Details
Accessories
Description
Mounting kit, shoulder bag, protective

cover, batteries (4 sets) and a battery
charger
12.4.7
Alarm Annunciators
Alarm annunciators shall be microprocessor based and provided for
generating audio visual alarms for each abnormal condition as
wherever defined. Alarms shall be initiated by the opening and closing
of volt-free contacts which shall remain unchanged throughout the
periods in which the alarm conditions exist. Alarm circuits shall be
capable of conversion from open-healthy to open-alarm or vice versa by
a simple modification after installation requiring no additional parts or
special equipment. Each alarm shall initiate the operation of both visual
and audible devices. The sound intensity of each audible device shall
be suitable for the maximum sound level of its environment, and shall
be adjustable by the user. The sequence of alarms shall be user
selectable by a dip switch. The operation or acceptance of one alarm
shall not inhibit the operation of the audible device or the flashing of the
appropriate alarm indicator if a separate alarm condition occurs. The
alarm circuitry shall be arranged so that spurious or transient alarm
states persisting for less than 0.5 seconds (adjustable) do not initiate
any action. Isolation facilities shall be provided for the hooter using an
MCB. The annunciator shall be of the split architecture type and the
facia shall have an LED readout.
Alarm annunciator shall be provided on instrument control panel for
annunciation of alarms in control room. The technical particulars of
alarm annunciator shall be as follows:
Details
Description
Type
Mounting
Flush with front panel
2185 of 2461
PAGE 29 of 200
MMRDA
Details
Description
Construction
Modular
Inputs
Potential free, NO/NC contacts
Size of windows
50 mm x 35 mm
Operating sequences
First up (user selectable dip switch)
Bulbs per channel
2 (Cluster LEDs)
Push Buttons
For Reset, Accept and Test
Hooter
Electronic type
Power supply status indication
Required
Integration with Local SCADA Required
system
Weather protection
12.4.8
IP 54 of IS 13947
Multi-Function Energy Meter (Intelligent type)

Multi-Function Energy meters shall comply fully with IS 722 or BS 5685
Class 2 and shall have industrial grade accuracy (2.5%). Three
element units shall be used for 3 phase 4-wire systems. Two element
units shall be used for 3 phase, 3-wire systems.
Quantity
1 No. for each pump and incomers of 3.3 kV (or

more) Switchboard (250 KW & above motors) as per
site conditions.
Purpose
Power and Energy Monitoring
It shall monitor voltage, current, kW, kVAr, kVA, power factor and
frequency.
Technical Particulars:
Data logging
Data storage and it shall be retrieved via RS 485 port

2186 of 2461
PAGE 30 of 200
MMRDA
Soft Integration
The meter shall be integrated with SCADA system to provide remote

display of all measured parameters and meter configurations.
The
metering shall be via. RS 485 port.

Measurement
True RMS measurement
Instantaneous phase voltages, line voltages, phase currents and
line currents
Frequency
Active, reactive, apparent powers and power factor per phase and
line
Energy-Import and Export
Maximum demand kVA, kW, kVAr
Communications
RS 485
Baud rates minimum 9600
Accuracy Class
0.5 S
Accuracy Standards
2187 of 2461
PAGE 31 of 200
MMRDA
IS-14697:1999
Front Panel Display
LCD with back lighting
Display for all basic power and energy parameters
Password protection for setup parameters
Ratings
Voltage Inputs
50 to 347 VAC
Accuracy VL-N: 0.25% reading
Accuracy Hz : +/- 0.1 Hz
Support 3 phase 3 wire, 3 phase 4 wire connections
Standard screw in terminals

Current Inputs
5 Amp. nominal
Accuracy current: 0.25% reading
20% over range full accuracy
Power Supply
2188 of 2461
PAGE 32 of 200
MMRDA
110 V to 240 VAC & VDC
Environmental Conditions
As per process Requirement- Ambient Temperature.
Humidity: upto 95% non condensing
Dimension: Appr. 969696 mm
12.4.9
Surge Protection Devices

Two (2) surge protection devices (SPDs) shall be provided for each
signal loop and power loop for field instruments located outdoors. One
SPD shall be provided in the field near each transmitter and the other
shall be mounted in the control panel. The SPDs shall be suitable for
withstanding the surge arising out of high energy static discharges and
lightning strikes and shall protect the instrument from any damage.
SPDs shall provide three (3) stages of protection through a quick acting
semiconductor like tranzorb, zener diodes, varistors and an automatic
disconnect and reset circuit. The SPDs shall be passive units and shall
require no power for operation. During the occurrence of a surge the
SPD shall clamp on the allowable voltage and pass the excess voltage
to the ground. The SPDs shall be of self-resetting type to minimize the
down time of the measurement loop. The SPDs shall have a
weatherproof casing and shall be suitable for field or back of panel
mounting. There shall be total isolation between the input, output and
ground terminals. Each SPD shall have a minimum surge rating of 10
kA.
12.4.10
Online Analytical Field Instruments

Online measuring Instruments for the measurement of water quality
shall be selected from a range of proprietary manufactured items.
2189 of 2461
PAGE 33 of 200
MMRDA
They shall be selected to fulfil as many of the aforementioned

instrumentation criteria as technically practical
Instrumentation shall be positioned in a covered location and shall
receive its sample from a continuous fluid stream in order to obtain a
representative sample of the fluid being monitored.
The Contractor shall provide all facilities necessary in order to obtain
the samples. Where pumping is required in order to obtain a sample a
single pump shall be provided except for raw water and combined
filtrate where a duty / standby sampling pump arrangement shall be
provided.
I.
Online Residual Chlorine Analyzer
The Contractor shall provide on-line residual chlorine meters for

measuring chlorine content.
i) Residual chlorine (RCl) measuring system shall consist of RCl
transducer, RCl transmitter, digital RCl indicator and any other
item required to complete the RCl measuring system.
ii) RCl transducer shall be rugged in construction and shall be
suitable for continuous operation. RCl transducer shall work on
Amperometric Principle. It shall also consist of an integral pH
sensor for compensating against pH changes and integral
temperature sensor for compensating against temperature
changes.
iii) A sampling system consisting of sampling pump / pressure
reducing valves, flow regulator, rotameter, filter assembly etc.
shall be provided. The sample water will be connected to a
cabinet containing RCl analyzer equipment and RCl transmitter.
iv) The RCl sensor enclosure shall be of such a design that it
2190 of 2461
PAGE 34 of 200
MMRDA
contains some water even when sampling flow is cut off and
shall be provided with flow regulating devices.
v) The RCl transmitter output shall be suitable for transmitting over
long distance.
vi) Technical Particulars of on-line Residual Chlorine Measurement
1. General
i)
Overall accuracy of
5% of measured value
measurement loop
2. Residual Chlorine Sensor
i)
Type
Amperometric
ii)
Automatic Temperature
Required
Compensation electrode
iii)
Automatic pH
Required
compensation electrode
iv)
Range
Adjustable over full span
v)
Sensitivity
0.1 mg/lit
vi)
Standard Cable Connecting
Required
sensor and Transmitter

3. Residual Chlorine Transmitter
i)
Type
Indicating type having

back-lit LCD/LED
display
ii)
Mounting
Field
iii)
Input
From Residual chlorine

sensor
iv)
Output
4-20 mA (isolated )
v)
Zero and Span Adjustment
Required
vi)
Enclosure material
Non corrosive
vii)
Enclosure Protection
IP-65
viii)
Range
Adjustable 0 to 5 ppm, 0
to 50 ppm.
2191 of 2461
PAGE 35 of 200
II.
MMRDA
On Line Turbidity Measuring System
a)
Turbidity measuring system shall consist of turbidity detector

assembly, turbidity transmitter, digital turbidity indicator, and
any other item required to complete the turbidity measuring
system.
b)
Turbidity
detector
measurement
shall
principle.
operate
Turbidity
on
detector
Nephelometric
shall
have
ratiometric measurement system and shall be suitable for

insertion / flow through type mounting. It shall be possible to
calibrate the turbidity meter at site, with a formazine standard
or a glass cube.
c)
Turbidity detector shall be rugged in construction and shall be

suitable for continuous operation. It shall have an integral
bubble trap arrangement.
d)
Turbidity transmitter output shall be isolated and shall be

suitable for transmitting over long distances.
e)
A sampling system consisting of sampling pump / pressure

cabinet containing Turbidity analyzer equipment and turbidity
transmitter.
1. General
Overall
accuracy
of 2%
measurement loop
2. Turbidity Sensor
Type
Optical sensor
Material For Wetted Parts Non corrosive

2192 of 2461
PAGE 36 of 200
MMRDA
Cleaning Facility
Required
Bubble Trap
Required
Measuring Principle
Ratio-metric
Color Compensation
Required
Range setting
Selectable
Calibration Standard
Required, Standard Formazine

solution or Glass cube.
Accessories
Standard
cable
for Required
connecting sensor and

transmitter
Standard Glass cube or
formazine
solution
for Required
calibration
3. Turbidity Transmitter
Type
Indicating with back-lit LCD /LED

display
Mounting
Field
Input
From Turbidity sensor
Output
Zero
and
Span Required
Adjustment
III.
Enclosure material
Non corrosive
On-Line pH Measuring System
a)
The pH measuring system shall consist of a pH electrode, pH

transmitter, digital pH indicator, electrode holder assembly and
any other item required to complete the pH measuring system.
b)
The pH transducer shall be rugged in construction and shall be

suitable for continuous operation. pH transducer shall include
measuring electrode, reference electrode, and a temperature
2193 of 2461
PAGE 37 of 200
MMRDA
compensator electrode. All wetted parts of the transducers

shall be of non-corrosive material.
c)
The pH transmitter output shall be isolated, and shall be

suitable for transmitting over long distances.
d)
The electrode holder assembly shall be of such a design that it

contains some water even when sampling pump is cut off and
shall be provided with flow regulating device.
e)
A sampling system consisting of sampling pump / pressure

cabinet containing pH analyzer equipment and pH transmitter.
i)
General
a)
Overall
accuracy
of 1% of measured value
measurement loop
b)
Standard pH solutions For pH 4,7 and 10 shall be

for onsite calibration
ii)
pH Sensor
a)
Type
provided
Encapsulated combined
electrode
b)
Mounting
On flow through assembly
c)
Automatic temperature Required

compensation
d)
Standard
cable
for Required
connecting sensor and

transmitter
iii)
pH Transmitter
a)
Type
Indicating type with Back-lit

LCD / LCD display
b)
Mounting
Field
c)
Input
From pH electrodes and
2194 of 2461
PAGE 38 of 200
MMRDA
temperature compensator
d)
Zero
and
span Required
Adjustment
e)
Enclosure material
Non corrosive
f)
g)
Output
4 to 20 mA(Isolated) for
connecting to pH indicator
iv)
12.5
Digital pH Indicator
: Required
WTP Plant Laboratory
The WTP shall be provided an administrative building that will house

the laboratory. The laboratory shall be equipped with instruments,
equipment, chemicals and other infrastructure that is necessary to
perform the routine analysis for the parameters.
WTP Contractor shall submit the complete list of lab equipments
required for full analysis of parameters to the Engineer for approval.
Contractor shall include in his offer supply of chemicals required for
analysis along with proposed lab instruments and associated
equipment, including for the O&M period as specified elsewhere in the
bid document.
Typical Laboratory equipments to be provided are detailed as below:
Ite
Description
Unit
Quantit
y
DPD Chlorine Analyser Digital
No.
Multi parameter (pH, DO & Conductivity
No.
No.
No.
Meter)
3
Turbidity meter - Bench Model
Turbidimeter - Hand held (Portable)
Photoelectric
calorimeter
2195 of 2461
PAGE 39 of 200
Ite
MMRDA
Description
Unit
Quantit
y
Spectrophotometer
6
Water bath with 6 to 8 concentric holes and
No.
discs, electrically heated

7
Hot plates
No.
25
Distilled water plant
No.
Refrigerator
No.
10
Muffle furnace
No.
11
Electric oven
No.
12
Analytical balance with weight box
No.
13
Jar-Test apparatus (Phipps & Bird)
No.
14
Centrifuge
No.
15
Gas cylinder if gas supply is not available
No.
16
Fume cupboard
No.
17
Equipment
No.
Needed
For
Bacteriological
Examination
18
Autoclave
No.
19
Incubator 37C or 44C (Water/Air-Jacketed)
No.
20
Pipette Box (Stainless Steel)
No.
10
21
Wooden Racks/Aluminium Racks
No.
22
Wire Baskets
No.
10
23
Test tube stand & Plastic toppers
No.
10
24
Burners (Bunsen) With Pilot Lamp
No.
25
Suction Flask (1 Litre Cap)
No.
26
Sampling Bottles
No.
10
27
Measuring Cylinders (1000 Ml, 500 Ml, 200
Set
No.
Ml, 100 Ml, 50 Ml, 25 Ml)

28
Vacuum pump
Bacteriological Media
29
M. Endo Broth (dehydrated)
No.
30
Lactose or Lauryl Tryptose broth
No.
31
Brilliant Green Bile Lactose Broth
No.
32
Peptone/Triyptone Water
No.
2196 of 2461
PAGE 40 of 200
MMRDA
Ite
Description
Unit
Quantit
y
33
Chemical Flask (250 Ml & 150 Ml)
Set
34
Volumetric Flask (100Ml,250 Ml,500Ml &
Set
1000 Ml)
35
Nestler tube (50Ml & 100Ml)
Set
36
Pipetts 10Ml (Graduated), 1Ml, 5Ml
Set
37
Plastic cans
Set
38
Distilled Water Washed bottle
Set
39
Sampling
pumps for
No.
including
piping
Set
LOT
Laboratory sample
arrangement
with
other
accessories at minimum four locations as

follows: Raw water, Settled Water, Filter
Water and Chlorine contact tank etc.
40
Furniture for Laboratory Room suitable with

Anticorrosive material
The equipment shall be supplied with all the accessories that are
necessary to make the equipment functional for analyzing parameters.
Contractor can offer additional equipment if necessary.
I.
UV Visible Pre-programmed Spectrophotometer
UV Visible Pre-programmed Spectrophotometer for measurements

of water Quality parameters and Spectral Analysis Shall be preprogrammed for more than 150 parameters for common drinking
water testing parameters like residual chlorine, Iron, Hardness,
alkalinity,
fluoride
and
sulfate
etc.
The
spectrophotometer
instrument shall be a multi-wavelength, UV-Visible, single beam

spectrophotometer designed for Water analysis. The instrument,
depending on the test selection, shall automatically select the
wavelength.
Readout
modes
shall
include
transmittance,
absorbance,
concentration, optional wavelength scan and time course graphs.

2197 of 2461
PAGE 41 of 200
MMRDA
Spectrophotometer should come along with the following reagents

and accessories: Power supply, Operators manual, one pair 10mm
rectangular path length cells and reagents for common drinking
water parameters like residual free chlorine, Iron, sulfate, silica Low
range and Fluoride for 1000 tests.
Technical Specifications
Wavelength Range
190- 3300 nm
Spectral Band width
4nm
Lamp type
xenon flash lamp
Durability
5x 108 fleshes, corresponding to at

least 13000 h permanent operation
Monochromator type
Grating Monochromator with step

motor
Wavelength calibration
Automatic
Max. scan speed
Approx. 3300 nm/min.
Light sensor
Photodiode
Photometric
measuring :
3.3 A
range
II.
Colorimeter/Photometer
The instrument shall be capable of colorimeter tests for more than

90 parameters, from aluminum to zinc for testing natural waters.
The instrument should be designed specifically for field testing. The
instrument shall be water proof, dust proof and should have a
2198 of 2461
PAGE 42 of 200
MMRDA
chemical resistant housing. The instrument should have simple,

push-button program selection and step-by-step prompts that guide
users through each testing procedure.
Technical Specifications:
Wavelength Selection
Auto select
Photometric Range
0 to 2 A
Operational Modes
Concentration, ABS, %T
Concentration Unit
ug/L, mg/L, g/L, ABS, %T
External Outputs
RS 232 via Data Transfer Adapter

(optional)
Data logging
50 sample readings (each reading

includes
date/time,
program
number
absorbance,
parameter,
concentration,
transmit-tance,
sample number, instrument serial

number)
User programs
Five user-entered programs, 12

data points each
Display
Large liquid-crystal display (LCD)

displays results, parameter name,
and units
Power
Storage
:
Temperature :
4 AA alkaline
-40 to 60 deg.C
2199 of 2461
PAGE 43 of 200
MMRDA
Range
Operating
Temperature :
0 to 50 deg. C
Range
Environmental
Meets IP67 standard, dustproof and

waterproof to one meter for at least
30 minutes
III.
Laboratory p H Meter
Instrument should able to give quick and easy pH measurements.

Instrument should have large LCD display. Instrument should have
RS232 interface with data logging facility.
Range: pH: -6.00 to 20.00, mV: -2000 to 2000 mV, Temp: -10.0 to
120.0C
Resolution: pH: 0.01 pH, mV: 1.0 mV, Temp: 0.1C
Accuracy: pH: 0.01 pH, mV: 0.05 % full scale 1LSD, Temp:
0.5C
IV.
Bench Top Multi Parameter Meter
A multi parameter instrument capable of analysis of
pH, ORP,
dissolved oxygen, conductivity, TDS, salinity and temperature shall

be provided. The instrument shall be capable of a quick response
and have a intuitive user interface. The instrument shall have
automatic temperature correction/compensation. Downloading and
storage of data should be easy and convenient .It shall provide RS232 interface and shall have a minimum of 150 points recall feature.
Technical Specifications:
2200 of 2461
PAGE 44 of 200
MMRDA
Range: pH : - 2.00 to 19.999

ORP: 2000 mV
mV: 2000 mV
Conductivity : 0 to 199.9 S/cm;
200 to 19,999 S/cm;
2 to 199.9 mS/cm;
20 to 199.9 mS/cm.
TDS : 0 to 50,000 mg/L as NaCl
Salinity: 0 to 42 ppt (%)
Dissolved Oxygen: 0 to 20.0 mg/L (ppm); 2 to 100%
saturation
Temperature : pH Test: -10 to 330 C (-50 to 230 F)
Cond. Test: -10 to 105 C
DO Test: 0 to 50 C
Resolution: pH : 0.1/0.01/0.001 (selectable)
ORP : 0.1 mV
mV: 0.1 mV
Conductivity: 0.00 to 19.99 S/cm; 20.0 to 199.9 S/cm; 200 to
1999 S/cm; 2.00 to 19.99 mS/cm; 20.0 to 199.9 mS/cm; 0.01
S/cm; 0.1 S/cm; 1 S/cm; 0.01 mS/cm; 0.1 mg/L; 1 mg/L; 0.01
g/L; 0.1 g/L
TDS : 0.00 to 199.9 mg/L; 200 to 1999 mg/L; 2.00 to 19.9 g/L; 20.0
to 50 g/L; 0.1 mg/L; 1mg/L; 0.01 g/L; 0.1 g/L
Salinity: 0.1 ppt
Dissolved Oxygen : 0.01 or 0.1 mg/L; 0.1% saturation
Temperature : 0.1 C
Accuracy: pH: 0.002
ORP: 0.2 mV or 0.05% of reading, whichever is
greater.
mV: 0.2 mV or 0.05% of reading, whichever is
greater.
Conductivity: 0.5% of range
2201 of 2461
PAGE 45 of 200
MMRDA
TDS: 0.5% of full scale

Salinity: 0.1 ppt (-2 to 35 C)
Dissolved Oxygen: 1% full scale
Temperature: 0.3 C at 0 - 70 C;
1.0 C at 70 - 330 C
V.
Laboratory Turbidity Meter
Turbidity
meter
shall
have
pre-programmed
features
for
measurement of turbidity with ratio color correction covering the

range from 0 to 10,000 NTU with auto signal averaging. Turbidity
meter should come along with the following accessories: A
complete set of calibration standards (0.02, 10, 100, 1750 NTU),
Two measuring corvettes with light shield caps, Operators manual,
and plug in power adaptor
Technical specifications
Principal of operation: Nephelometric

Light Source: Infra red
Extended auto ranging up to 10,000 NTU
0 - 2,450 EBC
0 - 10,000 FNU
0 - 10,000 FAU
Resolution: 0.0001 NTU on lowest range
Accuracy: 2% to 10% of reading (in 3 ranges)
Response time: less than 6 seconds
Sample size: 30 ml
Air purge: connection for external dry air supply
Auto alert calibration prompt.
Outputs: RS-232 Serial Port
Reusable Calibration Standards
Certification: UL, CSA, CE, ISO7027
Instrument should have option for connecting flow thru cell.
2202 of 2461
PAGE 46 of 200
VI.
MMRDA
Portable Turbidimeter
The instrument should have microprocessor-control operation and

Ratio optics to bring greater accuracy, sensitivity and reliability to
field testing. The instrument shall compensate for color in the
sample, light fluctuation and stray light, allowing analyst to achieve
laboratory-grade performance on a wide range of samples, under a
wide range of conditions.
Ranges
: 0 - 1000 NTU in automatic range mode; 0-9.99, 0-
99.9 and
Accuracy
0-1000NTU in manual range selection.

: 2% of reading or 1Least significant digit up to 500
NTU
3% of reading above 500 NTU to 1000 NTU
Repeatability
1% of reading or 0.01NTU, whichever is
greater.
Resolution
: 0.01 NTU on lowest Range
Stray Light
: < 0.02 NTU
Sample required : 15 ml
VII.
Dissolved Oxygen Meter
Meter should be microprocessor based hand held type instrument

with rugged & field proven design and should be easy to operate
with less maintenance.
Dissolved Oxygen meter should come
along with the following:

12FT cable and probe
2203 of 2461
PAGE 47 of 200
MMRDA
Battery Alkaline 4NOS 1.5V EACH

Instruction Manual
Hardware Kit Fitted
Kcl soln,
Membrane, O-RING SET
Range
Accuracy
Dissolved
0 20 mg/L, 0 200
Oxygen
% air
Temperature
- 5 to 45o C
Dissolved
0.3 mg/L, 2%.
Oxygen
Resolution
Temperature
0.4o C
Dissolved
0.01 mg/L, 0.1% air
Oxygen
Temperature
Dissolved
Oxygen :
0.1 o C
Steady-state polarographic
Sensor
Salinity
Desired
Desired
Automatic
Power
Battery operation
Cables
12 feet or more
Other features
Backlit Display
compensation
Altitude
compensation
Temperature
Compensation
Built-in calibration chamber Waterproof,

2204 of 2461
PAGE 48 of 200
MMRDA
IP 65
VIII.
Residual Chlorine Meter
The instrument should be a handy model which should be capable

of analyzing three water quality tests. Instrument should be simple
to use and should display error messages as and when they occur.
The instrument should be pre-programmed to conduct the following
tests:
pH 6.8 8.6
Chlorine 0 5.0 ppm
Alkalinity 0 500 ppm In addition, Instrument should include the
following: In transclam packing with reagents for 100 free chlorine
tests, Crushing rod and 2 test cells. The instrument should be
provided with an operations & instructions manual.
IX.
Associated Lab Equipment

a) Sterilizer, Autoclave
Purpose: For sterilization of glassware and culture media for

bacteriological analysis.
Double wall construction with inner & outer chamber made of
Aluminum. Electrically heated by means of superior quality
emersion heaters with working pressure 15 PSI. Inner Chamber
Size: 550X750mm. Rating: 6.0 KW, Volume: 175litre.
b) Balance, Analytical (Electronic)
Purpose: For preparation of standard solutions used in
chemical analysis.
2205 of 2461
PAGE 49 of 200
MMRDA
Specifications: Should be based on E.M.F.C. Technology
Type: Electronic single Pan, Capacity: 200 mg, Resolution: 0.1

mg, Stainless steel weighing pan; Pan size: 100 mm Diameter,
Display: Sharp, Clear LED Display and Standard bi-directional
RS232C interfaces. Multiple weighing Units: Grams & Carat. It
should have auto calibration facility, Overload protection and
auto zero facility. Balance should come along with Set of
certified calibration weights, Voltage stabilizer, Dust proof cover,
Operational manual and necessary tools.
c) Incubator Bacteriological
Purpose: For incubation in bacteriological analysis

Double walled cabinet. Outer wall should be made of mild steel,
inner wall of stainless steel, lagged with a special insulating
material. The inside door should be made of glass panel set in a
metal frame fitted with a felt gasket and be fastened by a ball
catch.
Temperature range: 5C above ambient to maximum 60C.
Accuracy: 2C
Size: 600X600X600 cm
Rating: 1000 Watts
d) Refrigerator
Purpose: For cooling and storage of (standard) solution in a
laboratory
2206 of 2461
PAGE 50 of 200
MMRDA
Specifications:
Type
Vertical double door
Capacity
approx.280 litre.
e) Water Bath, General Purpose
Purpose: For enhancement of chemical reaction in various

analyses and evaporating of water from samples
Specifications:
Doubled walled construction Fitted with imported thermostat of

30 Deg C to 330 C Accuracy of +/- 1 Deg C.Working Temp.
from 5 Deg C above ambient 80 C made of double wall,
stainless steel construction, with glass wool Capacity: 15 Ltrs,12
holes of 75 mm dia , 2000 Watts
f) Ware Purifier, Distillation Unit (Automatic)
Purpose: For generation of reagent water type III which is used
for washing and quantitative analysis.
Made of stain less steel, vapor baffle, condensing tube and lid
are stainless steel
This is fitted with immersion type element.
The stopcock fitted to the unit.
The still is provided with wall mounting iron bracket to be fixed
on the wall which the still can rest.
Supplied with 3 core wire and plug to work on 220 Volts AC
2207 of 2461
PAGE 51 of 200
MMRDA
Capacity: 2 Litre
Load: 2 K.W
Low water cut-off device for 2 liter and 4-litre cap.
12.6
Approved Vendor List for Instrumentation
S.
Description
Vendor / Manufacturer
No
1
/ Make
Level Transmitters
M/s EMERSON
M/s ABB,
M/s Siemens
M/s Endress+Hauser
M/s Yokogawa
Flow
meters/Flow
Indicator/ M/s ABB
Transmitter (Electromagnetic flow M/s Siemens

meter & Open Channel Ultrasonic M/s Yokogawa
Flowmeter
M/s Endress+Hauser
M/s Krohne Marshall
M/s Millitronics
Level/Float Switches
M/s EMERSON
M/s ABB
M/s SBEM
M/s Endress+Hauser
M/s Pune Techtrol
Pressure
Gauges/Pressure M/S Warree
Switches
M/S ABB,
M/s Wika
M/s Gen Inst Co
M/s Switzer
M/s Dandfoss
2208 of 2461
PAGE 52 of 200
S.
MMRDA
Description
No
5
/ Make
Pressure Indicator Transmitter
M/s EMERSON
M/s ABB,
M/s Siemens
M/s Endress+Hauser
M/s Wika
Online Residual Chlorine Analyzer
M/s Hach Company

M/s Yokogawa
M/s EMERSON
M/s WTW
Temperature
Indicator M/s Endress+Hauser
Transmitters
M/s ABB
M/s Siemens
Analytical Online Instruments and M/s Hach Company

other Lab Instruments
M/s EMERSON
M/s WTW
Temperature Scanner, DPM
M/s Masibus
& Alarm Annunciator
M/s Minilec
M/s Peacon
M/s Nishco
10
Multi-Function Energy Meter
M/s Enercon,
M/s L&T
M/s Masibus
11
Cables
M/s Polycab
M/s Universal
M/s Havells
M/s Finolex
M/s
KEI
Wires
and
Cables
12
Fiber Optical Cable
M/s Finolex
M/s Polycab
M/s Ericson
M/s Molex
2209 of 2461
PAGE 53 of 200
S.
MMRDA
Description
No
/ Make
M/s Optel
M/s Sterlite
13
Surge
Protection
Devices
/ M/s Hensel
Lightning Protection Units
M/s Phoenix
M/s Crompton Greaves
M/s MTL Instruments
M/s Pepper & Fuchs
M/s Cirprotec
M/s MH Instruments
14
Digital Panel Meters, Temperature M/s Masibus

Scanners,
Flow
Indicator
and M/s Alan
Totalizer, Alarm Annunciators
M/s Omron
M/s NISHKO
15
Vibration Monitoring system
M/s Krohne Marshall

M/s IRD
M/s Time
16
Annubar
M/s EMERSON
17
RPM Meter
M/s Jayshree Electric

M/s Proton
M/s Kana Electric
18
Magnetic type level Indicator / Magnetrol, General

Gauge
Instruments, Pune
Techtrol, SBEM
19
Portable Noise Meter
CYGNET,
HTC,
Sigma,IRD
20
Portable Vibration Meter
CYGNET, HTC, Sigma,

IRD
2210 of 2461
PAGE 54 of 200
12.7
MMRDA
Particular Requirements for Programmable Logic Controllers

(PLC) and Supervisory Control and Data Acquisition (SCADA/HMI)
This part covers the Particular requirements for the design, supply,
installation, Inspection and testing of Programmable Logic Controllers
(PLC) and Supervisory Control and Data Acquisition (SCADA/HMI) and
associated plant and materials.
12.7.1
All equipment shall comply with all applicable national and local laws
regulations and standards, in addition to those listed below:
A. ISO 9000 and 09004
- Quality Systems
B. IEEE 587
- Power Supply Surge Protection
C. IEC 63331-3
- Programming Languages for
Programmable Controllers.
D. IEC 63358-2
- Communication Protocols
E. ISO 9075 (BS 6964)
- Structured Query Language (SQL)
F. BS 5515
- Documentation of Computer Based
Systems
G. BS 7165
- Recommendation for Achievement of
Quality in Software
H. BS EN 50081
- Electromagnetic Compatibility
I. ISO 3533
- Process measurement control functions -
instrumentation
symbolic representation.
2211 of 2461
PAGE 55 of 200
12.7.2
MMRDA
J. ISO-OSI
- 7 Layer Communication Model
K. IEEE 472-1974
- Surge protection.
L. IEC 61850
- PLC sub-station automation protocol.
M. IEC 8705101
- Modbus protocol conversion
The Contractor shall provide a list of the reference standards used and
shall provide a compliance/non-compliance statement during the Bid
submission, and FDS submission. Failure to do so will be treated as a
non-responsive bid. Contractor should take note on the importance of
this obligation.
12.7.3
Quality Assurance
The Manufacturers shall be operating under an accredited ISO 9001
Quality System.
All hardware and software proposed shall have been successfully used
in a similar water application for period of at least five (5) years.
Upgrades and improvements to the manufacturers standard system
that are released before the expiration of the warranty period shall be
supplied, installed and commissioned at no additional cost.
These shall include all hardware and software necessary to implement
the upgrade, including telemetry for future expansion.
12.7.4
Control System
This section outlines the particular requirements for the control
systems. Unless specified in this section to the contrary control system
2212 of 2461
PAGE 56 of 200
MMRDA
Plant provided by the Contractor and workmanship shall comply with

the General Chapters of these Requirements.
i) Introduction
The pumping stations (RWPS & CWPS), treatment plant (WTP) &
each MBR control system shall be based on the use of
programmable logic controllers (PLCs), which shall be configured
with hot-standby CPU. These shall be distributed throughout the
treatment plant and be dedicated to specific control areas.
Secondary PLC s or remote input/output modules (RI/O modules)
may also be used to link remote areas of a given process. Or the
smaller processes in order to save on the amount of cabling
required or for other practical reasons.
The PLCs and Input/output modules used for the Works shall be
from the same manufacturer and series and shall as far as be
practical allow for the interchange of plug in parts.
The PLCs and the central HMI shall be linked over dual line local
area network (LAN) which shall be established on optic fiber cable
with a single mode glass type.
A general arrangement of a typical control system is shown in the
Drawings.
The control systems shall recover fully to a normal operational state
on restoration of the power (either from the mains or the generator)
after a power failure without manual intervention. (i. e. to remove
doubt this requirement refers to a real failure of power to the control
system such as would be experienced if the control system UPS s
were not present).
The pumping stations (RWPS& CWPS), treatment plant (WTP) &
each MBR shall be designed with a combination of manual and
2213 of 2461
PAGE 57 of 200
automatic
systems.
MMRDA
Where
automatic
systems
result
in
improvements in plant operation, reliability or water quality they

shall be used otherwise manual systems shall be employed.
In all cases, facilities shall be provided to permit these automatic
controls to be overridden and the systems to be manually
controlled. Local manual controls shall be located adjacent to Plant
where required for day to day operation. All drives essential for the
continuous operation of the plant shall be provided with a standby.
The process control system must be state-of-the-art in terms of
structure and function as a process information and control system
and its hardware and software must be future-oriented. The control
system should be a modern system with an appealing user
interface, open to the office and process world, with sophisticated
and reliable functions, efficient to configure and scalable for simple
and complex tasks. It must also be usable and supported
worldwide.
Industrial Grade PCs are to be used as the operator control
stations and server stations.
If the project grows, it must be possible to carry out a no-cost
upgrade of the amount of variables at any time, i.e. the priceoptimized start-up and later expansion is only slightly more
expensive than immediately using the larger solution. The
communication channels for the connection to the Programmable
logical controllers via various communications media must be
included in the scope of delivery of the control system, the same
applies to drivers for simple types of coupling such as point-to-point
via the MPI interface. In addition, it should be possible to establish
the coupling to other devices and applications from various
manufacturers via the standardized software interface OPC.
In addition to the basic packages, it must be possible to expand the
2214 of 2461
PAGE 58 of 200
MMRDA
system by means of the option packages listed below. These must

be integrated into the user interface, i.e. a switchover between
various applications using standard controls such as Alt-Tab or CtrlEsc is not permitted for safety reasons.
ii) Hardware
The control system hardware shall consist of field controls which

comprises:
-
PLC s;
power supplies;
local HMIs;
field cabling interfaces

and central controls which comprises:
central HMI and auxiliaries;
engineering station;
LCD type large screen(Min 62);
Operator Work Stations (Min 32);
Uninterruptible power supply.
The site instrumentation shall also form an integral part of the

control system.
The equipment detailed in the aforementioned field controls list
(with the possible exclusion of the power supply) and some
components of the instrumentation system shall be housed within a
number of control panels
(CPs). Each panel shall be located
adjacent to or form an integral part of a motor control centre or

switchboard associated with the plant being controlled.
The control panels shall provide separate areas for the PLC,
internal power distribution, instrumentation, field cabling and for any
surge (lightning) protection devices (SPD s).
A separate
instrumentation earth (a clean earth) shall be established within

2215 of 2461
PAGE 59 of 200
MMRDA
the control panel. Instrumentation and control cable screens shall

be connected to this earth.
The central controls (SCADA / HMI) shall be located in the Central
Control Room for the treatment plant and SCADA / HMI shall be
Located in Local Control Room for the Pumping Station (RWPS &
CWPS) and each MBR with Panel Mounted HMI.
iii) Power Supply
The control system shall be powered from a number of

uninterruptible power supplies (UPSs).
These shall be sized to
provide sufficient power to maintain the control system and Online

Field Instrument (except water quality monitoring instrumentation)
systems functioning for a period of not less than 60 minutes.
The UPS for use with each CP may be free standing or integral with
the CP and shall derive their primary power from the CP.
The status of each UPS shall be monitored and an alarm raised via
the control system if a fault occurs or the UPS battery supply is
about to expire.
iv) Voltages
The following control voltages shall be used:
Item
Voltage
1. within starter enclosures

2.
instrumentation
240 V AC
power 240 V AC / 24 V DC
supplies
3. PLC inputs cards
24 V DC
4. PLC outputs
24 V DC
2216 of 2461
PAGE 60 of 200
MMRDA
v) Control System Protection

a) Short Circuit
All circuits shall be protected against short circuit by the

provision of adequate numbers of fuses or miniature circuit
breakers.
For ease of maintenance and system security power supplies to
each instrument loop and each PLC output shall be protected
with an individual fuse (terminal type).
b) Surge Protection
Surge protection devices (SPDs) shall be provided at the control

panel end of all instrumentation and control cables which run for
distances in excess of 50 m outside the confines of the building
in which the CP is housed. The SPD s shall be grouped in a
specific area within the CP to ensure dirty signal cables do not
come into direct contact with clean signal cables.
12.7.5
Contractor submittal Procedures

I. Functional Design Specification (FDS)
The Functional Design Specification (FDS) shall be submitted to

the Engineer within 3 months of the award of contract and
approved before manufacture and purchasing commences. The
system vendor and/or Contractor shall include the following
material as a minimum:
a. Project
Overview,
design
concept,
criteria
and
system
architecture
b. Description of the design and design criteria.
2217 of 2461
PAGE 61 of 200
MMRDA
c. Details of associated equipment.

d. Plant
Operating
Screens
(mimics),
Functional
Design
Specification.
e. Electrical Design Specifications
f. Quality Plan.
g. Outline of acceptance test procedures (FAT & SAT).
h. Implementation program for manufacture, installation and
commissioning.
i.
Manufacturers literature for each item of equipment supplied.
j.
Outline of factory and site acceptance test procedures
II. Drawings and Documentation
1. All drawings of telemetry and instrumentation control and

Automation (ICA) equipment shall be on A3 or A4 size sheets,
with title blocks approved by the Engineer.
2. Signature of the Contractors authorized representative to
indicate the drawings have been checked prior to submission.
3. The text of all drawings and documentation provided by the
Contractor shall be in the English Language.
III. Contractors Drawings
1. The Contractor shall submit 3 (three) reproducible copies plus

two
photocopies
of
general
2218 of 2461
and
detailed
dimensioned
PAGE 62 of 200
MMRDA
arrangement drawings, schematics and wiring diagrams of all

major items of Plant, for the Engineers approval Manufacture of
an item of Plant shall not commence until the associated
drawings have been approved in writing by the Engineer.
2. All modifications or revisions to drawings shall be clearly
indicated and the revision reference changed.
3. Drawings affecting work by other disciplines shall be provided to
the Engineer, within 6 weeks from the date of enterprise.
4. Drawings for electrical equipment shall include:
a. Manufacturers general arrangement drawings for all items
showing clearly the position of all cable glands and main
components including, where appropriate, foundation plans,
showing the position of all holes required for fixing bolts and
cables etc.
b. Manufacturers schematic diagrams and connection diagrams
for all items showing all internal wiring and terminal
connections, suitably referenced. Connection diagrams shall
include existing and proposed outgoing cable connections.
c. General layout of plant showing cable routing.
d. Block diagram showing all plant, cable runs and cable
reference numbers.
e. Cable schedules giving full details of use, destinations, size
and number of conductors, grade, class and length.
f.
Layout of grounding facilities.
g. Proposed arrangements for cables laid below ground

2219 of 2461
PAGE 63 of 200
MMRDA
showing identification references, voltage, depth of laying,

route and length, crossings with other services, location of
any joints and position of ducts, with cross sectional
arrangements.
5. The Contractor shall modify existing drawings to show the
modifications. If suitable existing drawings are not available the
Contractor shall provide drawings showing the modifications.
IV. Record Drawings
1. As part of the Works and before Taking Over, the Contractor

shall provide and forward to the Engineer, a complete set of
drawings comprising two original size permanent transparency
and six paper prints, of all final drawings of the Works as
installed,
schematic
wiring
diagrams,
panel
wiring
and
connection diagrams, cable route diagrams and schedules and

any other special drawings which have been prepared during
the course of the Contract. The Contractor will also provide
drawings on computer disk in AUTO CAD (Latest Version), for
the modification and printing of drawings. Also all drawings have
to converted in to PDF files and stored in the Engineers
workstation.
V. Training Plan and Manuals
1. As part of the Works and before beginning training, the

Contractor shall submit to the Engineer, 6 copies of complete
operating and maintenance instructions for the system, referring
specifically to the Plant. The documents will also be presented
on computer disk in Microsoft Office 2003/2007 Word or latest
version available for Windows software format and manual
should also be prepared in local regional language i.e.in Hindi.
2. Each copy of the instructions shall be contained in a substantial
2220 of 2461
PAGE 64 of 200
MMRDA
binder.
3. These manuals shall include but not be limited to the following
information:
-
Detailed descriptions of the Plant operation and control

scheme
Manufacturers
original
operation
and
maintenance
procedures
-
Complete parts list for all items of the Plant
Recommended spare parts list
Detailed maintenance instructions for all items as necessary

to maintain the items in good working order, including all
step-by-step
procedures
for
troubleshooting
and
fault
correction
-
Configuration of data base, reports, logs and screen displays
Data communication interface standards and protocols
All ladder logic and control loop flow diagrams
Programme user instruction for all software
The
system
shall
provide
on
line,
complete
user
documentation, including examples of how to operate the

various modules within the system. The documentation must
be in electronic format, HTML based with the ability to search
for topics by keyword or search for specific text
12.7.6
Approved Vendor List for Automation
2221 of 2461
PAGE 65 of 200
S.
MMRDA
Description
Manufactures/Makes
N
o
1
Workstations, Servers
Programmable
Dell, HP, ,Lenovo
Logic Schneider Electric (Quantum Series),
Controllers
Siemens
PLC(S7-400H
Rockwell
(Control
Logic
series),
series),
Mitsubishi
3
SCADA
Programming Vijeo
Software
4
Citect,
Intellution
IFix,
Wonderware, Win CC , Mitsubishi
Control
Panels
/ Rittal, Pyrotech, Hoffmann
Enclosures
5
Monitors / Display Screen
Samsung , LG
UPS
Emerson, APC, Hirel, Nelco, Aplab,

DB Electronics
Printers
HP, Canon
System Console
Godrej,
Fire & Alarm Systems
Siemens,
Honeywell,
Xtrails,
Edwards, Simplex,
I
Intelligent Detectors(Photo Siemplex, Notifier, Edwards, Siemens

electric,heat,thermalUL/FM/ULC approved)
Ii
Intelligent
Fire
Alarm Same as above
Control Panels
Iii
Addressable manual call Same as above

points including handsets
Iv
Monitor
modules,
fault Same as above
isolation modules, control

modules
V
UV flame detector
Same as above
vi
Beam Detectors
Same as above
10
EPABX System
Panasonic, Samsung, Matrix, Betel
11
V-SAT
i-Direct
2222 of 2461
PAGE 66 of 200
S.
MMRDA
Description
Manufactures/Makes
N
o
12
Radio Modem
ELPRO/MTL,
Prosoft
Technology-
USA, Calamp-USA
13
Wireless Gateways
ELPRO/Calamp/Teletronics
14
CCTV
Siemens,
Honeywell,
NELCO
LIMITED
a.
CCTV CAMERA
BOSCH, PELCO, SANYO,, SHARP,

SONY, SAMSUNG
b.
CCTV MONITOR
SHARP,
HITACHI,
PHILIPS,
LG,
SONY, SAMSUNG, SANYO

c.
CCTV CABLES
POLYCAB,
FINOLEX,
THERMOCABLE
12.7.7
Particular Specification for PLC & SCADA / HMI

The purpose of this part of the Specification is to define the basic
requirements
for
microprocessor-based,
programmable
logic
controllers (PLC) integrated in to control system and Supervisory

Control and Data Acquisition System (SCADA) intended for RWPS,
CWPS, WTP and each MBR.
I. Programmable Logic Controller (PLC)
A. Design and Construction Requirements
PLC shall be provided as a Hot-Standby configuration to perform

combinational and sequential logic functions, status monitoring
and reporting functions with counter and timer facilities.
PLC Panel interrogation power supply should be fully redundant.
PLC shall comprise of necessary processors, input/output (I/O)
modules, RIO Modules, communication interface modules and
2223 of 2461
PAGE 67 of 200
MMRDA
Human-machine interface (HMI) required to perform the desired

functions.
Each PLC shall have memory protected built in historical
archiving/data logging of system alarms & events and process
variables. Data logger shall be able to log data based on time or
an event. PLC shall have enough memory allocated to allow
200,000 time and data stamped discrete and /or analog values to
be archived. The historical archive shall allow the oldest data to
roll off the system as memory is used keeping the 200,000 most
current data points available. Process point time stamping
frequency shall be selectable within the configuration software. It
shall be possible for the archived data to be exported in CSV
format allowing use with standard spreadsheet and data software
applications.
PLC shall have the following attributes as a Hot-Standby
configuration.
-
carry out sequential logic implementation for operations of

plant;
carry out computation and interfacing for data acquisition, data

storage and retrieval;
it shall accept downloaded program from a programmer;
it shall have different functional modules to perform the

desired functions;
it shall scan the inputs in time cycles and update the status of
its outputs.
2224 of 2461
PAGE 68 of 200
MMRDA
B. Dual Redundant Processors
The master station shall be provided with two identical central

processors configured such that they operate in Hot-Standby
mode.
Redundant system with hot back up redundancy feature should
be built in the CPU. Software engineered hot backup systems are
not acceptable. CPU should have the memory expansion
capability up to 7 MB. Both the CPUs should have separate
backplane and associated hardware for redundancy.
CPU system should have built in WEB server
SCADA connectivity with the CPU will be on dual Ethernet
network (10/100 Mbps with open Modbus TCP/IP protocol). On
the event of hardware failure in primary system the standby
system will provide dual connectivity with the SCADA.
Redundancy of switch for SCADA (industrial grade managed
switch) connectivity is to be provided.
Failure to do adhere to the above will be treated as a nonresponsive bid and lead to technical disqualification. Contractor
should take note on the importance of this obligation.
The system shall be designed and implemented such that when
the Main processor fails, the Standby one shall automatically take
over. The changeover shall be seamless, smooth and without any
time delay and shall not cause any disruption to the overall
Control System and to the ongoing processes.
The PLC system shall be expandable (OPC compatible) and shall
be modular in construction, so as to capable of future expansion
without hardware modifications. External OPC servers will not be
2225 of 2461
PAGE 69 of 200
MMRDA
considered.
-
The system hardware, application software and database

shall be sized to accommodate a total of 50% increase in
signal capacity and up to 100% increase in an individual zone
Sufficient plug in modules shall be provided and wired to

terminals ready to accept future signals of up to 10 % for each
IO card
Each Back plane of the Control System / RIO shall be able to

accept at least two more I/O cards without requiring
replacement of, or additions to, the original equipment
PLCs shall be microprocessor based. PLCs shall use standard

known protocols and structures for communication outside the
system. In case of system failure or power supply failure the
outputs shall attain a predetermined fail safe condition (this shall
normally be off).
The PLC used shall have a proven record in the type of
application concerned and in the prevailing environmental
conditions. PLC shall be of an approved type from a major
international manufacturer. Refer Vendor list. The PLC shall be
furnished with a dual redundant microprocessor. The PLC shall
be open systems standard for all elements of communications
and programming and shall be designed for ease of use and
minimum configuration.
Application logic programs shall be fully compliant with all five
logic development methods detailed in IEC 63331-3. The PLC
shall be powered by two independent sources provided by the
UPS system and all internal operating supplies shall be derived
from the UPS. The power supplies, I/O, CPU and communication
modules and battery backup rates shall be monitored by the PLC
2226 of 2461
PAGE 70 of 200
MMRDA
and shall be available by report.

During the times of the battery discharge, the PLC shall initiate an
orderly self-shutdown and automatically restart on the main power
restoration without the need for reloading or initiation of any kind.
The PLC shall comply with the specification specified elsewhere
in this specification.
Each PLC shall have built in web server capability allowing
system information to be stored in a format that allows for easy
access and viewing with standard Windows based browser.
Each unit shall be furnished with built in O & M data associated
with its specific site including; as a minimum, basic system
information, panel layouts, wiring diagrams, material lists w/part
numbers, and operational summary. This information shall be
accessible locally or remotely.
a) Redundancy Levels for WTP:
i. Controller Level
ii. Power Supply Level
iii. Communication Network level from RIO panels to Controller
/ CPU Panel over by TCP / IP Ethernet by Using Fibre Optic
Cable (F.O.C)
iv. SCADA System Level
b) Redundancy Levels for RWPS , CWPS and each MBR:
i. Controller Level
ii. Power Supply Level
2227 of 2461
PAGE 71 of 200
MMRDA
iii. SCADA System Level

C. Central Processing Units
The central processing units (CPUs) shall be a high performance

processor with modular configuration suitable for real time
process application.s
The following features shall be provided on a minimum.
Communication between CPU and peripherals shall be by an I/O
bus. The individual device, interfaces shall be capable of being
plugged into the I/O bus.
On resumption of power following a power failure the PLC shall
automatically restart its controlling function.
CPU shall have a real time clock capability to accept a time
synchronisation pulse and adjust its internal clock with the pulse.
CPU shall have extensive self-diagnostic facilities and watch dog
timers to identify faults at card levels.
D. Memory Unit
Memory unit shall comprise of highly reliable memory chips which

are industry standard, proven design with fast random access and
suitable for operation in process environments. Main memory
shall be modular and facility shall be provided for the upgrading
and expansion of memory to meet future demands.
Not less than 50 % spare program memory and data memory
space shall be provided. System initialisation and application
software shall be stored in EEPROM or EPROM. Operating data
shall be stored in a RAM fitted with an internal battery backup.
2228 of 2461
PAGE 72 of 200
MMRDA
The battery backup provided shall support the memory on loss of

power for at least one month. The battery life shall be at least 2
years.
E. I/O Modules
Standard rack mounted plug in I/O modules shall be provided. I/O

Modules should be of the same series as the PLC CPU. Deviation
from this would be treated as a non-responsive bid and lead to
technical disqualification. Contractor should take note on the
importance of this obligation. Field wiring shall be terminated in
screwed terminal blocks and interconnected to the processor I/O
system with prefabricated cables and plug in card type
connectors. The I/O modules shall be hot swappable.
20% extra IO Channels of installed capacity for each type of
module channels shall be provided as spare. Provision shall be
made for future expansion of additional 20% extra I/O modules of
the installed capacity. RIOs to have dual redundancy on network
level connected to both the CPU. Even on the failure of one CPU
backplane the other system should be available on dual network
at RIO level. All the RIO rack should have redundant power
supply modules for the backplane.
All I/O module should be rack mounted type.
I/O modules shall be as follows :
-
inputs shall be opto isolated;
filters shall be provided for noise rejection;
output status shall be indicated by an LED;
all outputs shall be fuse protected and have fuse failure
2229 of 2461
PAGE 73 of 200
MMRDA
indication the fuses may be mounted externally from the output

module;
-
all the modules shall be of addressable type
Ethernet I/O modules shall be connected to the PLC by on board

Ethernet 10/100 Base connection port. Ethernet I/O modules shall
support multiple communications including TCP/IP and Modbus
ASCII and RTU allowing connection to any device supporting
these protocols over standard Ethernet backplane
F. Analogue Input Modules
They shall consist of an input isolation unit, signal conditioning

unit and an analogue to digital converter (ADC). In addition, the
following features shall be provided.
-
cross talk attenuation
provision for monitoring of the ADC for overflow detection
gain amplifier with high common mode rejection ratio
G. Analogue Output Modules
They shall consist of signal conditioning unit and a digital to

analogue converter (DAC).
In addition, the following features
shall be provided.
16 bits resolution minimum
provision for monitoring of the DAC for overflow detection
2230 of 2461
PAGE 74 of 200
MMRDA
H. Digital Input Modules
The following design features shall be provided.
I.
contact bounce protection;
choice of type of contacts
Digital Output Modules
The digital output module shall provide contact closure output by

driving relays. The features to be provided are as follows:
-
contact bounce protection shall be provided
relay output shall be provided to operate pump motors and

motorised valve actuators
fail safe position in case of output module failure and fault

indication
PLCs provided under this specification shall be capable of

performing the necessary logic to control the system as previously
defined. These capabilities shall include, but not be limited to the
following:
1. Discrete input/output
10.
Latch/unlatch
relays
2. Analog input
11.
Counters
3. Analog output
12.
Comparators
4. Timers
13.
FBD logic
5. Pump Controller
14.
Flow
Totalization/Integration
2231 of 2461
PAGE 75 of 200
MMRDA
6. Pump Alternation
15.
Intrusion Detection
7. Mathematical Function Blocks 16.
Time of Day Control

w/Lockout
J.
8. Stage Blocks
17.
Ramp Blocks
9. Trending
18.
Data Logging
PLC Programming
Where ever possible PLC programming shall be carried out using

Ladder Logic based on the approval of the employers
representative. The logic shall be prepared using proprietary
programming software and shall be comprehensively annotated
with subroutine and rung comments to assist further development
and maintenance.
The system shall support a simple programming of the application
software complying with IEC 63331-3.
The system shall support a structured, modular programming. At
least the following standard operations shall be applicable:
1) Logic functions (such as AND/OR/AND NOT etc.);
2) Timer functions (externally adjustable);
3) Counter functions;
4) Skip functions;
5) Comparison functions;
6) Limit value functions;
7) Arithmetic functions;
2232 of 2461
PAGE 76 of 200
MMRDA
8) Physical unit functions;

9) Closed-loop functions such as P/PI/PID/etc.
The Contractor shall submit the logic diagrams for review. The
Contractor shall include the as-built logic in the final submission.
K.
Programming Unit
The programming unit shall be of the portable type, industrial

model designed to be used during commissioning on site. A
functional keyboard which supports different type of programming
methods shall be included, as well as a CRT or TFT display.
-
At least the following functions shall be included on a

minimum:
On-line programming
Off-line programming
Flexible corrections during input
Full screen editing functions
Absolute and symbolic programming
Input of comments and title blocks for complete documentation
Complete
Printouts
application
of
software
application
documentation
software
logic
functions.
functions
shall
preferably be in Ladder logic diagrams.

-
Load and transfer functions
2233 of 2461
PAGE 77 of 200
MMRDA
The computer shall be provided complete with proprietary PLC

programming and SCADA software complete with plant mimics
and documentation software. Communications cables required to
interact with the PLC, (Eg: Modbus Cable) would be supplied by
the contractor. The software shall provide facilities for:
-
carrying out program revision management;
insertion of comprehensive program subroutine and rung

comments;
search and find and search and replace contacts and coils;
simulation functions and testing of the program by changing

the status of contacts and monitoring the outputs;
preparation of coil and contact list and their locations and

memory maps;
make system backup copies while the system is online;
upload and down load programs to the PLC on line;
carry out on line maintenance and fault finding on the PLC.
II. Supervisory Control and Data Acquisition System (SCADA/HMI)
SCADA / HMI system in a dual- redundant configuration shall be

provided at each Control Room of RWPS, CWPS, WTP and each
MBR.
The SCADA /HMI shall be a fully integrated microprocessor based
control and data acquisition system which will monitor, control,
display, record and trend all assigned plant inputs and outputs. The
SCADA /HMI shall be a fully dual redundant server microprocessor
2234 of 2461
PAGE 78 of 200
MMRDA
based computer system such that reliable and automatic plant control
can be achieved. The main process monitoring and control shall be by
means of VDU (monitor) based process operator workstations that
shall be located in the central control room.
SCADA/HMI system would be Dual Redundant server system. The
system shall be designed and implemented such that the failure of a
central processor or HMI console does not inhibit continuous
automatic control of the plant. In the event of such a failure, historical
data shall be recoverable to a condition where a worst-case maximum
of 15 minutes of historical data is lost.
Failure of a single outstation or communications to that outstation
shall not effect control or operation of any other outstation, unless the
failed outstation provides essential data to another outstation, in
which case the non-failed outstations shall revert to a fail-safe mode.
An alarm shall be generated whenever a communications system
failure occurs.
A. Hardware
The system shall support hardware and software interconnectivity

to other networks generally in accordance with the ISO Open
System Interconnect 7 layer reference model.
1. Computer Hardware
The computer hardware shall be of current technology at the

time of installation, Standard PC technology with modern
hardware, Windows operating system and data transmission
over Industrial Ethernet must be used for the engineering
workstations.
-
It must be possible to install more than one engineering
2235 of 2461
PAGE 79 of 200
MMRDA
station in a system.
-
The engineering system must be an open system that, for

example, permits the importing of project data from
Microsoft Excel or from CAD/CAE programs. It must be
possible to import/export messages to/from Excel and
Access for simple processing.
Removable memory media must also be provided for each

workstation.
It must be possible to back up all database and

configuration data both on removable media and on nonremovable storage media without the system being offline.
Provision of redundant storage media must be possible for

the configuration database.
The computer shall, as a minimum comprise of a personal

computer (PC) type architecture, with IBM compatible
Pentium IV based system or better, capable of running a
multi-tasking real time operating system suitable for
process control applications:
hardware
The specs for computer
shown are indicative only. The contractor to
select the appropriate hardware to suit the process

requirements and data archiving. The minimum Hardware
and Software configuration shall be as follows:
I. Specifications for Operator Work Stations & Engineering
Station:
PROCESSOR
Intel Core i7 6700 (3.4GHz) Processor
MEMORY (RAM)
8 GB DDR4
OPERATING
Windows 10 Professional (or) latest
2236 of 2461
PAGE 80 of 200
MMRDA
SYSTEM
compatible with SCADA software
MICROSOFT OFFICE Latest Version

OTHER PREBUILD
Adobe PDF, Antivirous, etc.
SOFTWARES
HARD DISK DRIVE
SCREEN
SIZE
1TB HD 7200RPM
& 32" LED
TYPE
GRAPHIC CARD
OPTICAL
Integrated Graphics
DISC DVD RW
DRIVE
PORTS AND SLOTS
Card Reader: 7 in 1
Front ports: 2 x USB 2.0
Rear ports: 2 x USB 2.0,
2 x USB 3.0
Num of PCI-E*16 slots: 1
Numof PCI-E*1slot: 2
HDMI out
Audio Port: Headphone Output
Microphone
Chipset: Intel H 110
Keyboard & Mouse
WiFi + Blue Tooth:
802.11AC BT4.0 1X1
2237 of 2461
PAGE 81 of 200
MMRDA
PTOP- Specifications
PROCESSOR
Intel Core i5 6200U
MEMORY (RAM)
8 GB DDR III
OPERATING
Windows 10 Professional (or) latest
SYSTEM
compatible with Automation softwares
MICROSOFT OFFICE
Latest Version
OTHER PREBUILD
Adobe PDF, Antivirous, etc
SOFTWARES
HARD DISK DRIVE
SCREEN
SIZE
1 TB SATA HDD @ 5400 RPM

&
35.56 cm (14) LED BACKLIT ANTI
TYPE
GLARE DIsplay with HD Camera
GRAPHIC CARD
Intel HD Graphics
OPTICAL
DVD RW
DISC
DRIVE
PORTS AND SLOTS
Card Reader: 7 in 1
Front ports: 2 x USB 2.0
Rear ports: 2 x USB 2.0,
2 x USB 3.0
Num of PCI-E*16 slots: 1
Num of PCI-E*1slot: 2
HDMI out
2238 of 2461
PAGE 82 of 200
MMRDA
Audio Port: Headphone Output

Microphone
Chipset: Intel H 110
Keyboard & Mouse
WiFi + Blue Tooth:
802.11AC BT4.0 1X1
Battery
48Whr Battery (upto 6 Hours on idle

conditions*)
All workstations, servers, communications equipment and

peripherals shall be from reputed manufacturers, suitable for
continuous operation and shall be the most currently available
models at the time of construction, subject to approval.
Adequate spare capacity shall be included to meet the
specified requirements and future expansions.
2. Data Storage
A historical data storage system with removable media for

archive and backup will be provided.
The data storage system shall store alarms and events, with
the time of occurrence for one month and selected analogue
signals connected to the system. All alarms and events shall
be archived in a first in first out buffer, for a period of 40 days.
A high speed back up device with removable media, such as
streaming tape cartridge or optical disk, shall be provided for
each , suitable for backing up the whole system on a weekly
basis. Data selected for archive shall be written to removable
media which shall be sized to support at least 40 days worth of
2239 of 2461
PAGE 83 of 200
MMRDA
archive data.
External portable hard disk along with at least one DVD
write/rewrite/read with +R and -R capacity in addition to the
historical data storage device in the Engineering Station should
be provided.
3. Visual Display Unit (VDU)/Monitors
1. Visual Display Units (VDUs) shall be colour monitor screens,

capable of displaying information in alphanumeric, bar
histogram, graphical and mimic diagram formats. Monitors
shall simultaneously display a minimum of 256 colours, noninterlaced, low radiation, flat screen with no discernible flicker.
Display of characters shall be legible and stable on a shadow
mask tube, having a resolution of not less than 1024 by 768
pixels and a refresh rate of not less than 70 Hz. The units shall
include all the necessary picture controls to adjust the
sharpness, contrast and position of the image. LCD VDUs shall
be flat screen, TFT type, minimum requirements: brightness
250 cd/m2, 500:1 contrast ratio, 1600 x 1200 pixels,
2. VDUs shall be 32 inch.(Minimum)
3. VDUs shall be fitted with a power management system to

reduce consumption upon detection of a stand-by signal from
the PC.
4. Printers
i) Desk Jet Printer: Logging / Alarm / Report Printers

Continuous Feed:
Printers used for logging of system wide events and alarms
shall comply with the following:SECTION 6C.12: INSTRUMENTATON CONTROL & AUTOMATION
2240 of 2461
PAGE 84 of 200
MMRDA
a. print speed
160 characters per second
b. print quality
letter print with optional draft mode
c. paper feed
adjustable width tractor feed
d. paper width
18 to 38 cm fan fold
e. print pitch
10 or 12 cpi
f. print width
132 characters at 10 cpi
g. character set
Full ASCII
h. noise level
< 50 dBA.
mechanism
ii) Colour Printers

Laser Jet printers shall be used for the production of colour
screen dumps and reports and shall have a sufficiently sized
buffer memory such that system performance will not be
degraded when the colour printer is operational and comply
with the following:
a. print speed
text, 80 characters per second
b. print speed
colour graphics, 2 minutes per full page
c. colours
compatible with VDU graphics
d. paper feed
A3 and A4 with auto sheet feeder
(max.)
mechanism and minimum 50

2241 of 2461
PAGE 85 of 200
MMRDA
sheets per tray

e. paper width
f. resolution
g. RAM
A4/A3
:
600 DPI
min. 8 MB
B. System Overview
The SCADA/HMI system shall follow the International Standards

Organization (ISO), Open Systems Interconnect (OSI), reference
model guidelines. All central system hardware and software
devices shall be interconnected using a bus topology data
highway. The communications protocol used shall generally meet
the requirements of the ISO.
The system shall provide efficient and safe operation of the
process plant by detecting alarm and error conditions, alerting the
operator to these conditions both visually and audibly, monitoring
all important system parameters and providing facilities for plant
optimisation. The system will allow operators, technicians and
engineers to issue commands to change system parameters, start
and stop equipment, provide configuration tools and operate
diagnostic facilities from Operator Workstations (OW) and
Engineers Terminal (ET), after successful log-on by security
password.
The System shall perform all the necessary functions for the
optimum monitoring, control and operation of the entire system.
For each abnormal condition, Plant failure, Plant unavailable or
failure to respond to a command within a given period, the HMI
shall provide the appropriate alarm. Printed and archived alarms
shall be time and date stamped for occurrence and acceptance.
2242 of 2461
PAGE 86 of 200
MMRDA
Alarms, logs and reports shall be output to separate printers.

Alarms shall be in red. The ability to generate alarms within the
system software based upon digital and / or analogue events and
set points shall be provided.
An alarm horn with silence button shall be provided to alert the
operator of an alarm condition.
Specific alarm, monitoring and control input / output requirements
shall be determined from the particular control specifications and
the Project Drawings.
SCADA/HMI system should be housed in an air-conditioned
environment.
C. SCADA Software Functions
1.
The Contractor shall be responsible for supplying complete

software packages to enable the equipment to operate as
stated in this specification. Provision must be made for the
adding of further software tasks as and when required. All
software functions shall be user friendly, with instruction and
messages to aid the operator. The Contractor shall make
available all standard software functions, even if not
specifically detailed in the specification.
2.
The computers shall utilise a real time multi-tasking and

networked operating system with a proven track record in real
time control applications.
3.
The Operating System shall be Windows 10, loaded with MSOffice latest licensed version suitable for interconnection with
external
networks
in
Wide
Area
Network
(WAN)
configuration, where specified.
2243 of 2461
PAGE 87 of 200
4.
MMRDA
The Application Software shall provide communication with

other industrial standard open networks. The Software shall
support Object Linked Embedding for Process Control
(OPC).External interfaces are not allowed for OPC.
5.
The
System
shall
support
fully
distributed
64 bit
Client/Server architecture.
6.
The System shall include Visual Basic for Applications (VBA)

as a built-in programming language. Facility shall be available
for building custom objects using VBA.
7.
Object oriented graphics and tools to easily build reusable

control strategies.
8.
ODBC Application Program Interface (API) capable of

collecting and writing secure real-time electronic records to
one or more relational database.
9.
The SCADA software & Hardware shall support OPC

standards as both a client and a server for fast and reliable
communications with a wide variety of hardware devices.
10. Provide Active-X controls with selection of third-party Active-X

controls for ready-made solutions without VBA programming.
11. The SCADA software shall use SQL server as the integral
database.
12. A standard software package, such as Crystal Report shall be
provided to facilitate generation of free format, intuitive and
presentation quality reports.
13. The Engineering Workstation shall be provided with simulation
tools to support off-line testing of the control logics.
2244 of 2461
PAGE 88 of 200
MMRDA
14. The Server shall provide the master clock for the SCADA time
synchronization.
15. The system software shall be from the SCADA equipment
manufacturer. Third party software is not acceptable.
16. It is a requirement that the system be supported by on line
configuration and editing of all VDU mimic displays and
database and to create new displays and additional database.
17. Operational mimics and other graphics shall be presented in
an industry standard graphical user interface (GUI) format. A
minimum of three active windows shall be displayable
concurrently. Both text and graphics shall resize automatically
to accommodate changes made to the size of a window. The
system shall be designed to minimise the operators use of the
keyboard. All major functions shall be accessible on-screen
through use of the mouse or track ball.
18. Operator system entry, for each area will be password coded
with different levels of entry depending on the level of
authority of the operator. Development and systems level
entry passwords will be provided for engineering workstations.
Each action taken by any operator at any level of entry, or at
any operator terminal, shall be log file recorded and time and
date stamped. Log in and out time and dates will be printed on
the control room event logging printer.
19. VDU mimics will display dynamic colour details of flow rates
and pressures, pump status, well levels, alarms, electrical
power
supplies
and
other
general
equipment
status
conditions. All requests and commands shall be via icons,

whether menu linked or linked to equipment control actions. A
permanent dynamic alarm banner shall be displayed at the
2245 of 2461
PAGE 89 of 200
MMRDA
bottom or top of each operator screen. Each control action will

be routed through a series of confirmation routines. The
reports shall be available for printing in graph or tabular
format. Dynamic trend displays shall also be available for all
analogue flow, level and pressure values. Custom, as well as
preconfigured reports and trends shall be available to a higher
level of entry. A colour, A4/A3 size, screen dump printer shall
be provided for graph and trend prints.
20. An operator help utility shall be provided, offering help linked
to the particular action being carried out by the operator at that
time. At least one help screen per screen page shall be
available. This facility shall be preconfigured with an option for
updating by operators, via a password entry.
21. The Application Server software shall be configurable to
provide for the monitoring and control of all points, loops, and
systems through graphic display screens and hard copy
reports. These shall include:
Parameter Displays for signal control
Control Loop Status Displays
Real Time and Historical Data Trend Displays
Event Displays and Log Reports
Alarm Displays and Log Reports
Equipment Diagnostic Displays and Reports.
22. The system shall provide on-line diagnostics that display the
current status and operation of the local area network and its
nodes. The diagnostic display shall include the LAN adapter
2246 of 2461
PAGE 90 of 200
MMRDA
status for the machine showing the display, as well as the

current number of messages, errors and retries.
23. The system shall conform to and take advantage of industry
standards. These shall include, but not be limited to:
ODBC
OLE
ActiveX
COM/DCOM
DDE and Advance DDE
C programming language
Visual Basic
Microsoft Windows XP or the most current Operating

System
TCP/IP
OPC
XML
24. It
must
be
possible
to
integrate
standard
Windows
applications such as Microsoft Excel, Microsoft Word and

Microsoft Access by means of the standard mechanisms
OLE/ActiveX, ODBC/SQL. Any user programs (e.g. individual
data management, analysis, process optimization) must work
together with the control system via the integrated C
programming interface and then utilize both the control system
data and the control system functions.
25. The control system must be OPC-compatible in order to allow
cross-vendor communication. The different OPC standards
(DA, HDA and A&E) must be taken into consideration here.
Current process data regarding this should be made available
to other computers and applications. In this way, any
computer that is connected to the network should be able to
access all of the control system's data. The use of a standard
2247 of 2461
PAGE 91 of 200
MMRDA
database (Microsoft SQL Server 2000) is required to store

(write-protected) all of the list-oriented configuration data such
as lists of variables and message texts as well as current
process data such as messages, measured values and user
data sets in order to be able to access the database via the
opened programming interfaces C-API or OLE-DB. Work
steps in the engineering phase should be automated and the
configuration environment should be individually expandable
through the integration of the standard tool Visual Basic for
Applications (this simplifies the generation of mass data).
26. It is critical that the control system should offer the capability
of
homogeneously
integrating
other
applications
and
application blocks into the user interface for process

operation. Both the application windows and the OLE Custom
Controls (32 bit OCX objects) or ActiveX Controls can be
integrated into the control system application as if they were
the control system's own objects. It should be possible to use
the ANSI-C script language and Visual Basic Scripting for
dynamizing graphical objects.
D. Display Facilities
The displays shall be user configurable, with the user being able to
construct any desired symbol for display. Any display shall appear
(excluding historical recall) within 1 seconds to 3 seconds of
selection and the displayed data shall be updated from the
database .Alarms shall typically appear within 3 seconds to 5
seconds of occurrence and within 1 second of being received into
the central system database.
The Contractor shall configure all display pages as fully as
possible. However, facility must be incorporated to permit easy
construction and modification of the display pages, by using a
standard library of shapes and symbols. The library shall be added
2248 of 2461
PAGE 92 of 200
MMRDA
to and modified by the user as required. The configuration shall

be object orientated for ease of use.
The initial application software shall provide for the display pages
listed below and any pages necessary for the system to function
as a complete entity.
-
Mimic displays
Graphic displays
Trend displays
Alarm summary tables with date and time
Event logs of past 72 hours with date and time
Tabular display of data
Inset windows showing analogue trends may be mixed with mimic

displays.
In such a display the main mimic and inset trend shall
all be live with automatic display updates.

Indexing of information and menus shall be presented in the form
of active windows on the screen, while the mimics etc. are still
available for view.
No display or function shall effect the logging/monitoring of data. It
shall be possible for the master station terminal and auxiliary
terminals to perform simultaneously, different tasks within the
display.
E. Monitoring and Alarms
1. The operator shall be able to monitor all of the information at the

workstation. He shall be able to view active equipment information
on a series of VDU based graphical and tabular displays.
2. In the event of an equipment alarm, the following shall occur at the
master station:
2249 of 2461
PAGE 93 of 200
MMRDA
a. Alarm message displayed in the alarm message area of the

screen.
b. The audible alarm shall sound.
c. The appropriate Section of the display page shall change
colour and flash.
d. A full message shall be written on the alarm page.
e. The full alarm message shall be printed on the alarm printer.
f. The full alarm message shall be recorded, stored on disk and
automatically archived.
3. The operator should be able to acknowledge the alarm by pressing
an accept alarm key or icon. This action shall stop flashing of all
associated alarm messages and displays. However the display
shall remain in the alarm state fixed colour to indicate an accepted
alarm. When all outstanding alarms have been acknowledged the
audible alarm shall be silenced.
4. Once the alarm has cleared, the messages and displays shall
return to normal. The alarm message shall stay recorded on the
event/alarm log and an alarm cleared message shall also be
recorded.
5. If the alarm clears before being acknowledged the sequence of
events shall continue as above except the message shall change to
indicate a cleared alarm.
6. An audible alarm silence function shall be provided to enable an
operator to silence the audible alarm without acknowledging all
alarms. On occurrence of any subsequent alarm, the audible alarm
2250 of 2461
PAGE 94 of 200
MMRDA
shall sound.
7. Each signal within the configured system shall be capable of being
assigned an alarm based on the following:
a. Four levels per analogue (Lo, Hi Hi, Lo and Hi)
b. Rate of change
c. Deviation from set point or other control parameter
8. Alarms shall be time tagged to 1 second resolution at the I/Os.
9. A minimum of four alarm priorities shall be provided so that those
requiring immediate attention may be separated from alarms of
lower priority. An audible alarm shall sound for alarms requiring
operator action.
10. Typical alarm assignments are as follows:
a. critical alarm
- an alarm that requires immediate operator
action
b. non critical alarm
- an alarm that requires operator action but
not
necessarily immediate action
c. operator guide alarm

to the
d. event
- an alarm that provides information

operator
- a low priority condition which is recorded.
F. Data Archiving
The Microsoft SQL Server 2000 database system must be

provided for managing the archives and the system parameters.
2251 of 2461
PAGE 95 of 200
MMRDA
In addition to the required scope of performance of the

databases, the capability for modifying or creating new
applications must be considered by the customer in the licenses
offered. The selected database system and the tools needed by
the contractor within the scope of the database application must
be named in the bid.
Continuous process (analogue) data, digital event states, alarms
and operator actions shall be archived to a removable media
system.
The archive media shall be sized to store logged
analogue data, at a maximum sample rate of 15 minutes for a

period of 15 months. Data recording shall be on dual media.
The archive system shall generate an alarm when a file is 75%
full.
Analogues will be stored at a rate selected by the operator in the
range 1 second to 1 hour. The operator shall have the facility to
select the way in which an analogue is stored. The system will
provide any combination of the following:
a. Instantaneous value
b. Average value
c. Maximum value
d. Minimum value
e. Not stored
Maximum, minimum and average values shall be calculated
over a period set by the operator in the range 15 minutes to 24
hours, the default shall be 1 hour.
The logging of new data and reception of alarms must be carried
out at the same time as the operator is viewing archived data.
Any alarms received must be displayed as an overlay on the
visual display unit.
2252 of 2461
PAGE 96 of 200
Note:
MMRDA
In Addition with SCADA Operator Work Stations, One
Number of Historian Operator Work Station shall be provided for

SCADA data Backup at every 3 Months period.
G. Mimic Displays (Mimics)
The Contractor shall configure all the mimics to provide total

detailed coverage of the monitoring and control of equipment as
detailed in this specification.
It is expected that display
modifications will be required in the future and therefore the ability

to change the displays without programming skills is essential.
Instrumentation shall be displayed using ISO standard symbols.
For mimic configuration, it shall be possible to call up a library of
standard symbols representing items (e.g. pumps, valves) and add
new symbols to the library. Building mimics shall be simple and be
achieved by using a mouse or tracker ball pointing device. The
mimic displays shall consist of the following pages:
a. A general diagram covering the whole of the system on a
single screen with key data
b. A general block diagram for each site or area of Site showing
the equipment displayed on a series of single screens with key
data
c. Mimic of the equipment and instrumentation connected to each
IO module displayed on as many screens as necessary.
H. Trend Displays
Archived values (instantaneous values or compressed values) can

be displayed as curves and in tables on the screen and in reports.
The colors and pattern indicate, for example, overshot limits,
substitute values, faults and time jumps. Like the message
2253 of 2461
PAGE 97 of 200
MMRDA
window, the curve window also has a toolbar for curve controls. A
quick help explains the meaning of the individual icons.
Individually designed keys can also be configured and saved with
the associated operating functions. For authorized operators, it is
also possible to change the parameterization online, i.e. to change
the colors of the curves or to regroup the groups.
Access to the archives is supported by targeted, direct selection of
measuring
point
groups,
measuring
points
and
individual
measured values. The selection can be made via names or time

windows. The values of an display section can be focused on in
detail using the reading line and zoom function. The scaling of the
time axis and value axis is adjusted accordingly and the curve
values for the display are interpolated. For a curve window, a
shared or separate axis can be configured for each curve with a
different value range. Limit violations should be identified by a
configurable color change when displayed in the curve window.
Horizontal and vertical "recording directions" of the curves can be
set by the configurable direction of the curve display, which makes
a recording function possible. Compared to the normal curve
display, the x axis and y axis are interchanged by means of the
recording function. The y axis is used as time axis. With the
recorder function, you can also determine whether the current time
is counted down on the upper or lower edge of the curve window.
If several curves are displayed at the same time, the control
system should also offer the facility for staggering the curves. This
setting displays the curves that are to be displayed in a curve
window one above the other. For each trend, a value range that is
to be displayed can be set for the Y axis.
It shall be possible to plot dynamically updated real time data and
archived data on a line graph, to represent analogue or digital
information. Each graph shall be capable of displaying 8 plots
overlaid on a graph of different colours and line texture. Next to
2254 of 2461
PAGE 98 of 200
MMRDA
the graph, there shall be a key relating each colour to its function.
The horizontal axis shall be time based and user selectable in
minutes, hours, days, weeks, for example, together with a start
time.
The vertical axis shall be scaled as a percentage of range and be
displayed in the colour of the selected reading. To avoid cluttering,
the vertical axis scale shall be changed by selecting the individual
display. The vertical axis shall be automatically scaled for each
selected point, between limits entered by the user. Actual values
in engineering units shall be displayed by positioning a cursor at
the desired point of the trend graph.
The display of the data shall also be available in tabular form.
All digital and analog parameters of the RWPS, CWPS, WTP
should be programmed and available for trending.
i) Manual Data Entry
The system shall be provided with facility for entering data

manually via the keyboard. This data will fall into two types:
a) Constants which will be changed infrequently. This data
may have time and date associated with it.
b) Maintenance related comments.
ii) Manually Corrected Data
The system shall allow a person with authorised access to

correct manually, erroneous data via the keyboard.
2255 of 2461
PAGE 99 of 200
MMRDA
I. Reports
There shall be a real time spreadsheet facility supplied and

installed by the Contractor in the master station. The users shall
be able to transfer data from either the archive system or live data
to the spreadsheet. The user shall be able to produce daily,
weekly, monthly and annual reports using any data and a mixture
of formats (tables, graphs, summaries, spreadsheets). It shall be
possible to generate reports, either automatically at predetermined
intervals, or manually on demand by the Operator.
Typical
reports on a minimum would be:

a. Flow rates and total
b. Failures of equipment
c. Analytical instrumentation parameters, Electrical parameters
d. Tank levels
e. Discharge pressures
f. Maintenance schedules
g. Process alarm conditions
h. Chlorination equipment status etc.
J. Profiling
From an average, typical or manually entered plot, it shall be

possible to set an exception profile whereby readings within an
upper and lower level are acceptable.
Profiles shall be set
graphically via OW. The user may select for the system to alarm if
the reading is outside the profile and highlight such exceptions as
part of a report, thereby reducing the need to examine all data, to
ensure acceptability. The number of exceptions shall be logged.
K. Data Manipulation
It shall be possible to perform simple mathematical functions on

any data, including the following functions:
2256 of 2461
PAGE 100 of 200
MMRDA
a. Addition
b. Subtraction
c. Multiplication
d. Division
e. Square root
It shall be possible to log, display or use in a control loop, the
resultant data.
L. Database Query Facilities
The system shall support the use of database relationships and

wild card characters to provide database query facilities. It shall be
possible for applications integration to configure queries easily and
save them for future use. Support of Dynamic Data Exchange
(DDE) or Structured Query Language (SQL), to permit data
exchange between the DCS and external applications, including
spread sheets and databases.
Data shall be presented in tabular format and contain any
combination of fields from the main system database. It shall be
possible to manipulate the data by specifying search and sort
criteria to define data range limits. Once a query table has been
created, it shall be possible to store the configuration and initiate
successive look-ups, using a point and shoot technique.
M. Downloading IO Configuration
It shall be possible to download configuration to the IOs from the

Engineers terminal and the Portable Programming Unit (Laptop)
N. Diagnostics
The system shall have on-line diagnostic facilities to report system

2257 of 2461
PAGE 101 of 200
MMRDA
faults as they occur. A set of off-line diagnostic routines shall be

supplied for more extensive fault diagnosis.
O. Security Access Levels
The functions available on the system shall be fully flexible so as

to allow users access levels to be customised by the system
operator, to suit individual user requirements.
Access to management and engineering levels shall be restricted
by user selectable passwords or software key switch. The security
systems shall be based on a set of privileges, which may be
granted or denied to individual uses by the system operator.
The security/access levels would be divided between engineers,
supervisors and operators.
The system shall be protected from un-authorized changes to the
operating system and application programs.
The system shall prevent un-authorized users from re-booting the
system or aborting or suspending system-related programs.
The system shall provide three levels of operator access to the
system as a minimum, with the first level permitting access to
viewing selected plant conditions as described below and the
highest level intended for the system manager.
A mechanism shall be provided which prevents users operating at
a lower level from accessing functions assigned to a higher level.
The system shall provide a password-protected, user log-on
facility for definition of the user access level. It shall be possible to
define a minimum of eight privilege levels.
2258 of 2461
PAGE 102 of 200
MMRDA
Passwords entered during the log-on process shall not be printed

or displayed.
The software shall monitor the actions of the user currently logged
on at each node and shall log the current user off after a definable
extended period of no operator interaction with the system and
produce a printed log-off message.
Logging off of the user shall not shut down the system.
CTRL-ALT-DELETE function of the windows operating system
should be disabled to prevent un-authorised use of the system.
System-generated log messages relating to operator actions, such
as alarm acknowledgements or set-point changes, shall include
the identification of the current logged-on user.
The Contractor shall provide the following defined user access
levels as a minimum and additional levels as instructed by the
Engineer:
i) Default level
The default level shall permit users to view all displays except
those specifically assigned to a higher level of access.
ii) Operator level
The operator level shall permit authorised users to access

default level activities in addition to the following:
a. Perform control actions;
b. Acknowledge alarms;
c. Enter or modify manually entered data for inclusion into
reports.
2259 of 2461
PAGE 103 of 200
MMRDA
iii) System manager level
The system manager level shall permit authorised users to

access default level and operator level activities in addition to
the following:
a. Modify alarm and control set points, dead bands and time
delays;
b. Enter or modify historical data;
c. Add, delete or modify individual I/O points or point
attributes;
d. Add, delete or modify field device configurations;
e. Create, delete or modify control algorithms;
f. Create, delete or modify graphic displays;
g. Create, delete or modify system reports;
h. Configure trend displays;
i. Access the operating system;
j. Assign access levels and user passwords;
k. Perform any other system maintenance function
P. Programming
The method of programming will depend upon the Manufacturers

system requirements. However, the following standards shall be
followed:
a) All programmes shall be written such that they lend themselves
easily to alterations and additions.
b) Good programming practice shall be followed using structured
programming techniques.
All programmes shall be tidy in
format and logical to follow. Programmes should be extensively

annotated with comments and be self-documenting.
2260 of 2461
PAGE 104 of 200
MMRDA
c) The system shall be supplied with programmes that use a high

level language for the OW
Q. Multilingual Configuration Environment
A software version of the PLC system and HMI must support at a

minimum the language, English. The user must be able to change
back and forth between the different languages supported in the
configuration environment and operator production mode without
having to retranslate his application for this.
R. Programme Documentation
As part of the requirements of this specification full documentation

is required as below:
a. Software user manuals
b. Database point allocation table
c. Complete program listing, flow charts for all sequences and
control routines
d. Application software source code
e. End user license agreements
S. MIMIC Panel
A 62 LCD screen with necessary CPU shall provide an

elementary full colour pictorial flow diagram display of the
treatment plant including points at which chemicals are injected.
The mimic shall also include displays of process values e.g.
reservoir levels, process flows, water quality etc. Mounting of LCD
mimic panel shall be as approved by employers representative.
The operator interface shall provide facilities to:
-
display status of devices associated with the process area
2261 of 2461
PAGE 105 of 200
MMRDA
concerned (i.e. running, stopped, fault etc.);

-
display analogue values associated with that area of the plant;
annunciate alarms associated with the area of the plant

concerned;
provide facilities for the operator to:
silence the alarm (the alarm shall automatically silence after

one minute (manually adjustable) if not manually silenced);
acknowledge alarms
select the duty drive of duty / standby drive pairs;
adjust process set points;
prompt process actions (i.e. the backwash of a particular

filter)
12.7.8
Control Room Furniture (System Console)

In addition to the SCADA/HMI system equipment, the Contractor shall
provide furniture (system consoles) to complement or match both the
colour and styling of the equipment. Control room furniture shall comply
with relevant IEC standards for ergonomic design. System console
shall be so designed to house all servers, workstations, Monitors,
Printers, interface equipment with cables having back entry. Details
and design of system consoles shall be submitted to the Engineer for
approval.
Typically, The Contractor shall provide two fabric-covered upholstered
swivel-type adjustable arm chairs with casters, a rigid and lockable
steel cupboard for the storage of operating and maintenance manuals,
2262 of 2461
PAGE 106 of 200
MMRDA
drawings, logger paper, charts, disks and the like.

The visual display unit consoles or VDU desk shall incorporate at least
one drawer unit with drawers for operators use and for standard files.
12.7.9
Spares for PLC and SCADA Component

Contractor shall provide all the services and supplies in accordance
with approved procedures for handling of spare parts, which shall
include arranging for their proper receipt, stacking and storage.
I.
Spares for Commissioning & Start-up:
Contractor shall identify, define, procure, and supply construction,

pre-commissioning, commissioning and start-up spares, special
tools and handling gear for each item of equipment.
On a minimum, 1PLC CPU, 1 DI Module, 1 DO Module,1AI
Module,1 AO Module, 1 RIO Module, communication module ,fuses
of each type and size installed.
II.
Spares list for 1st Year of Operation:
Contractor shall identify, define, procure, and supply construction,

pre-commissioning, commissioning and start-up spares, special
tools and handling gear for each item of equipment.
These items and quantities should be subject to
Employers
Representative approval. Upon completion of commissioning,

contractor shall take inventory and ensure that spares for first year
of operation as identified and defined are available on site.
III.
Spares List for subsequent 2 Years of Operation:
Contractor shall identify, define and procure subsequent 2 years of

2263 of 2461
PAGE 107 of 200
MMRDA
operation, spare parts for each item of equipment.

IV.
Spares List for subsequent years of operation
Contractor shall identify, define and procure subsequent years of

operation, spare parts for each item of equipment as necessary.
Note: Contractor to include Spare list during their bid
submission based on the manufacturers recommendation for
each item of equipment proposed.
12.7.10

The power for Programmable Logic Controllers (PLC) and Supervisory
Control and Data Acquisition (SCADA/HMI) shall be derived from UPS.
The central PLC based SCADA system and all the remote I/O systems
shall be powered by UPS. This shall also include corresponding
managed Ethernet switches, internal and external communication
systems, monitors, LCD Screens, Online Filed Instruments including
online Analytical instruments etc.
The UPS provided shall be sized to provide sufficient power to maintain
system functioning for a period of minimum 1 hour, in case of power
failure.
a) Specification of Uninterrupted Power Supply (UPS)
The Contractor shall provide an on-line Uninterruptible Power

Supply (UPS) system with a one (1) hour back-up time at full
load for each of the PLC based SCADA systems. The
Contractor shall clearly indicate the offered UPS rating and the
details of each system in his design submittals.
The UPS shall be floor mounted, self-contained and metal clad.
The UPS shall incorporate a six (6) pulse rectifier and pulse
2264 of 2461
PAGE 108 of 200
MMRDA
width modulation inverter technology with microprocessor

control. It shall incorporate a static bypass switch that shall
operate in the event of a UPS failure, overload or manual
initiation in order to transfer the output supply to the main utility
power supply without disruption in the output supply.
The design of all of the power supply items shall be in
accordance with the latest national and international standards
such as IS, BS and IEC. The Employer has right to reject the
system at any time, if standards are not met by the Contractor.
The Contractor shall clearly indicate the standards of design in
his design submittals. The power supply scheme and all design
calculations for selection of UPS and Battery capacity shall be
furnished by the Contractor in his design submittals.
Based on the three phase 415 VAC power supply available at
the Project Site all required AC/DC voltages for the SCADA and
communication systems, etc. shall be derived from this supply
and proper isolation, earthing and safety requirements as per
Indian Electricity (IE) Rules shall be complied with by the
Contractor. The Contractor shall provide the required and a
sufficient number of AC and DC feeders as required for the PC
based local SCADA system. At least 2 spare feeders shall be
provided in each of the AC and DC systems.
The batteries used for the UPS system shall be rechargeable, of
the sealed maintenance free (SMF) lead acid type. The battery
supply to the UPS shall be via a fused load break switch
disconnect circuit breaker. The battery recharge time to 90% of
full charge shall be approximately ten (10) times the discharge
time at full load.
The various alarms and status parameters of the UPS system
shall be made available to the local SCADA system for
monitoring purposes using a RS-232 serial communication port.
2265 of 2461
PAGE 109 of 200
MMRDA
Software for shutdown of the PC in case the main power supply

is not restored shall be provided as a part of the UPS.
Total Harmonic Distortion (THD) of the UPS shall be less than
five percent (5%) and any single harmonic distortion shall be
less than three percent (3%)
After a dip or failure of the main power supply, the rectifier
controller shall ramp up the DC voltage slowly.
The Uninterruptible Power Supply (UPS) System with SMF lead
acid
battery
shall
conform
to
the
minimum
following
specifications:
Details
i)
Description
UPS General Information
Function systems Required for the SCADA and communication

Rated Power at PF = 0.7
The Contractor shall design
and indicate
Input Voltage
240 VAC single phase to be furnished by the

Contractor from 415 VAC 10%, 3 phase,
4W, 50 hz 5% to be made available at one
location at each PLC location.
with Required
Integration
Local
SCADA
systems
ii) Allowable Variations in Input
Voltage
10%
Frequency
5%
Combined
voltage 10%
and frequency
iii) Output
Voltage
230 VAC, single phase
Frequency
50 hz 0.5% (free running ) and 3% (Sync
2266 of 2461
PAGE 110 of 200
MMRDA
mode)
Regulation
Less than 1%
Transient
5% for 100% load variation, correction in 10
Response
milli-sec or better
Inverter
PWM (IGBT)
Technology
Distortion(AC
(i) < 5% THD
harmonics)
(ii) < 3% for any single harmonic
Short term overload (i)
(maximums)
110% for 30
min (ii) 150% for 10

secs (iii) 200% for 5
cycles
Efficiency
(i) Inverter - 92% or better and (ii) AC to

AC - 85% or better
Load Power Factor 0.6 to unity

Static Bypass
Required with a transfer time of less than 5

milli-sec
Bypass Required
Manual
Switch
Backup Period
one hour back-up time at 100% of full load
iv) Protections
Mains Over/Under
DC
Required
Over/Under Required
Voltage
Inverter Over/Under Required
Voltage
Inverter Overload
Required
Overheat
Required
Built-in Soft/ Cold Required

start
Snubber circuits for Required
devices
v) LED Indicators
Mains On
Required
2267 of 2461
PAGE 111 of 200
MMRDA
Inverter On
Required
Battery on Charge
Required
Mains
Over/Under Required
Voltage
Battery Required
Low
Imminent
DC
Over/Under Required
Voltage
Inverter Overload
Required
Load On Inverter
Required
Load on Auxiliary Required
Supply
Overheat
Required
vi) Digital Metering
LCD
16 x 2 or better
DC Volts
Required
AC I/P and O/P Required
Volts
DC Current
Required
AC O/P Current
Required
Frequency
Required
% Battery
Required
Audible Alarm
Required
Isolation
of
UPS Required
output from main

power input
Alarm Contacts for Required
Self-Diagnostics
Protection Class
IP 54 or better
Operating
0 to 50 C
Temperature
Relative humidity
Up to 95%, non-condensing
vii) Batteries
Type of battery
Sealed maintenance free (SMF) lead acid
2268 of 2461
PAGE 112 of 200
MMRDA
Number of cells per Contractor to design and indicate
unit
cell Contractor to design and indicate
Nominal
voltage
Final cell voltage
Contractor to design and indicate
Capacity at 100% To provide one hour back-up time
load
Mounting
Open type multitier
arrangement
The following
(i)
Set of inter-cell, inter-row and inter-bank
Accessories
connectors
shall be
(ii) Number plates as required for the
provided but
complete installation
not limited to:
(iii) Centre zero voltmeter
b) Tests on the UPS System
The UPS systems shall be tested at manufacturers factory and

also
at
Project
Site
for
its functional
and operational
performance.
The following tests shall be carried out:
a) Voltage regulation at 0%-100% of full load
b) A load test, with verification of the current limiter operation
c) A test of the acceptability of the output voltage variation
d) Ripple and harmonics measurements
e) Efficiency and power factor measurements
f) Megger and HV tests for insulation
g) Heat run tests
h) Functional tests
i) Alarms and self-diagnostics tests
j) A verification of the communication with the Local SCADA
system
k) A DC start test for the UPS
2269 of 2461
PAGE 113 of 200
MMRDA
The above test feature should be demonstrated during Factory

Acceptance Test (FAT) & Site Acceptance Test (SAT).
The above feature should be demonstrated during Factory
Acceptance Test (FAT) & Site Acceptance Test (SAT).
12.7.11
Telemetry Equipment Specifications

I.
VSAT (Very Small Aperture Terminal)
1. VSAT should work on Ex-C band with min. 1.2 meter antenna and 2
Watt BUC.
2. VSAT modem should have,
a. 1 Ethernet Port
b. Frequency support- Tx - 6.725 - 7.025 GHz , RX- 4.5-4.8 GHz
c. Approved Make for VSAT hardware is i-Direct
d. Support for two way communications.
3. Bandwidth Allocation
VSAT bandwidth to be shared among all stations but within the
group. System should support double hop . Min 64 kbps full duplex
bandwidth is required .Offer should be submitted to 64 kbps band
width . If required service provider should be able to provide
additional bandwidth on chargeable basis.
4. The VSAT Service Provider should have
a. A valid license from DoT
b. minimum 25,000 installed base
c. VSAT Service provider should have hub in Mumbai
d. Similar SCADA system for water application should have been
installed
2270 of 2461
PAGE 114 of 200
MMRDA
e. TL9000, ISO 20000 and ISO 27001 certified VSAT Hub and
NOC services
Feature
Value
Operating Temperature
From -20 to +50
Antenna cable
Low Loss
Performance
Data Reception availability of 99% or

better
Specific Features
Communication
Direction
Double Hop
VSAT Radio system to allow two-way

communication system between Data
Centre and remote station
VSAT communication will be
double
hop system
VSAT bandwidth will be able to be
Bandwidth Sharing
shared among all stations but within the

same customer group. It should not be
shared with other users.
All
associated
Antenna
Accessories
all
equipment,
cables
and
including
mounting
hardware
Radio Modem Specifications
Radio Modem should have : Ethernet Interface , RS 232 and

RS 485 Interface on single Radio
Frequency Band should be :License Free : 865 to 867 MHz
Radio Modem Should work as a Master , Remote , Repeater
RF Power should be 1 Watt
Data speed upto 76 kbps on Ethernet and 38.4 kbps on

Rs232 & RS 485 interface
2271 of 2461
PAGE 115 of 200
MMRDA
Point to Point as well as Point to Multi Point operations
AES encryption should be built in
Mac ID filtering and secure Firewall protection should be

available as a built in feature
Built in Spanning Tree 802.1d
Temp : -40 to + 60 D C
Radio Modem should have multiple layers of error-detection

and correction
RF Connector : SMA Female
Radio Modem should have one Discrete I/O for Fault

detection
Radio Modem Should Have Receiver sensitivity -108 dBm @

10-6 BER
Protocol CSMA/CA with 32 bit CRC and auto-correction
On-line Configuration and Diagnostics
Radio Modem should provide Modbus serial to Modbus TCP

conversion
HTTP with remote configuration via wireless link RF signal
strength, Bit Error Rate, connection monitoring and statistics
PPP Protocol Access to diagnostics
Din Rail mounting
2272 of 2461
PAGE 116 of 200
MMRDA
Power Supply 10 30VDC
Indicators: Power/OK, Radio Rx and Tx, Radio Link, LAN

Link/Activity,
Serial Activity, Digital I/O, LAN 10/100Mbit Link
Approved Makes for Radios : ELPRO / MTL , Prosoft

Technology- USA , Calamp - USA
Should use Low Loss Foam Di Electric Coaxial Cable i.e.

inch Heliax
Lightning protection unit : Make Polyphaser / Andrew
Antenna should have atleast 6 dBi gain fibre Glass .
Contractor should have ISO 9001 certification
II.
Wireless IO & Gateway Specifications
A.
Wireless IO at remote locations
Should work in Non line of site conditions
Frequency band : 865 to 867 MHz ( License Band )
It should have built in 4 DI/1 DO and 6 AI and facility to extend

the IOs
Each device should be able to work as a repeater for other

remotes as well as master
Each device should have RS 485 interface for Expansion
2273 of 2461
PAGE 117 of 200
MMRDA
Unit should be with Din Rail mount
System should have built in CRC error check
Analogue Set points : High and low set points may be

configured for the analogue inputs to control a remote digital
output contact. The digital output will set (on) when the
analogue input value drops below the low set point and will reset
(off) when the analogue value exceeds the high set point
DC Supply Voltage : 11 to 30 VDC with overvoltage and reverse

power protected
Diagnostics, Testing : The 105 modules provide diagnostic and

test functions by connecting a PC terminal to the module. I/O
and communication functions may be tested. The 105U module
includes a radio strength measurement, which provides an
indication of background noise and received radio strength
Temp : -20 to 60 degC
Digital Inputs opto-isolated (5000V) inputs suitable for voltage

free contacts or NPN transistor, contact wetting current 5mA
Digital Outputs : four relay output contacts, normally open, AC

50V 5A / DC 30V 2A
Analogue Inputs floating differential inputs, common mode

voltage 27V, 24VDC for powering external loops provided,
digital filtering 1 sec. with 4-20mA resolution 15 bit, accuracy
10 bit
Pulse Inputs
digital inputs Max pulse rate 100Hz, pulse width
2274 of 2461
PAGE 118 of 200
MMRDA
min 5ms one input (DI1)
Pulse Outputs FET 30VDC 500mA max
RF Power out put should be 1 Watt
Preferred Make : ELPRO / Calamp / Teletronics
Receiver sensitivity should be : (-115dBm) 12dB SINAD
Typical radio message transmission time 80ms
Peer-To-Peer protocol with no reliance on a single network

master
Protocol must include message acknowledge to monitor

communications
Exception Reporting no delay for polling cycle, changes

reported immediately
Supplier will coordinate with the WPC , New Delhi to apply and
to get the frequency
Suitable antennas with atleast 6 dBi gain should be used ( Omni /

Yagi ) Antennas should be designed with DC grounded
Suitable Low loss coaxial cable should be used ( inch Heliax )
Suitable Lightning Protection Units should be used
Power supply to the radio should have a facility of battery charging

with auto changeover facility in case of power failure
2275 of 2461
PAGE 119 of 200
B.
MMRDA
Wireless Gateway at Master Station
Should work in Non line of site conditions
Frequency band : 865 to 867 MHz ( License Band )
It should have built in Built in physical 8 digital I/O to facilitate

alarm monitoring and sending independent of the serial protocol
Built in communications monitoring, including comms fail, time

since last communication and receive signal strength, which can
all be reported on the Modbus RTU bus
All
units should operate a level 7 firewall which Isolates the
radio network from the serial network allowing only permitted

values to pass, while protecting the serial network from any
interruptions/ disturbances on the radio link
Ability to operate as a Modbus RTU Master or Modbus RTU

slave in a single unit
Each device should be able to work as a repeater for other

remotes as well as master
Each device should have RS 485 interface for Expansion
Unit should be with Din Rail mount
System should have built in CRC error check
DC Supply Voltage : 11 to 30 VDC with overvoltage and reverse

power protected
Diagnostics, Testing : The 105 modules provide diagnostic and
2276 of 2461
PAGE 120 of 200
MMRDA
test functions by connecting a PC terminal to the module. I/O

and communication functions may be tested. The 105U module
includes a radio strength measurement, which provides an
indication of background noise and received radio strength
Temp : -20 to 60 degC
I/O Capacity : Modbus / DF1 4300 I/O points (analog plus

discrete)
Fail-to-transmit and fail-to-receive alarms configurable
RF Power out put should be 1 Watt
Preferred Make : ELPRO / Calamp / Teletronics
Receiver sensitivity should be : (-115dBm) 12dB SINAD
Typical radio message transmission time 80ms
Peer-To-Peer protocol with no reliance on a single network

master
Protocol must include message acknowledge to monitor

communications
Exception Reporting no delay for polling cycle, changes

reported immediately
Supplier will coordinate with the WPC , New Delhi to apply and
to get the frequency
Suitable antennas with atleast 6 dBi gain should be used ( Omni /

Yagi ) Antennas should be designed with DC grounded
2277 of 2461
PAGE 121 of 200
MMRDA
Suitable Low loss coaxial cable should be used ( inch )
Suitable Lightning Protection Units should be used
Power supply to the radio should have a facility of battery charging

with auto changeover facility in case of power failure
12.7.12
Intercom system
An EPABX system shall be provided at a control room of Water
Treatment Plant (WTP)
for voice communication.
All instruments located for outdoor applications shall be weatherproof

type.
Following paragraphs describes the minimum requirements for the
design, manufacture and application of the EPABX System. The
purpose of this specification is to ensure consistency in selection,
design and application of the EPABX System. Minimum hardware and
application software requirements of these systems are defined.
Contractor shall design, manufacture, test, supply, install, and
commission the EPABX system in control room of Water Treatment
Plant
Bidder shall make his own estimate of quantities for all items
and subsystems such as cards, MDFs, IDBs, cabling, conduits,

capping and casing, earthing, lighting protection, UPS, batteries
auxiliary power distribution, labour work etc. it should be clearly
understood that the Contract will be on turnkey (lump sum) basis and
no variation will be allowed for items of works not foreseen or omitted
by the Bidder. It is the responsibility of the Contractor to provide all
labour, materials, equipment and services necessary and required to
furnish and install a complete and operating EPABX system. Any
material not specifically mentioned in this specification, but required for
proper performance and operation shall be included.
2278 of 2461
PAGE 122 of 200
MMRDA
A. Applicable Standards
EPABX system shall comply with the requirements of International

Telecommunications
Union
(ITU-T)
Telecommunication
recommendations and relevant Indian/International applicable

statutes, regulations and safety codes in the locality where the
equipment will be installed.
B. System Requirements
The proposed EPABX, power supply, all type of cables and

accessories required to make the system complete shall cater to
the voice and data requirement of the WTP. Public Switched
Telephone Network (PSTN) cables (suitable multi-core cable) from
nearest PSTN exchange to WTP will be arranged by the Employers
Representative and terminated on Main Distribution Frame (MDF).
Contractor will terminate this telephone cables and Telephone
cabling from MDF (including MDF) to EPABX and their distribution
and termination up to extensions shall be in scope of Contractor.
The EPABX shall support analog, digital and ISDN extension,
analog lines from PSTN, BRI level DID lines from PSTN, and BRI
ISDN lines from PSTN.
EPABX shall be suitable for:
a)
Capacity
Equipped
Call Office (CO) analog
8 numbers
3 numberslines
b)
Call Office BRI ISDN
1 numbers
Nil
lines
c)
Analog extensions
2279 of 2461
64 numbers
PAGE 123 of 200
MMRDA
40 numbers
d)
Digital extensions
8 numbers
4 numbers
e)
Operator console
1 numbers
1 number
Multi function interface
1 card
Nil
card (PA system, relay
and voice system)
f) EPABX offered shall support the voice mail system (min. 4 port PC
based or 4 port in skin card based voice mail system, to be
procured in future by Employer, if required). However, the offered
EPABX system presently need not be fully equipped for voice mail1
EPABX is planned for intercom purpose. The EPABX shall have
centralized architecture. EPABX shall cater to the voice and data
requirement within the WTP premises and through trunk line from
BSNL to outside world.
C. System Description
The Exchange shall be modular and fully digital, using Pulse Code
Modulation (PCM) and Time Division Multiplex (TDM) techniques
conforming to ITU-T recommendations and shall be of Stored
Program Control (SPC) type.
The Exchange shall support Integrated Services Digital Network
(ISDN) and BRI level DID Extensions. Limitation, if any, regarding
maximum number of ports/cards supported shall be clearly brought
out by the Bidder. All systems must have provisions that enable
2280 of 2461
PAGE 124 of 200
MMRDA
connection to Employers Representative provided peripheral

equipment
such
amplifier/speaker
as
sound
music-on-hold
system,
and
system,
automatic
paging
telephone
answering equipment. The bidder is requested to specify all other

peripheral equipment that may be connected to the system
The system platform shall be based on open system architecture.
The EPABX shall accept DP (Pulse Dialing), DTMF (Dual Tone
Multi Frequency), Digital Phones and Fax and shall also have
support for interconnection with PA system, SCADA and other
control relay sys-tem.
The system shall be of 100 % non-blocking type and all the port
cards shall have equal access to any free available time slot and
shall have equal access to TDM Bus. System shall be based on
universal port architecture and shall not impose any restriction
whatsoever in terms of slots usage for a particular functional
benefit.
The upgradation shall be in building block architecture by adding on
additional stacks/cabinets. However, such expansion shall neither
involve any processor up-gradation nor any of the other common
control cards and cabinet. The EPABX system central processor
shall be controlled with non-volatile or stored programs. The
software pro-gram stored in a volatile memory and subject to
commercial power interruption shall be either a) protected from loss
by a short term memory retention battery, or b) permitted to be lost
but reloaded from some memory storage device after the normal
condition is restored.
The system shall be capable of working as transit switch, local
switch, data circuit switch, and packet switch in both digital and
analog environment.
System shall support following signaling protocols:
2281 of 2461
PAGE 125 of 200
MMRDA
a. ISDN BRI and PRI

b. E&M (2W/4W)
c. Dual Tone Multi Frequency (DTMF)
d. Interface cards suitable for PA system Interface and any other
protocols needed for the specified functions.
In case of emergency failures, the modules in hot standby mode
shall take over without dropping/interrupting any of the existing calls
in progress. EPABX offered shall be capable of providing hot
standby configuration, if required in future, using CPU and common
control cards. Presently the bidder shall offer the EPABX system
without hot-standby configuration. But feature demonstration will be
tested during Factory and Acceptance Testing of the EPABX
system. The bidder shall arrange for the test bench / setup for the
same on his own.2 The redundant system configuration shall
ensure high reliability and maximum MTBF (Mean Time Between
Failures) and minimum MTTR (Mean Time To Repair).
General System Features
Each subscriber shall be programmable for various COs say as
Class C1 Incoming and outgoing local calls.
Class C2 Local plus STD calls with software programmable barring
facility.
Class C3 Local
plus
STD
programmable barring
and
ISD
calls
with
software
facility.
2282 of 2461
PAGE 126 of 200
MMRDA
The EPABX shall have the following features:

a. Automatic distribution of incoming calls at reception desks
b. Auto attendant feature in case of all reception desks being busy
c. Direct Inward Dialing
d. Digital attendant console shall be with the following facilities:
e. All incoming PSTN calls shall land on operators desk and
operator shall divert the same to desired destination. Auto
attendant facility also shall be provided.
f. Automatic and manually selected trunks access
g. Operator controlled trunk-to-trunk connections
h. Adjustable time operator recall to advice caller that called station
is busy
i.
Automatic call return to attendant when called station fails to

answer within preset time period
j.
Emergency intrusion and, if necessary, disconnection of call in

progress by attendant
k. Call intrusion tone, which will announce to the engaged lines

that an intrusion is taking place
l.
Abbreviated dialing of up to 64 pre-entered numbers for

authorized stations
m. Howler tone on stations dialing incorrectly or left off hook
2283 of 2461
PAGE 127 of 200
MMRDA
n. Touch tone dialing, with pulse converters wherever required by

local public telephone company
o. Verify the status of a voice terminal that appears to be out of
order and quickly identify a faulty trunk
p. Alphanumeric display
q. Hands free operation shall be possible with the console
provided.
The System should support following features:
Abbreviated Dialing, Last Number Redial, Call Forwarding, Call
Pickup, Camp on, Leave Word Calling, Conference, Emergency
Transfer Facility, Speed Dialing, Direct Outward Dialing (DOD),
Group Hunting, Barge in facility, Direct Inward Dialing (DID), Call
Forwarding, Different ring for internal, external and feature activated
calls (e.g. call back), Password protected trunk access, Direct in
line facility for pre defined senior executives, Operator/Attendant
consoles
System shall support operator console for call handling application.
Console features include the following:
a) Music on hold
b) Automatic and manual call waiting tone to busy line
c) Visual indication of camped call holding beyond prescribed time
limit
d) Busy lamp field or traffic status feature
e) Incoming trunk identification
f) Outgoing trunk identification
g) Constant or pulsed trunk status display
h) Calling station number display
i) Display confirmation on dialed extension
2284 of 2461
PAGE 128 of 200
MMRDA
j) Display confirmation of attendant dialed outside number

k) Calling extension readout
l) Extension number display
m) Add on conference calls
n) Ring again on busy C.O. and internal extensions
o) Automatic last number redial
EPABX Software Requirement for Voice Mail Facility
EPABX shall support Voice mail facility. Every extension shall be
allotted a mailbox. Incoming calls shall be routed to extension
through operator. After predetermined number of rings, if call is not
responded, EPABX with voice guidance shall route caller to called
ex-tensions mailbox.
D. Telephone sets
Analog telephones shall have the following features.

a) Instruments shall be desk types
b) 80 cm coiled cord on handset
c) Message waiting light
d) Last number re-dialing
e) Volume control on ringer. Key pad lock
f) Redial
g) Flash (300 ms)
h) Pause (2 sec)
i) Mute
2285 of 2461
PAGE 129 of 200
MMRDA
j) Tone/Pulse selection by switch

k) Ringer volume control
l) Visual indication of ring by LED
m) Pulse/Tone dynamic change over
E. Power Supply
The EPABX shall use 230volts power supply and make provision
for 2 hr battery back up with suitable un-interruptible power supply
(UPS)
of
sufficient
capacity
Contractor
shall
pro-vide
un-
interruptible power to the EPABX system during normal availability

of commercial power and during commercial power transients and
failure. The UPS shall be non-redundant and consist of a battery
rectifier/charger, a "SMF" type battery pack, an inverter, and an
UPS failure bypass transfer switch. The battery discharge time shall
be no less than 120 minutes and the battery recharge rate shall be
8-15 times the discharge time. The equipment shall be sized for the
line/station capacity of the configuration. The inverter can be
omitted if the total system requires only DC power. The bidder shall
specify the equipment to be provided. The Contractor shall indicate
the maximum load requirement for the proposed capacity. Wire,
cable, and hardware shall be provided to interconnect the system,
connect the system to the wall service outlet power receptacle. The
system shall include a power line transient voltage suppressor
(TVSS), central office telephone service TVSS devices, and interbuilding cable TVSS devices to protect user personnel and pre-vent
equipment damage or total loss resulting from voltage and current
surges superimposed upon the commercial power line and all
telephone line circuits by lightning strikes, commercial power faults,
and power line to telephone line faults.
2286 of 2461
PAGE 130 of 200
MMRDA
It shall be the Contractor's responsibility to provide any wiring for

system components such as rectifier and inverter required on the
system side of the electrical receptacle. The EPABX cabinet shall
be grounded with a No. 6 AWG or larger solid copper insulated
ground wire to a single point ground. The ground wire shall be
tagged and identified at the service equipment enclosure and panel
board.
The Contractor shall provide main Distribution Frame (MDF) and
Internal Distribution Box/Board panel (IDB) along with suitable
cables from MDF to EPABX and EPABX to IDBs to individual
extension. Capacity of IDB and Cables shall be suitable for
distributing the EPABX capacity extensions.
F. Telephone Cables
Telephone cables going out of the building shall be jelly filled steel
armoured, fire retardant, outdoor type. All indoor as well as out door
cables shall have approval of DoT and other telecommunication
and standard organizations. Wire, cable, and hardware shall be provided to interconnect the system, connect the system to the wall
service outlet power receptacle, and to connect the system to the
PSTN network demarcation or Employers Representative provided
PABX interface point. The telecommunication wiring should be in
accordance with the requirements specified in ANSI/EIA/TIA-568.
12.7.13
Fire Detection & Alarm Requirement In Control Room

I. Requirement for Intelligent Fire Detection And Alarm (FDA)
System
This
section
covers
the
technical
requirement
for
MICROPROCESSOR BASED ANALOGUE ADDRESSABLE TYPE

INTELLIGENT FIRE DETECTION AND ALARM SYSTEM (FDAS).
2287 of 2461
PAGE 131 of 200
MMRDA
A. The FDA system shall cover design, engineering, manufacture,

supply,
erection, installation, testing & commissioning of the FDA
system. FDA System
The FDA system shall consist of minimum following equipment:
Smoke detectors, & photo electric smoke detector, as per the

design criteria. All addressable electronic equipment should be
UL / FM approved
Main fire alarm control panel (FACP)
Break glass type microprocessor based addressable manual call

points with chain &hammer
Hooters
Transponders/ Interface Modules
Response indicators where required for above false ceiling

detectors & normally closed rooms
Power supply equipment
Battery back - up for 24 hours, in case of power failure, shall be

provided
U.P.S system
Siren and Accessories
All types of cables (FRLS) and cabling accessories
Erection materials
2288 of 2461
PAGE 132 of 200
MMRDA
Earthing Materials & Earthing
Minor civil works required for installing FDA System equipment

as required
GI pipes /GI conduits /PVC rigid conduits and other accessories

wherever required for laying of cables
Trench work, if required, for cabling
Furniture, Racks etc.
All erection accessories, consumables and miscellaneous

material not indicated in specification but required for completing
the job in all respects
Preparation of Design and detailed engineering drawings and

documentation, bill of materials with specification
Submission of operational and maintenance manuals
Submission of as-built drawings
Commissioning spares till handing over of the system
Two years maintenance spares
Special tools & tackles for testing & maintenance of the system
B. Area to be covered by Fire Detection & Alarm System
Local Control rooms,
Main SCADA room, UPS room, PLC
room, computer room, Battery room, Telephone exchange room,

2289 of 2461
PAGE 133 of 200
MMRDA
or other rooms as required, False ceiling / flooring etc.

C. Information to be furnished by Tenderer along with Offer
BILL OF MATERIALS with make and model no. of equipment
Fire Alarm System schematic
Layout scheme of detectors with Fire Alarm Panels & cables in

complete
List of deviations Power requirement
General View of panels
Manufacturers product catalogues
D. Drawings to be prepared by Successful Tenderer

I. For Approval
Final Bill of Materials
Schematic of Fire alarm system
Location scheme of detectors
External connection diagrams
Equipment layout drawings with mounting arrangement,

termination details etc.
Cable routing
2290 of 2461
PAGE 134 of 200
MMRDA
Specification data sheets for equipment and cables
Panel general view
Cable and pipe schedule
Quality Assurance Plan for equipment & cables
II. For Information and Reference
Wiring Diagram of Panel
Details of Panel and Installation
List of Components in Panels
Operation & Maintenance Manuals
As-Built Drawings
E. Tests and Inspection

All
equipment
shall
undergo
type
and
routine
tests
at
manufacturers works. All tests shall conform to UL / FM / N.F.P.A /

IS 2189 approvals & standards. Factory Test certificates shall be
submitted when requesting for inspection. The material shall be
dispatched only after issue of inspection or waival certificate and
after getting dispatch clearance.
F. Guarantee and Warranty
The tenderer shall study the specification & satisfy himself
thoroughly regarding the workability of the plant, equipment &
system offered & also take full responsibility for the guaranteed
2291 of 2461
PAGE 135 of 200
MMRDA
operation & performance of the same as well as for their smooth,

safe & reliable working. The tenderer shall guarantee the integrated
operation of the system & equipment covered in his scope as a
whole including inter faces required to be established with other
related system.
Should the tests specified show that the equipment has failed to
achieve the guaranteed parameters, the supplier shall carry out
necessary modification or part replacements to achieve the
guaranteed parameters & successful demonstration, and the tests
shall be repeated without any extra cost to the purchaser. The
tenderer shall submit quality assurance program (QAP) in the
format enclosed for individual equipment, panels, cables and overall
system. This shall be followed for inspection / waive.
G. Enclosure Classification
Degree of protection of equipment shall be as per IEC 947.1.1988

and IS 13947 (part I) 1933.
Panels, Boxes and Centers in electrical rooms
IP 42
Panels and Boxes in heavy environment condition
IP 54
Field devices
IP 65
Air conditioned control rooms
IP 4X
H. Application Codes and Standards
S.
Code Number
Description
No.
1
IS-2189-1988
Reaffirmed
1998. NFPA
Code of practice for selection, installation

in
- and maintenance of automatic fire detection

and alarm system (second revision
Amendment-II for IS 2189)
NFPA 72 & UL For selection of Fire Alarm Panel, all
2292 of 2461
PAGE 136 of 200
S.
MMRDA
Code Number
Description
No.
268
detectors & modules.
UL 864
For Fire Alarm Panel
IS-5-1994
Color for ready mixed paints and enamels

(Fourth Division)
IS-9537PART-II-
Specification for conduits for electrical
1981
wiring
IS-694-1990
PVC insulated cables for working voltages

upto and including 1100V (Third revisionAmendment-I)
IS-1554
PART-I- PVC insulated (heavy duty electric cables
1998
part-I for working voltages upto & including

1100V (Third Edition-Amendment-I)
IS-10810
PART- Method
53-1984
of
test
for
cables
part-53-
flammability test
Reaffirmed in 1991
9
IS-1255-1983
Code
of
practice
for
installation
and
Reaffirmed in 1991
maintenance of power cables upto and

including 33KV rating (Second revisionAmendment-I)
10
IS-3043-1987
Reaffirmed in 1991
11
Inspection
& As per QAP
Testing
The system shall have proper listing, comply & or approval of the
following recognized agencies.
U.L.
Under writers Laboratories Inc .U.S.A
F.M.
Factory Mutual
NFPA
National Fire Protection Association
IS
2189
2293 of 2461
PAGE 137 of 200
MMRDA
I. Micro Processor based, Analog Addressable type Intelligent

Fire Detection & Alarm System
i) Design Requirements
All equipment & component shall be new & MANUFACTURERS

current
model.
The
computer
aided
microprocessor
based
addressable analog type Fire Detection and Alarm system shall be

software controlled automatic. The system shall consist of central
processing units (CPU), various man machine interface module
communication system, microprocessor based fire alarm control
panels, printer, video display unit. Addressable analogue automatic
sensors and interface unit as applicable.
The system basically comprises of Detectors, Indicators, Manual
Call Points, Fire Alarm Control Panels, Power supplies and other
accessories required for completing the system.
The system shall use both Automatic fire detectors and
addressable manual fire alarm call points.
Microprocessor based Break glass type manual call points with
chain & hammer.
An electronic hooter or horn or electric bell, siren associated with
fire alarm system.
Annunciation
of
alarm
condition,
type
and
location
of
acknowledged detector
Audible signal with flashing of light, until acknowledged
Frequency of audible signal shall be as per IS-2189-1988
Indication of Alarm / trouble location on the Main Fire Alarm
2294 of 2461
PAGE 138 of 200
MMRDA
Panel / on the local Graphics computer in the control room
Suitable number of N.O & N.C potential free contacts shall be

kept in the Fire Alarm Control Panel.
A distinctive audible and visible signal indicating the occurrence

of a fault within the system (for example break in circuit, short
circuit, fault in power supply etc.)
ii) Features:
Diagnostics: The system shall be self diagnostic type, involving
detection and alarm of any fault or open / circuit in the system. On
acknowledging audio alarm is silenced while alarm lamp persists, till
rectification of fault.
The system shall have test mode facility to check the
healthiness of the system
Audio alarm for fault shall be different from fire signal alarm in
tone and intensity
Isolation of line in case of line faults and give alarm
Audio visual alarm for fuse blown out
Release of loud alarm /siren under the control of operator
Resetting of the system
J. Detectors
a)
Smoke Detectors Analog addressable photo electric smoke

detectors:
2295 of 2461
PAGE 139 of 200
MMRDA
These shall be operated by detecting the scattering or

absorption of light by smoke particles. The detectors shall be
plug in type and shall have common base. The visual alarm LED
shall be clearly visible from outside by a flashing light. The
detectors shall have provision for connecting repeat response
indicator. The detector shall be suitable for 24V D.C operation.
Any other type detector the, Tenderer feel necessary. The
detectors shall be plug in type and shall have common base.
The visual alarm LED shall be clearly visible from outside by a
flashing light. The detectors shall have provision for connecting
repeat response indicator. The detector shall be suitable for 24V
D.C operation.
b)
Manual Fire Alarm Call Points (MCP), Addressable Type
MCPs shall be Manually operated device used to initiate an

alarm signal. Usage of all types of MCP shall be as per IS-21891988. All devices such as automatic pull switch, circuitry etc,
shall be totally enclosed in the box. The manual call point
stations are break glass type general alarm station. The manual
call point shall consists of a MS enclosure with a glass front.
One NO contact is built into the enclosure. The front glass keeps
the switch in pressed condition. The contact changes and this
change over is sensed by the monitor module and alarm
generated at the control panel. The manual call points are
available in whether proof / flame-proof enclosures also. The
operation of manual call point in the event of emergency, shall
be by breaking the shutter proof glass with the help of hammer
provided along with call point. Manual call points are installed
near exit / entrance doors, stair cases or outdoor locations
where automatic fire detectors cannot be installed.
c)
Interface Units
Addressable Interface Unit The interface unit shall be suitable
2296 of 2461
PAGE 140 of 200
MMRDA
for connecting normally open type alarm initiating devices such

as pressure switch, flow switches, level switches, potential free
contacts etc. in the addressable loop, if required. The interface
unit shall be a sealed electronic unit with an address switch for
individual address. It shall be housed in a metallic /high impact
plastic enclosure and suitable for indoor / outdoor installation.
The operation voltage shall be 24 V D.C. Monitor Module
Monitor Module monitors are dry contact type fire or security
initiating devices. It reports its unique address to the panel to pin
point the exact alarm location. Features: Provides individual
addressable input for fire alarm or security devices Monitors
either two or four wire (fault-tolerant) initiating device circuits.
The monitor modules shall provides a two or four wire fault
tolerant initiating circuit for normal open contact fire alarm
devices
and
supervisory
devices.
Provides
full
analog
supervision of circuits.
The monitor module shall be assigned a point address via two
direct dial decade switches. Its address and circuit status i.e
normal, open, short are communicated to the control panel. An
integral LED blinks each time the controller scans the module
and LED latches in alarm condition by command from the
controller.
d)
Address Control Module
The control devices shall form part of loop devices. Control

module shall supervises and controls indicating devices and
their associated wiring. The module shall also provide SPDT
(single pole double throw) switching action for other locally
powered equipment. Features: Provides addressable control to
indicating devices Controls and supervises two or four-wire (fault
tolerant)
indicating
device
circuits.
Provides
full
analog
supervision of circuits. The module provides a supervised 2 wire

or 4 wire fault tolerant output indicating circuits for audible
2297 of 2461
PAGE 141 of 200
MMRDA
devices, strobes and response to normal open circuit or short

circuit condition of the circuit. Application: For Controlling
hooters or any other switching device.
e)
Microprocessor based Fire Alarm Control Panel (FACP)

Fire Alarm Control Panel shall be intelligent, with its own
Microprocessor and memory in each every card.
The control panel as a built in feature shall have one / two
modules & each module without adding any card shall be able to
create additional loop i.e. 2 loop/module.
100% hot redundancy shall be provided in the FACP control unit
& other critical component like CPU, memory, memory control,
power supply cards, RAM etc. to ensure uninterrupted operation
of the FDA system. The standby cards shall perform the entire
functions of the system when the main CPU & other control
cards fail without affecting the functioning of FDA system. Any
failure of cards shall be brought to the notice by audio visual
alarm. The control panel shall have facility to process the input
signals and also have facility to control all the input data
received from addressable analogue type detectors/addressable
interface unit. Fire alarm control panel shall have number of
electronic filters to ignore false alarm and increase sensitivity to
real fires from sensors. The electronic filters shall recognize the
unwanted alarm from detectors due to electrical spikes.
The Fire Alarm panel shall have facility to connect to a local
graphics work station comprising of PC, Printer, Keypad,
Mouse, peripherals etc. The graphic work station shall form
part of mimic. Also the Fire alarm panel shall be connected
to the facility LAN point for feeding data to the Main
SCADA). The necessary TCP/IP hard ware & software shall
be built- in the panel.
2298 of 2461
PAGE 142 of 200
MMRDA
Control panel shall have the following features:-Logging an

alarm, time and action text on printers. Status check of disabled
alarm addresses before they are restored. Storing of alarm and
the possibility of internal organization of alarms. The fire control
panels offered shall have high degree of flexibility with:
The possibility of expanding to a bigger system with several
control panels and control and information units.
Fire control panel shall have facility for test features.
The status check of each detector, interface units for alarm, prior
warning, trouble, disabling shall be possible from control panel.
The control panel shall have memory storage for last events and
an alarm counter for number of alarms occurred after the control
panel is installed.
Fire alarm control panel shall have the sounder silence, reset,
more alarm push buttons and also push buttons for user menu
structures.
The Power Supply to the control panel shall be 240 V, 50 Hz.
Single phase, AC supply.
The fire alarm control panel shall be able to provide the following
features
Block Acknowledge
Automatic
day
To acknowledge the alarm

Night To have higher sensitivity during
sensitivity Adjust
unoccupied period.
Device Blink Control
For flashing LEDs on the detector.
Drift Compensation
For
compensating
response
2299 of 2461
due
to
the
detector
environmental
PAGE 143 of 200
MMRDA
Block Acknowledge
To acknowledge the alarm

changes.
NFPA 72 Smoke Detector For routine check-up of the sensors

sensitivity test
from the panel
System Status Report
Documentation of various system

parameter
Alarm
Verification,
by To eliminate generation of false
device with tally or
alarm due to dust cigarette smoke
Printer Interface
For printer interface which is used

for system documentation
Periodic Detector Test
For detector testing from the panel.

Which eliminates the need for
testing the detectors in the field
every now and then
Trouble Remainder
To remind the operator of the

maintenance
required
at
the
individual detectors.
Upload /download to PC For programming the panel in the
computer
Smoke
first power up
Detector Give an indication to the operator
maintenance Alert
that the detector requires cleaning.
The display assembly shall contain, and display as required,

custom alphanumeric labels for all analogue addressable
modules, and software zone for easy identification of fire
location.
The system display shall provide a 400 character back-lit
alphanumeric Liquid Crystal Display (LCD). It shall also provide
six Light - Emitting-Diodes (LEDs) that shall indicate the status
of the following system parameters: AC POWER, SYSTEM
ALARM, DISPLAY TROUBLE and SIGNAL SILENCE & CPU
failure.
The system display shall provide a 25 key touch key pad with
2300 of 2461
PAGE 144 of 200
MMRDA
control capability to command all system functions, entry of any

alphabetic or numeric information, and field programming. Two
different pass word levels shall be accessible through the
display interface assembly to prevent unauthorized system
control or programming.
The system display shall include the following operator control
switches: SIGNAL SILENCE, LAMP TEST, RESET, SYSTEM
and ACKNOWLEDGE.
f)
Field programming
The
system
shall
be
programmable,
configurable
and
expandable in the field without the need for special tools or

electronic equipment and shall not require field replacement of
electronic integrated circuits. The field programmability is
essentially required so as to make the necessary modifications
in the system parameters as per the site conditions. The field
programmability shall allow the client make changes in various
system parameters as per their operation philosophy. All
programming shall be accomplished through the standard FACP
key board or through the video terminal. All field defined
programs shall be stored in nonvolatile memory to ensure no
data is lost during the power loss.
g)
Specific system operations
Smoke Detector Sensitivity Adjust: Means shall be provided for

adjusting the sensitivity of any or all analog addressable smoke
detectors in the system from the system key pad or from the key
board of the video terminal. Sensitivity range shall be within the
allowed UL window.
Alarm Verification: Each of the Analogue Addressable smoke
detectors in the system shall be independently selected and
2301 of 2461
PAGE 145 of 200
MMRDA
enabled to be an alarm verified detector. The alarm verification

function shall be programmable from 5 to 50 seconds and each
detector shall be able to be selected for verification during the
field programming of the system or any time after system turn
on. Alarm verification shall not require any additional hardware
to be added to the control panel. The FACP shall keep a count
of the number of times that each detector has entered the
verification cycle. These counters shall be displayed and reset
by the proper operator commands. To eliminate generation of
false alarms due to dust or cigarette smoke.
h)
Point read
The system shall be able to display the following points status

diagnostic functions without the need of peripheral equipment.
Each point shall be annunciated for the parameters listed.
i)
Device status
Device type
Custom Device Label
Software Zone Label
Device Zone Assignments
Analog Detector Sensitivity
All Program Parameters
System history Recording and reporting
The fire alarm panel shall contain a history buffer that shall be
capable of storing minimum 800 system output/input/control
activations. Each of these activations shall be stored and time
and date stamped with the actual time of the activation, until an
operator requests that the contents be withered displayed or
printed.
2302 of 2461
PAGE 146 of 200
j)
MMRDA
Automatic Detector Maintenance Alert
The fire alarm control panel shall automatically interrogate each

Analogue addressable system detector and shall analyze the
detector responses over a period of time.
k)
Hooters Hooters
The electronic sounder / loud speaker being located at vital

places shall have minimum audible level of 65 dB OR 5 dB
above noise level of the working area.
l)
Power Supply, Cabling and Wiring and Control Centre

Power Supply:
The power to the Graphics computer shall be derived from a

suitable UPS with 50% loading.
Wiring type for fire alarm device loop: Style -6 4WIRE
FAULT TOLERANT
Central Processing Unit (CPU) of Fire Alarm Panel
CPU shall communicate with various microprocessor based fire

alarm control panel /peripherals of the system and execute
/receive FIRE & FAULT alarms, control the activation of o/ps
etc. CPU failure should be indicated by an LED on the front facia
CPU shall also communication with printer and video display
unit through RS-232C or current loop.
Indications / information received from detectors /field devices,
switches etc to CPU shall be repeated to other panels if
specified.
2303 of 2461
PAGE 147 of 200
MMRDA
The CPU shall serve as an interface between controller for

operator peripherals and remote fire alarm control panels.
The CPU serves as central processor, system software shall be
designed specifically to monitor status; processing alarms
according to priorities, controlling / processing communications
with operator peripherals; and synchronizing all system activity.
For reason of reliability and preventing inadvertent changes,
system shall be maintained in non-volatile memory. System
shall permit reprogramming by authorised personnel only.
The CPU shall indicate post dates for carrying out periodical
system maintenance for each detector without interrupting other
detectors. The same shall have printing facility. The CPU shall
derive power from panel Power supply
The looping scheme, scheme of detector connection shall be
software programmable.
m)
Local Video Display Unit: (Graphic Work Station)
The VDU shall be for data retrieval, alarm annunciation,

commands and programming functions.
The VDU shall have for the following functions,
Alarm and returns to normal
Commands, reports and programming
Time, day and date
Alarms and all other change of status shall be displayed in the
2304 of 2461
PAGE 148 of 200
MMRDA
screen area reserved for the information. Upon receipt of alarm,

an audible shall sound and the condition and point type shall
flash until acknowledged by the operator.
Multiple levels of access to the system shall be provided for
operators and supervisors via user defined passwords.
Monitor used for display shall be 21 inch color monitor.
n)
Printer
Printer used in the system shall be hard copy output device and
shall provide real time records of the system events and provide
system reports on demand.
The printer shall automatically record all alarms, troubles,
acknowledgements, return to normal and commands selected
by the user.
Alarm shall be highlighted differently than other messages and
shall be recorded, including type, location, time, date and
numerical address of alarm point. If an alarm is received during
the preparation of reports, the printer shall interrupt the report to
record
the
alarm
and
afterwards
resume
the
report
automatically.
All changes to system programming shall be recorded
automatically.
Power supply to the unit shall be 240V, 1phase. 50Hz AC.
o)
Cables
The cables required for detectors connection shall be multi core,

(2 core, 3 core, 4 core), stranded as per IS-1554, IS 8130 & IS
2305 of 2461
PAGE 149 of 200
MMRDA
- 5831 as in BOQ. The cable shall be Fire Resistant Low Smoke

(FRLS), screened type.
The power supply cables shall be as per IS-1554 part-I 1988,
Twisted pair, 1100 Volt grade.
However if any special cables are required for detector cabling
etc, the tenderer shall specify clearly briefing the specification.
For detector wiring - Annealed tinned solid copper conductor of
1.5 /2.5 /4.0 sq. mm, as required (IS 1554) PVC insulated &
PVC sheathed, Armoured cable.
Cables connected to detectors shall be given S loop on both
sides of the detectors which shall be properly clamped to the
ceiling.
S loop shall also be left where cables connect sounders,
panels, etc, Appropriate glands shall be provided for the
armoured cable near terminals of junction box.
Unused cable holes if any should be plugged.
p)
For all types of cables 20% spare core to be kept.
All the cables and wires shall be tagged for proper identification.
Wires shall be identified by ferrules at junction and cables by
colour bands at every 3 M distance.
Over-head lines for fire alarm system shall not be used when
connecting different building. They shall be laid under ground
according to IS: 1255-1983.
The cables and wiring for fire Alarm circuit shall not be clubbed
with other cables and wiring which must be laid well away from
2306 of 2461
PAGE 150 of 200
MMRDA
them.
The panel should have capacity to operate auxiliary equipment
like fire dampers, ventilation and / or pressurizing fans,
emergency light, smoke vents etc. if required.
The above requirements are indicative only.
12.7.14
Requirement for Closed Circuit Television Monitoring (C.C.T.V.M.)

System
I.
General
The Closed Circuit Tele Vision Monitoring (C.C.T.V.M) System will

be provided for comprehensive round the clock surveillance for
control and supervision of processes as well as for security to be
observed directly or which require monitoring from a remote control
center by operational people. The system consists of colour
cameras (CCD type) with fixed/zoom lens, 21 TFT color monitor,
monitor console, wiper & washer unit of the weather proof housing,
remote controlled Pan & Tilt unit, Receiver Driver unit, matrix
switcher,
Digital
Video
recorder,
camera
mounting
platforms/structures, control console with control units for complete

control of the cameras. Inter connecting video and control cables,
Video distribution amplifiers / Video cable equalizers (if required), &
all other auxiliary equipment, connectors & erection accessories
etc. as required for completeness of the system.
II.
System Requirements
The cameras will be of Charge Coupled Device (CCD) type and

these will be mounted in such a manner as to provide continuous
monitoring of the processes and security of the premises as
required. The system will provide clear and sharp picture on
monitors in industrial lighting conditions at any time of the day or
2307 of 2461
PAGE 151 of 200
MMRDA
night.
The complete CCTVM Systems will work on 240 V 10%, 50Hz 2
Hz, single phase AC supply. In case any other power source is
required, the same will be arranged from the above available
source. The CCTVM system will be provided with an uninterrupted
power supply system for feeding stabilized and continuous power
supply to all equipment All equipment for C.C.T.V.M systems
covered in this specification will comply with the CCIR standards.
All control functions related to the CCVTM Systems comprising
Cameras, Monitors,
blower unit and wiper & washer unit of the
weatherproof housing will be effected from the control units, which

are to be installed in the control rooms of the shop. All the CCTVM
Cameras shall be multiplexed to suitable number of monitors. The
CCTV Cameras along with multiplexing & control shall be interfaced
to the operator stations.
III.
Equipment Details
The C.C.T.V.M. system will comprise of the following.
Colored cameras with vari focal length/motorized zoom lenses
Camera mounting platforms / structures
Remote controlled Pan & Tilt units
Receiver Driver unit
Matrix switcher
Key board unit
Digital video recorder
Control console
Color video monitors
Interconnecting power, video and control cables
Video distribution amplifiers/ Video cable equalizers, as per

requirement.
Alarm annunciator
2308 of 2461
PAGE 152 of 200
MMRDA
All other auxiliary equipment connectors, erection accessories

etc. as required
IV.
Camera
The cameras will be compact, of rugged design and suitable for

industrial continuous monitoring applications. These will be
specially designed and tested to provide continuous good quality
video output throughout wide variations in environment conditions
like temperature, humidity, shock and vibrations and varying light
condition prevalent in the Water Treatment Plant. The cameras will
use 1/3 format interline transfer CCD imager and have virtually
zero lag, no image burns and no geometric distortion. These will be
of latest state of art technology ensuring high operational reliability.
The cameras shall deliver well defined, clear, high resolution
colored picture, with sufficient contrast to allow for good object
recognition even in poor light conditions. A highly sensitive
automatic light compensation circuit will ensure constant video
signal independent of wide variations in light levels. The cameras
will have long life and require virtually zero maintenance in adverse
environmental conditions prevalent in the Water Treatment plant.
The Cameras will also possess the following features:
High resolution
Low power consumption
Phase adjustable line lock facility
All controls like back focus, lens select, phase adjustment, etc.
The camera unit will be complete with all electronic circuitry,

devices, components, control switches, standard mount for
2309 of 2461
PAGE 153 of 200
MMRDA
lenses, mounting assemblies etc. The mounting assemblies of

the cameras will be individually selected depending upon the
special requirements as per actual site conditions
Color cameras of 1/3 format with Auto iris remote zoom focal
lenses are envisaged to suit different requirements of site. The
camera shall be color CCD type, high resolution of minimum 450
TV lines.
Pick-up device
1/3-inch format, interline transfer, CCD

image sensor
Minimum illumination
0.01 lux at f 1.2
Signal to noise ratio
46dB minimum
Electronic Shutter
Automatic, On/off selectable.
Video outputs
Composite video - 1.0 V p-p, 75 ohm
AGC
On/Off selectable
Aperture Correction
Horizontal & Vertical
Synchronization
Line lock - for roll-free vertical interval

Switching
Crystal lock
Connectors
Video out: BNC Video/DC-Iris connector:

4-pinEIAJ
Operating
as per location indicated
Temperature
EMC
V.
CE/UL certification
Camera Lens
The camera lens will be suitable for the camera on which it is to be

mounted. The lenses chosen will be Auto iris remote zoom
controlled so as to meet the operational requirements. The choice
of lenses, their focal length and viewing angle will be judiciously
done for effective monitoring suited to the specific application
requirements.
2310 of 2461
PAGE 154 of 200
S. No.
VI.
MMRDA
Description
Motorized Zoom
1.
Type of lens
Motorized Zoom
2.
Lens format
1/3 ,
3.
Iris type
Auto IRIS
4.
Type of mount
C / CS
Camera Mounting Platform
The camera mounting platform will be suitable for mounting the

camera assembly on walls / column / structures as per the actual
requirements at site and keeping in view the area to be covered by
the individual camera. The mounting will be with adjustable support
so as to have flexibility to move the camera assembly as and when
required. Wherever necessary, structures / vertical poles to mount
the cameras shall be fabricated.
VII.
Receiver Driver Unit
The receiver shall be able to receive pan & tilt, camera and lens
positioning and adjust command signals from the operators
keyboard through the CPU/Matrix and execute them. The unit shall
generate the power for the enclosure, camera, zoom lens etc.
Receiver driver unit shall comply min IP 65 for outdoor. The
equipment shall be CE/UL certified. The receiver driver unit shall
withstand the temperature indicated for the corresponding area.
VIII.
Pan and Tilt unit
The pan and tilt unit will comprise of pan & tilt head and control unit.
The pan and tilt head will be remotely controlled from the control
unit. The pan & tilt head will be heavy/ medium duty type/light duty
type, rugged in construction and smooth in operation. The unit shall
be able to cater the load of weather proof housing, wiper & washer
2311 of 2461
PAGE 155 of 200
MMRDA
unit and compressed air pipe line arrangement. The unit will be
used to cover large area of interest for surveillance in different
directions, as required by the operator. The unit will be suitable for
mounting on walls / column / structures / hanging from ceiling as
per the site requirements. The unit will have complete freedom of
movement throughout the entire pan & tilt scan. The unit will be
completely sealed for all weather proof use.
The pan and tilt units will be designed so as to ensure long
operational life. The units will employ electric motors with quick
reversibility and dynamic braking characteristics, have rugged worm
gears assembly to minimize backlash and ensure drift free
operation. It will be possible with ease to reposition the cameras
field of view at any time. The unit will have manual over ride on the
auto mode to enable the operator to choose the area of scan as
and when required. The Pan & Tilt unit shall withstand the
temperature indicated for the corresponding area.
Technical Parameter of Pan and Tilt unit
S.
Description
Parameters
No.
1
Angular travel in horizontal 0-355 deg.

plane
Angular
travel
in
vertical +/-90 deg.
plane
3
Operating speedPanning
6 deg./ sec
Operating speed Tilting
3 deg./sec
Maximum load (Load rating

to be compatible for camera,
lens and housing fitted)
Braking
Mechanical friction type
Construction material
Main
body
Aluminium
casting
2312 of 2461
PAGE 156 of 200
IX.
MMRDA
Microprocessor Based Matrix Switcher
To control the C.C.T.V.M system microprocessor based matrix

switchers are envisaged. The system shall have matrix switchers at
control rooms. At control rooms matrix switchers of suitable inputs
and outputs and alarm interface units are provided for switcher to
handle the alarm events. The switcher system shall provide
minimum the following basic features
Full matrix switching
Synchronized video switching
A logging printer port which provides a hardcopy printout of

either the system status changes or system Tables and
Sequences
Keyboard log-on/log-off with password protection
16 character camera titling
Accommodation of alarm points
CE/UL certification
The matrix switcher must be modular in construction i.e. should

have Main base having CPU, power supply and main bay, and
required number of input and output cards must be put in the bay
for configuring a solution. The system should allow multiple number
of keyboards to be directly connected to it in star configuration. It
should allow prioritizing the keyboards as per the requirement.
2313 of 2461
PAGE 157 of 200
MMRDA
Video Inputs
As per Site requirements
Video outputs
RS-232 Ports
1 each for PC, printer and alarm signals
Input voltage
0.5 V p-p to 2.0 V p-p, Composite Negative Sync)
level
Gain
Unity (75 ohm terminated)
Switching
Cross point Matrix
Features
Full matrix switching, any camera to any monitor

Programmable switching sequences
Salvo switching capability
P/T/Z control outputs in the form of Biphase/RS485/RS-422 etc.
min 40 character on screen display for time- date,
camera number, camera ID, monitor or status
information & 16 character alarm titling
With the keyboard, following P/T/Z controls shall be
available:
a) Pan, tilt, auto pan and random pan
b) Zoom, focus and iris control
c) Zoom, focus and iris control
Operating
as per locations indicated
Temperature
Humidity
0 to 95 % non-condensing
EMC
CE / UL certified
X.
Alarm Interface Units
An additional alarm interface unit shall be also supplied along with

the above switcher. The unit shall have the ability to automatically
display video under alarm conditions. It shall accept upto 64 contact
closures or logic level inputs from remote sensing devices. The unit
shall also provide 8 relay closure outputs upon alarm conditions.
2314 of 2461
PAGE 158 of 200
XI.
MMRDA
Key Board for Matrix Switcher
Keyboard is envisaged for full function, for system control and

programming at control rooms. The keyboard includes integral
pan/tilt/zoom joystick for controlling cameras features.
Features
Control of Matrix switcher

Soft backlit keys with user friendly menu and easy to
read display
Joystick for P/T/Z control of camera
Shall be interfaced to Matrix switcher for control of
Camera selection and P/T/Z control
LCD display of complete menu for selection of
various functions
CE/UL certification
Connectors RJ11 connector for matrix switcher (power / data)

Aux. power, for extended distances
RS-232 port for remote programming
Other standard connectors
XII.
Digital Color Multiplexer Cum Recorder
This multiplexer and integrated digital recorder provides multicamera recording and playback with the added capability of multi
screen viewing. Programming is easily accomplished via front panel
control
keys
and
on-screen
display
menus.
The
duplex
multiplexer/recorder can encode up to 8/16 color video inputs on its

internal hard drive while simultaneously displaying video in the full
screen or any of the multi-screen modes. General Requirements:
The multiplexer specified shall be designed to record (encode) and
playback (decode) up to 8/16 color cameras. The unit shall also
have the added capability of multi screen viewing. In playback
(DECODE mode), the multiplexer shall provide a full screen display
of any of the sixteen previously recorded cameras or it can display
a selection of any of the cameras in various multi-screen modes
2315 of 2461
PAGE 159 of 200
MMRDA
The multiplexer/recording shall allow instant access to critical

recordings by alarm time, date, and camera searches.
The multiplexer/recorder in addition to camera video, shall provide
the time & date camera number, and a user programmable 16
character camera title, which is recorded. The multiplexer/recorder
shall provide, but not be limited to, the additional following features:
On-screen menu programming, Sequencing of cameras, Video loss
with on-screen indication, Freeze function, Action/Alarm output
relay
contacts,
Password
access
protection
The
multiplexer/recorder shall use good compression technology for

high quality video, and shall include a minimum hard drive capacity
for storing data for 24hrs X 15 days. The multiplexer/recorder
shall include a SCSI-2 / USB port for archiving video to external
media. A 21 color monitor shall also be supplied along with
above for viewing multiplexed / recorded video. The multiplexer
/ recorder shall be designed for use as a desk top unit or shall be
rack mounted using an optional rack mount kit.
Video Standard
PAL, 625 line, 50 Hz
Digital Memory
720H x 576 V
AGC
Automatic or manually adjust for each video

input
Inputs
Camera: 8/16inputs; 16/32 BNC connectors

Automatic looping termination
Outputs
min 2 composite monitor outputs
Recording
extremely
high
quality
video
recording
for15days storing capacity

Recording
Selectable
from
0.1
IPS
to
real
modes
timerecording, max recording speed 50 IPS

for 16cameras (max)
Resolution of
High, medium and low quality
recording
Input
voltage 0.5 V p-p to 2.0 V p-p, Composite Video
2316 of 2461
PAGE 160 of 200
level
MMRDA
signal
Display Modes
On monitor A - Full, quad and various

combinations of multi-screen viewing
Features
P/T/Z controls with keyboard

Motion detection with direction sensing.
Programming via included software
Sequencing of cameras
Video loss with on-screen indication
Instant access to critical recording by alarm,
time, date and camera searches.
Display of time, date, camera number and
user programmable 16 character camera title
for viewing and recorded information.
Ethernet
port For network video access, shall be provided.
(RJ-45) EMC
Remote
viewer
software
to
allow
simultaneous access shall be also provided

EMC
XIII.
CE / UL certified
CCVTM Monitors
The CCVM monitors will be suitable for industrial applications and

compatible for the cameras. These will be of fully solid state type,
modular in design, have low radiation and provide a bright, clear,
well defined and high resolution picture display on the Screen. All
controls for power supply on/off, brightness, contrast, color, vertical
hold, horizontal hold, etc. will be provided on the front panel behind
the flip open protective cover for readily adjusting the video signal.
The input and output video connectors for coupling the video
input/output to other equipment, DC restoration switch and power
supply connections will be provided on the rear panel. The monitor
will have easy access for servicing and other adjustments. The
video monitor will be housed in a dust-proof metal enclosure with
2317 of 2461
PAGE 161 of 200
MMRDA
anti-dazzling light shield. It will be suitable for rack mounting /

mounting on control console / ceiling hang as per the site
requirement at a type convenient viewing angle. The monitor will be
designed to produce high resolution. The monitor will have the
following features: All controls for power supply on/off, brightness,
contrast, color, vertical hold, horizontal hold, etc. Provided behind
the flip open protective front cover.
Automatic degaussing at power on. Desk type/rack mountable with
rack mountable kits. Quick start. Easy access for servicing and
adjustments.
Technical Parameter:
S. No. Description
Parameters
Picture tube size
21
Scanning system
PAL
Horizontal resolution 460
TV
lines
(Centre)
XIV.
Vertical resolution
420 TV lines
Video input
1.0 V pp
Input impedance
75 ohms
Controls
Power on/off, LED pilot light, brightness, color, contrast, V-hold, Hhold, impedance 75 ohm/ high SW, DC restoration SW etc.
XV.
Control Console
The control console shall house matrix switcher, Keyboard,

Multiplexer & recorder and other control equipments, interfacing
modules required for control of complete system. The console shall
be of industrial usage, dust & vermin proof. It shall be located in
2318 of 2461
PAGE 162 of 200
MMRDA
control room. The console shall be of pre-wired ready for installation

and
commissioning.
Required
protections
and
shall
be
incorporated. The equipment shall meet IP 54. temperature

indication of camera and audio visual alarm indication in case the
temperature violates the desired limits shall also be housed.
XVI.
Video cable equalizers
The video cable equalizers will be used to compensate for high

frequency losses due to long runs of coaxial cable used between
the camera and video monitor.
XVII.
Surge Protection
Surge protection for video, power and control signals shall be given
for cameras and associated equipment at both ends. The
equipment shall protect cameras and associated equipment in case
of surge. It shall be as per BS6651. Required junction boxes and
associated equipments shall be supplied to complete the installation
in all respects.
Surge capability shall be of min 10kA UL /CE listed.
XVIII.
Cables
For connecting the control room equipment with field equipment

following cables are envisaged. Co-axial cable for video signal
transmission, twisted pair shielded cable for controlling cameras are
envisaged.
XIX.
Control Console
a)
Co-axial cables are envisaged for video signal transmission

for cameras which are upto 500mts distance. Beyond 500
mts post equalizing amplifier shall be used.
2319 of 2461
PAGE 163 of 200
b)
MMRDA
Independent control and video cables are envisaged for

these cameras.
c)
Power cable can be looped for maximum 2 cameras only.
d)
Booster amplifier shall be used wherever video signal is

weak.
e)
The following criteria shall be used for selection of cables.

Power supply cable : min 2.5 sq.mm
Control cable
: min 2.5 sq.mm
While designing cable layout and selection of multi core cable

the following criteria must be satisfied.
Minimum 20% of pairs shall be considered as spare subject
to min one
XX.
pair
All cables shall be of FRLS type
Video Cable
The specifications shall be as under

Center conductor size
7/0.4
mm
Annealed
Tinned
(ATC)
Di-electric material
Polyethylene (PE), White color
Shield material
Copper braided
Jacket material
FRLS PVC BLUE
Armour
1.4 mm GI wire round
Outer jacket thickness
1.2 mm FRLS
2320 of 2461
PAGE 164 of 200
XXI.
12.8
MMRDA
Outer jacket
FRLS PVC BLUE
Nominal impedance
75 ohms
Requirement (Indicative)
Cameras -
8 Nos.
Monitors -
4 Nos.
Recorders
2 Nos.
Functional design specification for PLC and SCADA/HMI
The Contractor shall submit a complete functional design specification

(FDS) for approval by the Engineer within 3 months of the award of the
contract. This document shall serve as the primary mechanism by
which the Engineer may confirm that the Contractor possesses an
accurate understanding of the system and its control requirements. The
Contractor is encouraged to obtain clarifications and to suggest
refinements to the control descriptions contained in this Specification.
The FDS shall comprise an overall description of the plant, its
functioning and control, and a detailed description of each section of
the control system covering modes of operation, manual overrides, setpoint and parameter selection and adjustment. The detailed description
shall include a step-by-step control description which defines the
function of each piece of equipment and each control action and
interlock, including details of the program in each programmable item.
The FDS shall describe the fail-safe features incorporated into the
design for the event of failure of a plant item or system, or loss of an
input signal affecting a control loop or process sequence.
The FDS shall describe control actions taken and monitoring functions
which remain available during a power failure, and any automatic
2321 of 2461
PAGE 165 of 200
MMRDA
controls or sequencing which take place during system start-up and

shut-down.
The FDS shall be presented in a clear and precise manner and shall
include figures or drawings where appropriate.
1. Functional Design Specification (FDS, Sequence of Operation)
The Contractor shall propose the details the sequence of operation

for the RWPS, CWPS and WTP through careful study of the plant
proposed. Further, the contractor shall be solely responsible to
comply with any change/additional processes during the contractors
design stages.
2. Input / Output Schedules
Typical input / output (I/O) requirements for the various PLCs are
shown in Table 9.1 and Appendix - II Control & Monitoring Item
Schedule. These input/output schedules shall not be limited but be
complied with the process design during the contractors design
stage
Typical I/O Schedule
Item
PLC I/O
Modbus
commu
DI
DO
AI
AO
nication
(RS485)
1 Each drive
Running
Local / off / Remote
fault (see note 1)
X
X
X
2322 of 2461
PAGE 166 of 200
MMRDA
Item
PLC I/O
Modbus
commu
DI
DO
AI
AO
nication
(RS485)
available (see note 2)
alarm state (see note 3)
start
stop
2. Each motor actuated valve

opened state
closed state
X
X
Local / Off / Remote

fault (see note 1)
available (see note 2)
X
X
open command
close command
Stop command
3.
incoming feeders status
and generator incomer

X
opened
closed
tripped
power
X
consumed
incomer 1
power
X
pulse
consumed
incomer 2
X
pulse
4. Generator
running
fault
fuel system fault
2323 of 2461
PAGE 167 of 200
MMRDA
Item
PLC I/O
Modbus
commu
DI
DO
AI
AO
nication
(RS485)
low fuel level
5. Level (digital)
high
high
low
low
6. Level (analogue)
value
7. Flow (analogue)
value
8.
Pressure
X
differential
(analogue)
value
9. Water quality
chlorine residual
turbidity
pH
10. Control system
11.
UPS fault
UPS battery low
132 KVA Transformer

status signals:
ON
OFF
Tap changer position

12.
Outgoing Feeders
status
2324 of 2461
PAGE 168 of 200
MMRDA
Item
PLC I/O
Modbus
commu
DI
DO
AI
AO
nication
(RS485)
X
OPENED
CLOSED
TRIPPED
13.
Intelligent type Energy
Meters integration to
SCADA controller
14.
Sub Process system
Controllers integration
to SCADA Controller
Notes:
1. The fault signal is a logical AND of all drive faults.
2. Available status is derived at the starter and shall be a logical
AND of the following signals:
-
starter mounted manual / off / automatic selector switch

set to automatic;
no power failure at the starter;
emergency stop device not operated;
no drive fault.
In other words when the drive is available a start signal is

2325 of 2461
PAGE 169 of 200
MMRDA
received from the PLC the drive and device shall start.
3. An alarm in this context is a state that does not prevent a
drive from running but should be brought to the attention of
the operator.
4. The above I / O list is indicative of what is required. The
Contractor shall provide any additional I / O as required for
the control of the Works.
3. Duty / Standby Drives
The duty pump for each duty / standby pair shall be selected at the
local control panel and the Plant HMI.
The control logic shall automatically start an available standby in
the event of the duty drive failing. The new duty drive shall take on
the role of duty drive in all respects and shall continue to run as
duty until manually reselected to standby or it fails.
4. Interlocking
Hard wired interlocking shall be provided for safety circuits such as:
-
motor protection;
run dry protection;
emergency stop circuitry;
rotation monitor
In addition drives stopped as a result of the action of hardwired

interlocks shall in addition have a fault signal conveyed to the drive
in order that the PLC drive run output is removed. Soft wired
interlocking is provided by the PLC for process control and for
safety trips when the signal is derived from a remote source.
2326 of 2461
PAGE 170 of 200
MMRDA
5. Alarm Annunciation
Alarms shall be annunciate at three locations, at the drive starter, at

the local HMI and at the central HMI (see details later).
philosophy shall be adopted that all alarms associated with a drive

shall be annunciated at the starter whilst a general alarm only for
that drive shall be annunciated at the HMIs. Therefore the operator
observing a general alarm at an HMI shall have to go to the starter
concerned to determine the exact cause of the alarm condition.
A typical alarm schedule is detailed in below Table:
Alarm Schedule
Device
1.
Alarm at the
Alarm at the relevant
Starter/Panel
local and central HMI s
Power
- transformer fault
System
- mains incomer tripped

- generator incomer
tripped
2. Pump and
- overload (see note - drive fault (see note 2)
blower drives
1)
- earth fault (see note
1)
- emergency stop
operated
- run dry protection
operated
3.
Valve - drive fault
- drive fault
actuators
4. Alum Dosing
- as required
- as required
system
5. Service Water
- high level
tank level
- high level
2327 of 2461
PAGE 171 of 200
Device
MMRDA
Alarm at the
Alarm at the relevant
Starter/Panel
local and central HMI s

- low level
- low level
6. Chlorination
-As
per
sub
Vendor
system
Recommendation
7 Thickened
- high
sludge holding
- low (run dry protection)
tank
8. Service water
- high
tank
- low (run dry protection)
9.Filter Press
-As
per
sub
Vendor
Recommendation
10 Clearwater
- high water level
reservoir level
- high water level

- low water level
- low water level
11. Turbidity
- high level
- high level
12 Chlorine
- high level
residual
- high level
- low level
- low level
13.
Control
- SCADA to PLC and
system
PLC
to
communication
PLC
faults
(various)
14. UPS s
- fault
- battery low
Notes:
1. These alarms may be displayed on the motor starter panel.
If this is flush mounted further individual indication may not
2328 of 2461
PAGE 172 of 200
MMRDA
be necessary.
2. These alarms are derived within the PLC from the analogue
level value.
3. The Contractor shall provide alarms necessary for the proper
and efficient operation of the plant.
4. Communication Monitoring:
The
control
system
shall
continuously
monitor
LAN
communications and raise an alarm at the central HMI

located at SCADA Room. if communications should fail
between the central HMI and a controlling PLC or between
PLCs if inter-PLC communication is being used. A separate
SCADA screen (mimic) showing the real time status of
PLCs, I/O modules, LAN communication etc. is to be
incorporated.
The above mentioned alarms are indicative only of the number
and type of alarms that are required.
The Contractor shall
provide the above alarms on a minimum and other alarm

necessary for the proper and efficient operation of the plant.
The Contractor shall submit and obtain approval of the FDS from
the Engineer before beginning the detailed control system design.
The contractor should take note of the importance of this
obligation.
12.9
Submissions by the Contractor

I.
CONTROL SYSTEM EQUIPMENT
The submissions by the Contractor pertaining to the PLC & SCADA

System shall comprise the following as a minimum:
2329 of 2461
PAGE 173 of 200
MMRDA
a) A functional design specification (FDS) for the SCADA system.

This shall be combined with the FDS for instrumentation, control
and automation to form a complete document and shall comply
with the specification of the FDS for instrumentation, control and
automation. This document shall serve as the primary
mechanism by which the Engineer may confirm that the
Contractor possesses an accurate understanding of the system
and its control requirements. The Contractor is encouraged to
obtain any necessary clarifications and to suggest refinements
to the control descriptions contained in this Specification.
b) The FDS shall include a detailed block diagram of the PLC &
SCADA system with a description of the communications
scheme to be provided. The FDS shall include operational
details of the SCADA system which have an effect on plant
operations, such as power failure response, communication
failure response, and automatic shut-down and start-up of the
system.
c) The FDS shall include a description of the interface of the
SCADA system with Wireless Communication systems that
includes VSAT, GSM / GRPS systems for data transmission of
RWPS, CWPS, WTP and each MBR.
d) The Contractor shall submit a preliminary FDS and obtain
approval before the system architecture design is finalized or
detailed design takes place. The Contractor shall formally notify
the Engineer for approval of any amendments or additions to the
approved FDS. The final FDS shall be submitted for approval
before submission of the factory acceptance test definition
documents. The Contractor should take note of the importance
of this obligation.
e) Layout drawings for each piece of equipment fabricated or
2330 of 2461
PAGE 174 of 200
MMRDA
assembled by the Contractor, showing the position of each

component with required clearances where applicable, and with
overall dimensions.
f) Wiring diagrams indicating each component of the system and
all wiring and cabling thereto, showing manufacturers, types,
duties, ranges and nomenclature, referencing the P&I diagram
where applicable, with inputs, outputs, cable wiring and terminal
identifications clearly marked.
Mimic video displays in the form of hard copies or photographs
which are clearly legible and are notated to indicate dynamic
data and control pick points where applicable.
g) Control video displays in the form of hard copies or photographs
which are clearly legible and are notated to indicate dynamic
data and control pick points.
h) Logic diagrams of plant operation and control system interaction
(including modes of failure and shutdown routines).
i) Complete input and output list giving type, circuit number, tag
name,
short
description,
outstation,
database
reference,
associated field device, range (if applicable), critical/non-critical

alarm status and the like.
j) Description of quality control methods and approvals.
k) Detailed works and acceptance test procedures.
l) Programme
for
manufacture,
delivery,
installation
and
commissioning.
m) Appendices, as necessary, to include manufacturers literature
for each item of equipment supplied.
2331 of 2461
PAGE 175 of 200
MMRDA
n) Operation and maintenance manuals detailing the following:
General description and operating principles;
Technical description of the equipment (manufacturers

standard brochures only being acceptable if the particular
item of equipment described is clearly designated, adequate
information is supplied, and irrelevant information is deleted
or otherwise delineated)
Complete operating instructions defining the sequence of

operations, including flow charts;
Procedures for dismantling, cleaning, servicing, replacing

parts and reassembling, including recommended clearances
and tolerances;
Details of all instrument and equipment settings as

applicable to this contract;
Maintenance and lubrication schedules;
Fault diagnosis procedures;
Dated and priced list of significant spare parts and special

tools, including identification numbers and sources of supply;
Simplified arrangement drawings showing all components of

the equipment
o) General operating manual comprising the following:
General description and operating principles;
2332 of 2461
PAGE 176 of 200
MMRDA
Operating instructions for normal procedures in a step-bystep format including control operations, requirements for
display or printing of data, performance monitoring, response
to alarms or failures, changing of operational parameters,
and manual data entry
p) System back-up software comprising the following:
Application program software;
Operating and utilities software;
System
configuration
software
including
displays
and
operational plant data

q) Datasheet for each Online Field Instrument including Analytical
Instrument.
II.
SOFTWARE DOCUMENTATION
The Contractor shall provide complete software documentation for

each Programmable piece of equipment. The material to be
provided shall include, as a minimum:
a. All of the manufacturers standard published reference materials
and users guides.
b. Original of all licenses, the licenses shall have no restrictions
and no Tag limitations subject to selection of minimum tags
based on approved IO schedule with 70% spare at initial stage
and those Tags shall be Upgradable in add-on basis as and
when required during future plant upgradation period. (i.e...UnLimited Tags in add-on basis).
2333 of 2461
PAGE 177 of 200
c. Complete
MMRDA
documentation
for
any
packaged
software
incorporated into the system including software written by other

manufacturers.
d. A working copy and complete documentation for any programdevelopment software used for this project. This software and
documentation shall be of the same version and revision
numbers used for development under this contract.
e. A working copy and complete documentation for any database
management, report generation, screen graphic builder or other
similar software used for development under this contract. This
software and documentation shall be of the same version and
revision numbers used for development under this contract.
f. Hard-copy documentation of all configuration data, all useraccessible source code including control program code, reports
and database contents including listings. All program listings
shall be clearly and completely commented so as to convey to
the reader a full understanding of the function of the program.
So-called
self-documenting
code
without
additional,
supplementary comments will not be acceptable.

g. A complete input and output list giving type, circuit number, and
tag name, short description, outstation, database reference,
associated field device, range (if applicable), critical/non-critical
alarm status and the like.
h. A Software System Specification document which describes all
control
programs
furnished
with
the
system.
Design
documentation shall include, as a minimum:
A description of the software development environment,

including development procedures, limitations, restrictions,
configuration management, documentation standards and
2334 of 2461
PAGE 178 of 200
MMRDA
compatibility;
An overall description of the software design, including

application structure and subsystem divisions, control
strategy, monitoring and display hierarchy, data acquisition
and storage, notational and operational conventions and
operator access restrictions;
A description of each application sub-system;
A flow chart or pseudo-code description of each program

module detailing the flow of control throughout the module;
A list of files used by the system, including location and a

brief description
III.
DRAWINGS AND SCHEDULES
The contractor has to submit the following set of drawings

a. Process and instrumentation diagram.
b. General arrangement drawings of field-mounted instruments
showing Installation details.
c. General arrangement drawings of instrument and control panels,
fully dimensioned In plan and elevation views, showing
foundation and fixing Details, access doors, clearances, cableentry positions, weight and lifting arrangement.
d. Layout drawings of panel fascias showing instruments, controls
and details of all labels.
e. Layout drawings of panel interior showing equipment, terminal
blocks and Cable ways.
2335 of 2461
PAGE 179 of 200
MMRDA
f. Annunciators arrangement and engraving details.

g. Internal circuit and wiring diagrams for instrument and control
panels.
h. Schematic control diagrams.
i.
Instrument loop diagrams.
j.
Instrument wiring and piping diagrams.
k. Interconnection (interface/integration) wiring diagrams.

l.
Cable block diagrams, drawings and schedules.
m. Instrument system and panel power distribution diagrams.

n. Programmable-device functional design specifications which
shall include
o. Hardware details, logic flow charts, ladder diagrams and
program listings.
p. Schedules of inputs to and outputs from programmable
controllers and Telemetry outstations.
q. Labelling schedules.
r. Comprehensive testing schedules for all off-site, on-site, precommissioning, Commissioning tests and take-over tests.
s. Instruments Schedule
12.10
Inspection and Testing Requirements
2336 of 2461
PAGE 180 of 200
MMRDA
I. Inspection, Testing and Setting to Work General
Each item of plant shall be subjected to the manufacturers own

tests which shall be certified. Each item of plant and its installation
shall be subject to inspection and testing at the place of
manufacture. The Contractor shall be responsible for the provision
of all necessary test equipment. The Contractor shall demonstrate
to the Engineer, the correct operation of any item of plant and the
Engineer may witness any test. Tests which, in the opinion of the
Engineer, were failed or not performed correctly shall be repeated.
Before any test is made, the Contractor shall submit to the Engineer
a full list of test equipment to be used. Each item of test equipment
shall have a standard of accuracy better than that stated by the
manufacturer of the item to be tested. The Contractor shall provide
evidence of the condition and performance of any item of test
equipment, in the form of test certificates issued by an appropriate
authority independent of the Contractor and manufacturer, or as
otherwise directed by the Engineer. Test equipment shall be
checked frequently during the period of the tests.
The Contractors staff responsible for supervising and carrying out
tests shall be fully conversant with the various items of equipment
of other manufacturers and if necessary the Contractor shall
arrange for his personnel to attend suitable training courses on his
own expense. The contractor has to get approval from the clients
representative for the training personnel to be employed by the
contractor.
Any fault or shortcoming found during any inspection or test shall be
rectified to the satisfaction of the Engineer before proceeding with
further inspection or testing of that item. Any circuit previously
tested, which may have been affected by the rectification work,
shall be re-tested.
2337 of 2461
PAGE 181 of 200
MMRDA
II. Preliminary Inspection and Testing at the Place of Manufacture

A. Field-mounted instruments
After the successful completion of the manufacturers own

inspection and testing of instruments supplied under the
Contract, similar tests shall be carried out in the presence of the
Engineer and the Contractor, if requested. Such tests shall
include a demonstration that an increase or decrease of the
measured value at several points over the full range of the
instrument produces a corresponding increase or decrease in
the instrument output signal. These tests shall include checks on
the specified accuracy of the instrument at all points.
B. Instrument panels, enclosures and mounting boards
The
manufacturer
shall
not
present
instrument
panels,
enclosures and mounting boards (assemblies) for inspection

and testing until the manufacturers own tests and inspection
has been completed. A preliminary inspection and test of these
assemblies may then be witnessed by the Engineer. The
Contractor shall give not less than 7 days notice in writing that
he has completed his tests and inspection and is ready for the
witnessed tests and inspection. Where this notice period is
different in the Conditions of Contract this shall take precedent.
The witnessed inspection and testing shall include the following:
i) A visual inspection of the panel assembly to show that the
design, construction and finish are satisfactory and in
accordance with the Specification;
ii) A check that equipment is securely mounted, accessible for
removal or calibration without damage to or undue
disturbance of other components, wiring or piping;
2338 of 2461
PAGE 182 of 200
MMRDA
iii) That all engraving and labels are correctly positioned, fixed
and designated in accordance with the Specification;
iv) Panel
power-distribution
circuits
have
the
correct
breaker/fuse rating coordination and designation;

v) Power-isolation facilities meet the Specification;
vi) The main incoming supply voltage, frequency and/or
pneumatic supply pressure is within the required limits, these
being checked at the beginning and end of the test and the
results recorded on test certificates;
vii) The output of all power supply units again at the beginning
and end of the testing with results being recorded;
viii)The power supply voltage or air pressure of all component
instruments of the assembly(s), these voltages/pressures
being recorded on the test certificate;
ix) The insulation resistance of all circuits except sensitive
electronic equipment which is liable to damage by application
of the test voltage, such circuits being disconnected before
making the insulation resistance tests and these tests being
carried out in accordance with IEE Wiring Regulations;
x) That the clean earth bar is isolated from main frame of the
panel. Internal lighting and anti-condensation heaters and
associated thermostats, isolators, limit switches and wiring
shall be checked for compliance with the Specification.
Spare capacity within the panel(s) shall be checked to see
that it complies with the Specification. This shall include
future equipment space, spare terminals, space in wiring
trunkings and provision for additional cable entry
2339 of 2461
PAGE 183 of 200
MMRDA
III. Functional Testing at the Place of Manufacture

A. General Requirements
Once the preliminary inspection and testing is complete to the

satisfaction of the Engineer, functional testing shall commence.
The purpose of the functional tests is to demonstrate that
instrument
panels
enclosures
and
mounting
boards
(assemblies) conform with requirements of the Specification.

Not less than 30 days before the commencement of functional
tests, the Contractor shall submit to the Engineer, for approval,
two copies of comprehensive test procedural documents
detailing each test to be carried out. The document shall include
results forms on which the results of each test will be entered.
The forms shall include spaces for numerical values, where
necessary, and witness signatures. All applicable drawings and
data shall be provided at the place of inspection by the
Contractor.
The Contractor shall provide all test instruments and equipment
necessary to test the assemblies in their entirety.
The following is a typical list of the equipment required:
Switch boxes;
Indicator light boxes;
Analogue signal sources;
Dummy loads;
Meters;
Simulators;
Desk-top computers;
Programmers for SCADA or outstations;
2340 of 2461
PAGE 184 of 200
MMRDA
Insulation test equipment;
Electromagnetic Flow Meters
B. Testing for Programmable Logic Controller (PLC) and

SCADA
The Contractor shall carry out specified tests as follows in

addition to any tests stated or implied by the foregoing sections
of this clause.
The tests shall be carried out on the fully assembled control
panel containing the PLC and associated equipment in order to
demonstrate correct functional operation of the hardware and
software systems.
C. Factory Acceptance Test (FAT)
The Contractor shall conduct a full programme of tests of the

PLC & SCADA system and required integration at the
Contractors testing facility in the presence of the Engineer to
verify that all features of the system have been provided, are
operating correctly and are in full compliance with the
Specification. Unless otherwise specified or agreed by the
Engineer, the entire PLC &
SCADA system along with the
software shall be assembled and tested together as an

integrated system, including all master station equipment, all
operators consoles, all outstations and telemetry equipment all
instrumentation panels and uninterruptible power supplies
included in this Specification. The scheduled date for the factory
acceptance test shall be as agreed by the Contractor and the
Engineer at least four weeks before the test.
Not less than one month before the scheduled factory
acceptance test, the Contractor shall submit to the Engineer for
approval two copies of a comprehensive manual detailing each
2341 of 2461
PAGE 185 of 200
MMRDA
test to be conducted. The manual shall include a results form on

which the results of each test will be entered, including spaces
for numerical values where appropriate and witness signatures.
Not less than 7 days before the scheduled factory acceptance
test, the Contractor shall give written notification to the Engineer
that a complete dry-run of the factory acceptance test has been
performed successfully and that, in the opinion of the
Contractor, the system exhibits stable operation and is ready for
the formal factory acceptance test.
The factory acceptance test will be considered successfully
completed only when the system has successfully passed all
factory tests. The system shall not be delivered to Site until the
successful completion of the factory acceptance test is certified
by the Engineer or unless otherwise approved by the Engineer.
Delay in the delivery of the system due to failure of the factory
acceptance test shall not constitute an unavoidable delay. If the
system fails the factory acceptance test, the test shall be
extended or rescheduled at the discretion of the Engineer.
All hardware to be used in the testing of the system shall have
passed an agreed preliminary hardware performance test to
ensure known hardware operability before software testing
begins.
After successful completion of the factory acceptance test, no
software changes shall be made to the system without written
authorisation by the Engineer. Any changes to the system which
effect the system software documentation, such as input scale
modifications or changes to the control logic, shall be entered
into the system documentation before delivery of the system to
Site.
The entire cost of the complete FAT and any other required
2342 of 2461
PAGE 186 of 200
MMRDA
testing(interoperability, site visits etc..), including reasonable per

diem expenses to cover meals, lodging, transport and similar
expenses for all Employers & employers representative personnel
attending the tests, shall be the responsibility of the Contractor/
system supplier and shall be included in the contract price.
D. Factory Acceptance Test Procedures
1. General
The scope of the tests shall include the proving of every

aspect of hardware and software operation and functions as
detailed below.
2. Hardware tests
a) Verify the correct inventory of hardware including cables

and printed circuit boards;
b) Demonstrate that all spare-memory, disk-capacity and
system-expansion requirements have been met;
c) Demonstrate all hardware and software diagnostics;
d) Verify all power supply voltages are within tolerance;
e) Verify
proper
earth
connections
and
isolation
of
instrumentation earth for all equipment;

f) Demonstrate operation of test simulation and indication
equipment and its Suitability for adequate functional
testing of all system functions
3. Software tests
2343 of 2461
PAGE 187 of 200
MMRDA
a) Demonstrate the editing of all system parameters

including set-points, timers and the like;
b) Demonstrate system configuration capabilities including
the addition and deletion of input and output points,
outstations, and all data base parameters;
c) Demonstrate the addition, deletion and modification of
mimic displays and report formats;
4. Functional Tests
The functional tests shall verify proper operation of every

specified system function as an integrated system. These
tests shall be conducted in conjunction with functional tests
of instrumentation and control panels as specified elsewhere.
All failures or discrepancies found shall be documented in
the test manual.
Following a failure of any functional test, should software or
hardware modifications be required it shall be the decision of
the Engineer whether the factory acceptance test is to
continue, re-start or be aborted. If testing is allowed to
continue, any changes which are required shall be described
in a system modification document, signed by both
Contractor and Engineer and be incorporated into the final
factory acceptance test documentation. The failed test shall
be re-conducted and the Engineer may require the retest of
functions which may be affected by the modification.
The functional tests shall include, as a minimum, the
following:
a) Demonstration that the system meets the requirements of
the Specification for response time and speed of screen
2344 of 2461
PAGE 188 of 200
MMRDA
update
b) Verification of the accuracy of all analogue input points in
the system. The procedure shall include applying the
appropriate signal to each analogue input at a minimum
of three points within the range of the input, checking for
expected numerical results, and verifying appropriate
update of related mimic displays. Proper sensing and
action by the system to high and low out-of-range inputs
shall also be verified
c) Verification of the proper logic sense, pulse accumulation
and rate computation where appropriate, of all digital
inputs and verifying appropriate update of related mimic
displays;
d) Verification of all control and sequencing operations and
proper operation of all digital and analogue outputs. The
procedure shall include simulation of all related process
variables for both normal and abnormal conditions,
including
instrument
and
component
failure,
and
demonstration of fail-safe response of the system.

System outputs shall be indicated with appropriate lamps
and indicators;
e) Simulation of outstation communications errors and
failures and demonstration of error detection and
handling, failure detection and handling, and appropriate
changes to control actions as designed and specified;
f) Verification of fault detection and diagnostics by inducing
a sufficient variety of fault conditions in the system to
ensure that detection processes and fail-safe operation
are adequately tested;
2345 of 2461
PAGE 189 of 200
MMRDA
g) Demonstration of proper operation of all mimic displays,

help pages, reports, operator procedures and historical
data accumulation;
h) Demonstration of proper operation of all outstations
following a simulated master station central processor
failure;
i) Demonstration of proper operation of all equipment
during both a system wide or isolated power failure, and
following power restoration. The procedure shall include
the demonstration of battery backup of both master
station and outstation for the full length of time specified,
and proper operation of power fail, low voltage warning
and all associated alarms.
5. Reliability Test
After successful completion of the functional tests a 48-hour

continuous run of the system shall be performed. The test
shall be passed if no system function is lost or no hardware
or software failure occurs. Hardware failure is defined for this
test as the loss of a major component such as the computer,
an outstation, a VDU or a peripheral device. Non-repetitive
mechanical failures of loggers, push-buttons and the like are
excluded.
During this test, the system shall be exercised with simulated
inputs and conditions in a manner which approximates the
on-site operational environment. Unstructured testing by the
Engineer shall be included during this test. Upon any system
failure during this period, it shall be the decision of the
Engineer whether the reliability test is to continue or be
aborted. If testing is allowed to continue any changes to the
system which are required shall be described in a systemSECTION 6C.12: INSTRUMENTATON CONTROL & AUTOMATION
2346 of 2461
PAGE 190 of 200
MMRDA
modification document, signed by both Contractor and

Engineer and the document shall be incorporated into the
final factory acceptance test documentation.
IV. Factory acceptance test documentation
As a minimum, the following information shall be included in the

factory Acceptance test manual for each test:
Test identification number;
Test name and description;
List of all equipment to be tested including any special test

equipment required;
Description of the test procedure broken down into logical steps;
Description of the expected system response verifying the

completion of each logical step;
Space for recording the results of the test and the time and date
of the test;
Space for signatures of the Contractor and the Engineer
In addition, the Contractor shall provide a method for recording and

tracing all problems, discrepancies, queries and suggestions
regarding the system and software, and for formalised control of
any modifications to the system.
A. Pre-Commissioning Tests
The Contractor shall perform pre-commissioning, or preliminary,

testing of the SCADA system in accordance with that specified
2347 of 2461
PAGE 191 of 200
MMRDA
for instrumentation. The purpose of pre-commissioning tests is

to confirm readiness of the system for commissioning.
The scope of pre-commissioning tests shall be generally as
specified for factory acceptance tests but real field inputs and
final control elements shall be used wherever practical to
provide inputs to the system and to confirm proper outputs.
Where this is impractical, simulation signals shall be injected as
near as possible to their ultimate sources so as to include in the
tests as much of the cabling system as possible.
Each process system shall be set to work under manual control
and the system tested to confirm proper operation. After proper
operation of manual control mode has been verified, tests of
automatic controls of each process system shall be conducted
wherever practical.
B. Commissioning
The
Contractor,
the
Engineer
and
any
appropriate
personnel of the Employer shall be present when the

equipment or installation is tested & commissioned.
Commissioning shall include operating the equipment in a
variety of modes and sequences to prove its satisfactory
operation, prior to commencing the formal site inspection
and testing.
C. Site Acceptance Tests (SAT)
The Contractor shall submit all relevant draft operating manuals

for the PLC & SCADA System to the Engineer for approval prior
to commissioning tests. Any faults or failures of the system
detected during the previous tests shall be noted and corrected
2348 of 2461
PAGE 192 of 200
MMRDA
to the satisfaction of the Engineer before commissioning is

allowed to commence.
As part of commissioning, the PLC & SCADA system shall be
tested for availability for a continuous period of 60 days. During
this period, the system will perform the normal functions
according
to
the
procedures
described
in
the
SAT
documentation approved by the Engineer.

The system shall have passed the SAT if all major components
have been free from fault or failure and exhibit full error-free
functionality for 100 % of the total duration of the test, unless
otherwise agreed by the Engineer. Major components include all
master station equipment, outstations, communications facilities
and instrument panel components, excluding push-buttons,
switches and lamps and any equipment not supplied by the
Contractor.
During SAT, no modifications to the system shall be made by
the Contractor without the written approval of the Engineer.
Erroneous functioning which requires software modifications or
re-configuration to correct, other than set-point or parameter
changes, shall constitute a failure of the availability test. Any
changes to the system which are required and approved shall
be described in a system-modification document, signed by both
Contractor
and
Engineer
and
the
document
shall
be
incorporated into the final test documentation. The test shall be

restarted after corrections have been made.
V. Quality Assurance/Quality Control (QA/QC)
QA/QC shall comply with the Contract, with particular requirements

specific to the equipment or service being provided as outlined
below for PLC systems. The quality assurance/control procedures
shall include, but not be limited to the following:
2349 of 2461
PAGE 193 of 200
MMRDA
Continuity and Wiring tests;
Insulation and High Potential Testing;
Packaging and Shipping;
Welding;
Cleaning and Painting
The quality assurance/quality control documentation shall include,

but not be limited to the following:
Material Certifications;
Shop Test Reports;
All other documentation required by applicable codes and

standards
12.11
Training
The Contractor/ system supplier shall conduct training courses for

personnel selected by the Employer. Training shall be conducted by
personnel employed by the Contractor/ system supplier familiar with
the system supplied and who have experience and training in
developing and implementing instructional courses.
The entire cost of the complete training programme, including reasonable
per diem expenses to cover meals, lodging, transport and similar
expenses for all Employer personnel attending the training program, shall
be the responsibility of the Contractor/ system supplier and shall be
included in the contract price.
2350 of 2461
PAGE 194 of 200
MMRDA
The Contractor/ system supplier shall submit information on the training

programme for approval, prior to shipment of the equipment. This
submittal shall include a course outline; time required, course schedule,
sample workbook and instructor qualification information for each level.
The Contractor/ system supplier shall make a workbook on each course
available to every person taking the courses listed herein. The workbook
shall be of sufficient detail so that, at a later date, a trainee could review
in detail the major topics of the course.
The training times shall be scheduled by the Employer or their
representatives in advance with the Contractor/ system supplier so as
not to disrupt the Employer ability to operate the plant.
Operations and Maintenance Training:
Training shall be provided for Ten (10) of the Employer personnel or

their representative at the Contractor/ system supplier facility on
operations
and
maintenance
of
all
Instrumentation
& control
components. The training program shall be divided into two segments

and shall consist of at least 7 (Seven) working days, each of 8 (eight)
hours duration.
The maintenance training program shall be developed for personnel that
have instrument & electronics maintenance and repair experience and a
general knowledge of computer systems, but shall not assume any
familiarity with the specific hardware furnished.
As a minimum, the following subjects shall be covered:
System Architecture and Layout
Hardware Components
Module Switch Settings (Configuration Switches)
I/O Modules
2351 of 2461
PAGE 195 of 200
MMRDA
Power Supplies
Data Highway
Programmer connection
IOP programming and diagnostic techniques
Battery replacement and recharging
Troubleshooting
Disassembly
Cleaning
Component Replacement
Re-assembly
The operation training programme shall include the following topics:
12.12
Power-up, bootstrapping and shutdown of all hardware devices
Interpretation of all standard displays
Appropriate actions for software and hardware error occurrences
Use of operator interface displays and keyboards
Creation and editing of graphic operator display screens
Loading of any required software into the system
The Minimum Requirements for Instrumentation, control & Automation

Equipment.
2352 of 2461
PAGE 196 of 200
MMRDA
Minimum Requirement List for Instrumentation, Control & Automation Equipment:

Sr.
Description
RWPS
WTP
CWPS
No.
I.
Instrumentation Equipment
A.
Online Field Instruments
Flow Measurement + Accessories +fittings (Full Bore Electromagnetic
1x 2000mm
Flow meters)
1x700mm,
1x2000mm
MMRDA
MBRs / K.K Junction /
Office
Group Tapping
N.A
1x1600mm Chene,
9x400mm,
[1x1600mm+1x2000mm
8x90mm,
K.K
2x1600mm
Junction],[1x1600mmK.K
Junction MBR] and
7 Nos. for Group Villages.
Air flow measurement+ Accessories +fittings
N.A
LS
N.A
N.A
N.A
Parshal flume flow measurement with Ultrasonic Level Transmitter
N.A
LS
N.A
N.A
N.A
Level Measurement+ Accessories +fittings
LS
LS
LS
N.A
LS
Pressure Indicating transmitters+ Accessories +fittings
LS
LS
LS
N.A
LS
DP Transmitter
N.A
LS
N.A
N.A
N.A
Sight Glass
N.A
LS
N.A
N.A
N.A
Float & Board type Level Gauge
LS
LS
LS
N.A
LS
Pressure indicators/gauges + Accessories +fittings
LS
LS
LS
N.A
LS
10
Limit Switches+ Accessories +fittings
LS
LS
LS
N.A
LS
11
Control Air Pressure Switch+ Accessories +fittings
LS
LS
LS
N.A
LS
12
Temperature Transmitter+ Accessories +fittings
LS
LS
LS
N.A
N.A
13
Junction Boxes &Field Enclosures
LS
LS
LS
LS
LS
14
Level Switches+ Accessories +fittings
LS
LS
LS
N.A
LS
15
Alarm Annunciators+ hooters+ Accessories +fittings
LS
LS
LS
N.A
LS
16
Instrumentation Earthing
LS
LS
LS
LS
LS
17
Two & Three Position Selector Switches+ fittings(Electrical Accessories
LS
LS
LS
N.A
LS
Like :-P.Bs , LEDs, MCBs e.t.c)

18
Flow Integrator cum Totalizer+ fittings
LS
LS
LS
N.A
LS
19
Panel mounted Digital Indicators+ fittings
LS
LS
LS
N.A
LS
20
Temperature Scanner Indicators+ fittings
LS
LS
LS
N.A
LS
21
Multi-Function Energy Meters+ fittings
LS
LS
LS
N.A
LS
PAGE 197 of 200
2353 of 2461
Sr.
MMRDA
Description
RWPS
WTP
CWPS
No.
22
Surge Protection Devices, Surge arrester +fittings
B.
On-Line Analytical Instruments
23
MMRDA
Office
Group Tapping
LS
LS
LS
LS
LS
Residual chlorine analyzer+ Accessories +fittings
N.A
LS
N.A
N.A
LS
24
pH Analyzer+ Accessories +fittings
N.A
LS
N.A
N.A
N.A
25
Turbidity Analyzer + Accessories + Fittings
N.A
LS
N.A
N.A
LS
C.
Instrumentation, Control & Automation and WTP Laboratory
N.A
LS
N.A
N.A
N.A
LS
LS
LS
LS
LS
LS
LS
LS
LS
Equipment
26
Refer clause No: 12.5
D.
Instrumentation Cables/cable trays
27
Instrumentation(Analog) & Control Cables and Power Cables, OFC, LS

Trays, Glands & Lugs, cable conduits
28
cable trays
II.
Control & Automation Equipment
A.
Standalone Control System along with HMI for Sub process

systems of WTP
29
Filter Unit PLCs & Filter console Panels
N.A
LS
N.A
N.A
N.A
30
Sludge treatment
N.A
LS
N.A
N.A
N.A
31
Chlorination
N.A
LS
N.A
N.A
LS
32
Chemical System
N.A
LS
N.A
N.A
N.A
B.
Control & Automation system(PLC based SCADA system)
33
Hot standby PLC for Local Control Room
LS
LS
LS
N.A
LS
34
Power supply module for PLC CPU
LS
LS
LS
N.A
LS
35
Communication Module
LS
LS
LS
N.A
LS
36
RIO Modules along with Panels
N.A
LS
N.A
N.A
N.A
37
PLC Programming software
N.A
38
SCADA softwares (dual redundant configuration) and additional 2 Nos. of
[1x SCADA
[1x SCADA
[1xSCADA 2
SCADA Client Operator Work Stations at MMRDA Location.
OWS]
OWS]
OWS+2
Nos. of
SCADA
OWS
Clients]
PAGE 198 of 200
2354 of 2461
Sr.
MMRDA
Description
RWPS
WTP
CWPS
MMRDA
Office
Group Tapping
No.
39
Historian software
N.A
N.A
N.A
N.A
40
Control Panels with Internal Wiring
LS
41
Surge Protection Devices
LS
LS
LS
LS
LS
42
Industrial Type Ethernet switches
LS
LS
LS
LS
LS
43
SMPS for Automation System (Redundant)
LS
N.A
44
32 Operator Work Station PCs
45
62" LCD Screen with accessories and Commercial Grade PC
N.A
N.A
N.A
46
VSAT, GPRS and Radio Wireless communication modems including
N.A
LS
N.A
LS
LS
Communication PC
47
Redundant FOC equipment +cabling +Insulated Pipes on conduits
LS
LS
N.A
N.A
LS
48
Laptop
49
System console and Control Room (SCADA) furniture
LS
LS
LS
LS
LS
50
Engineering work station PC
51
UPS
LS
52
Printers
53
Interposing Relays with base terminal
LS
LS
LS
N.A
LS
54
2.5 kilometers of Fiber Optic Cables (OFC) for RWPS & CWPS PLC data
LS
N.A
LS
N.A
N.A
integration to WTP PLC + +Insulated Pipes on conduits

55
Fire Detection and Alarm System
LS
LS
LS
LS
LS
56
CCTV system
LS
LS
LS
N.A
N.A
57
EPABX system
LS
LS
LS
N.A
N.A
C.
Testing and Calibration Equipment
58
Multimeter
N.A
N.A
N.A
N.A
59
LAN Tester
N.A
N.A
N.A
N.A
60
Logic Analyser
N.A
N.A
N.A
N.A
61
Oscilloscpoe
N.A
N.A
N.A
N.A
62
Soldering Station
N.A
N.A
N.A
N.A
63
Simulator (4 to 20mA)
N.A
N.A
N.A
N.A
64
Pressure Calibration
N.A
N.A
N.A
N.A
65
Dead Weight Tester
N.A
N.A
N.A
N.A
PAGE 199 of 200
2355 of 2461
Sr.
MMRDA
Description
RWPS
WTP
CWPS
MMRDA
Office
Group Tapping
No.
66
Tool Box set
N.A
N.A
N.A
N.A
67
Laptop with authorized software
N.A
N.A
N.A
N.A
D.
Mandatory Spares to be supplied for Automation system (PLC

based SCADA system)
68
CPU for PLC
N.A
69
Communication Module
N.A
70
Digital input module
N.A
71
Digital output module
N.A
72
Analog input module
N.A
73
Analog output module
N.A
74
Industrial Type Ethernet switch
N.A
75
Power supply module for PLC CPU
N.A
76
SMPS for Automation System
N.A
77
Remote RIO drop adapter
N.A
78
Wireless GPRS communication gateway
79
Wireless VSAT communication gateway
80
Wireless Radio communication gateway
N.A
N.A
N.A
Note: Any other item required but not covered as above.
Abbreviations: N.A->Not Applicable, LS->Lump Sum
PAGE 200 of 200
2356 of 2461
SUB-SECTION 6C.13
ROADS, BUILDINGS AND OTHER ALLIED
WORKS
2357 of 2461
MMRDA
Table of Contents
SUB-SECTION 6C.13: ROADS, BUILDINGS AND RECREATION FACILITIES
13.1
General
13.2
Intake
Error! Bookmark not defined.
13.2.1 Road Works
13.2.2 Buildings
13.2.3 Garden
13.3
13.3.1 Road Works
13.3.2 Buildings and Recreation Facilities
13.3.3 Garden
13.4
Master Balancing Reservoir Kashidkopar
13.4.1 Road Works
13.4.2 Buildings
2358 of 2461
MMRDA
SUB-SECTION 6C.13: ROADS, BUILDINGS AND RECREATION FACILITIES

13.1
General
This specification describes employers requirements for civil work

comprising the following:
i.
Buildings
ii.
Roads
iii. Gardens and Recreation facilities

13.2
Road Works
13.2.1
Intake
At intake location
area
internal Roads along the boundary of land / plot
allocated shall be provided. This road shall be connected to all
locations Intake Raw water pump house, HT /LT substation and other
buildings & approach shall be connected to existing Kawadas weir
road.
a)
8.0 meter width -Roads along the boundary of land / plot area
, connectivity with raw water pumping and connectivity with
existing Kawadas weir road
b)
6.0 meter width
- Connectivity with 8 m road and other
building in premises.
c)
3.5 meter width connectivity with 8 meter and 6 m road and

leading to small building and staff quarters.
Scope of road work
Scope of work includes excavation of earthwork for subgrade of 300 mm

and laying of 100mm granular sub base, 75 mm water bound macadam and
150 mm pavement quality concrete of grade M-40.
SECTION 6C.13: ROADS, BUILDINGS AND RECREATION FACILITIES
2359 of 2461
PAGE 1 of 9
MMRDA
Storm drain arrangement on side of roads shall be provided for
collecting and disposing dewatering rain and other water with

interconnectivity. The water shall be disposed from storm drain from
the area at safe and suitable disposal point
Low growth Tree plantation on both side of road shall be carried
out and it shall be conserved.

13.2.2
Buildings
S.
Name of the Buildings
No.
1
No. of
Unit Size in MTR
Unit
Store and Tool Room
10 X 6
Staff
Room
10 X15
Wash Room
6X 6
Security Cabin (Gate
3X3
House)
Plan, elevation including R.C.C design for the building shall be

approved from the Engineer/client and approval from Municipal
authorities if required shall be obtained
All the above building shall be constructed with Anti-termite
proof
treatment for foundation and other area
Tree plantation shall be carried around the buildings
Washroom shall be provided with septic tank arrangement
All the buildings shall be provided with drinking water arrangement.

For this separate DI pipeline from break pressure tank or other
suitable tank / reservoir in WTP shall be provided upto intake so
as to make available drinking water at intake work premises
2360 of 2461
PAGE 2 of 9
13.2.3
MMRDA
Garden
The area for Garden =45 m x 15 m approx.
The area of garden shall be developed by landscaping and

maintained with lawn and decorative plant and flowers
Sufficient excavation, removal of unwanted
material,
spreading, suitable clay for gardening,
provision of piping
arrangement
providing,
of water for gardening, Sprinklers arrangement,
percolated water draining arrangement
Fountain arrangement with recirculation of water arrangement shall

be provided at suitable location
Post top lantern lighting arrangement around the garden shall be

provided
The plan for the garden shall be approved from the Engineer
13.3
13.3.1
Road Works
(i)
Branch from Charoti -Jawhar road
to water treatment
plant at Suryanagar
The proposed approach road (existing raw road) to Water

treatment plant shall start from Charoti -Jawhar road to water
treatment plant at Suryanagar (near to junction of Kawadas weir
road, Charoti Jawhar road) The width of the road shall be 5 m.
Raw water pumping main from Kawadas weir to water treatment
plant is proposed to be laid along this road side.
2361 of 2461
PAGE 3 of 9
(ii)
MMRDA
Inside water treatment plant Suryanagar
a) From Main entry gate 1 & 2 to sides of filter plant, aerator,

future plate settler plant -Width of road 8 m
b) Interconnectivity road between filter plant and plate settler width of road 6 m
c) Entry gate to pump house , HT substation - Width of road 8
m
d) The branching from the
8 m road approaching plant
structure , staff quarters, gardens, community hall shall be at

least 3.5 m
e) Detail road plan layout along with branches from gates to
approaching different plant structures and other structures in
premises
shall
be
approved
from
the
Employer
representative / Client
(iii)
Road from Water treatment plant to
towards Ghol upto
State Highway
The existing raw road from water treatment plant towards Ghol
upto straight highway shall be renovated with 5 m width & as per
directives from employer.
Scope of road work
The requirement under paragraph 13.2.1 is applicable

13.3.2
Buildings and Recreation Facilities
2362 of 2461
PAGE 4 of 9
S.
MMRDA
No.
No.
of
Unit
Unit
Size
in
MTR
Store and Tool Room
30 X20
Wash Room1
10X6
Wash Room 2
6X6
Guest house
30 X25
Community Hall and Indoor
40 X25
game
6
Volley ball ground
40 X25
Garden
100 X100
Staff Quarters
40 sq. MTR
(G+1)
50 sq. MTR
(G+1)
35 sq. MTR
(G+1)
D.G.
Room
10X 6

All the above building shall be constructed with Anti-termite
proof
Washroom and staff quarter building shall be provided with septic

tank arrangement
All the building shall be provided with drinking water arrangement
All the building shall be provided with well ventilation
2363 of 2461
PAGE 5 of 9
13.3.3
MMRDA
Garden
The area for Garden =100 m x 100 m approx.
The area of garden shall be developed by landscaping and

provided, maintained with lawn and decorative plant and flowers.
And shall include playing apparatus
Sufficient excavation, removal of unwanted
material,
spreading, suitable clay for gardening,
provision of piping
arrangement
providing,
of water for gardening, Sprinklers arrangement,
percolated water draining arrangement
Fountain arrangement with recirculation of water arrangement shall

be provided at suitable location
Post top lantern lighting arrangement around the garden shall be

provided
The plan for the garden shall be approved from the Employers
representative
Fencing arrangement to Garden with at least two gates shall be

provided
Inside fencing tree plantation, complete garden shall be provided

and conserved
13.4
Master Balancing Reservoir Kashidkopar
13.4.1
Road Works
Road Upto existing three MBRs is already in existence in plot no.11.
This road
shall
be extended
to approach
newly proposed
Kashidkopar site located in plot no. 10. The road shall be developed
2364 of 2461
PAGE 6 of 9
MMRDA
and constructed with width 0f 3.2 m starting from the point where
existing 3rd MBR. This road shall approaches to end of acquired plot
with branches to structures and staff quarter and office building of
MBR.
Scope of Road Work

13.4.2
Buildings
S.
No. of Unit Unit Size in MTR
No
1
Store and Tool Room
5X 6
Re-chlorination Room and
10 X 15
DG Room
2
Office /staff room
10 X 6
Staff
9X6
Wash Room
6X4
Security
3X3
Quarters
Cabin
(Gate
House )

All the above building shall be constructed with Anti-termite proof

Washroom and staff Quarters building shall be provided with septic

tank arrangement
2365 of 2461
PAGE 7 of 9
13.5
MMRDA
Master Balancing Reservoir Chene ( MBMC MBR Ghodbunder

Road)
13.5.1
Road Works
The approach road from shall be developed and constructed starting
from Ghodbunder road as new branching
to proposed premises of
Chene MBMC MBR

Scope of Road Work

13.5.2
Buildings
S.
No.
No. of
Unit Size in MTR
Unit
Store and Tool Room
5X 6
Re-chlorination Room and
10 X 15
DG Room
2
Office /staff room
10 X 6
Staff
9X6
Wash Room
6X4
Security
3 X3
Quarters
Cabin
(Gate
House )

2366 of 2461
PAGE 8 of 9
MMRDA
All the above building shall be constructed with Anti-termite proof

Washroom and staff quarters shall
be provided with septic tank
arrangement
2367 of 2461
PAGE 9 of 9
SUB-SECTION 6C : 14
OPERATION AND MAINTENANANCE OF
WATER SUPPLY SYSTEM
2368 of 2461
MMRDA
Table of Contents
SUB-SECTION 6C : 14: OPERATION AND MAINTENANANCE OF WATER

SUPPLY SYSTEM ..................................................................................................... 1
14.1
GENERAL ...................................................................................................... 1
14.2
OBLIGATION OF THE EMPLOYER AND CONTRACTOR........................... 1
14.2.1
Obligation of the Employer ............................................................................................................. 1
14.2.2
Obligation of the Contractor ........................................................................................................... 2
14.3
DEFINITIONS OF OPERATION AND MAINTENANCE ............................... 3
14.3.1
Operation Work .................................................................................................................................. 3
14.3.2
Maintenance Work ............................................................................................................................. 3
14.4
SPECIFICATION ............................................................................................ 5
14.5
STRATEGY FOR GOOD OPERATION AND MAINTENANCE ..................... 5
14.5.1
Introduction ......................................................................................................................................... 6
14.5.2
Preparation of a Plan ........................................................................................................................ 6
14.5.3
Categories............................................................................................................................................ 8
14.5.4
Job Description .................................................................................................................................. 8
14.5.5
Training ................................................................................................................................................ 8
14.5.6
Availability of Tools & Plants and Spares ................................................................................... 9
14.5.7
Maintenance of Records ................................................................................................................ 12
14.5.8
Plant and Machinery Register....................................................................................................... 14
14.6
ACTIVITIES DURING O&M PERIOD .......................................................... 16
14.7
OPERATIONS AND MAINTENANCE MANUAL ......................................... 20
14.7.1
Contents of O&M Manual ............................................................................................................... 21
14.7.2
Related Dimensions of O&M ......................................................................................................... 23
14.7.3
History Sheet..................................................................................................................................... 25
14.8
EXPERIENCE AND QUALIFICATION OF STAFF ...................................... 25
2369 of 2461
MMRDA
14.9
GENERAL REQUIREMENT FOR OPERATION AND MAINTENANCE..... 27
14.9.1
Intake System ................................................................................................................................... 27
14.9.2
Pumping Stations ............................................................................................................................ 28
14.9.3
Specific Requirements of Pumping Station Maintenance ..................................................... 31
14.9.4
Water Treatment Plant .................................................................................................................... 32
14.10
INDICATIVE MAINTENANCE SCHEDULES FOR INTAKE AND CWPS 35
14.10.1
Stop Log Gates ............................................................................................................................. 35
14.10.2
Screen ............................................................................................................................................. 36
14.10.3
Sluice gate ..................................................................................................................................... 36
14.10.4
Ventilation system ....................................................................................................................... 36
14.10.5
Civil works : ................................................................................................................................... 36
14.10.6
Silt deposition in Pump well ..................................................................................................... 37
14.10.7
Maintenance of Pumps ............................................................................................................... 37
14.11
INDICATIVE MAINTENANCE SCHEDULE FOR WTP ............................ 40
14.12
TRANSMISSION SYSTEM ....................................................................... 48
14.12.1
Checks to be Carried out ........................................................................................................... 48
14.12.2
Safe Operating Limits (SOL) and Maximum Operating Pressure (MOP) ....................... 50
14.12.3
Provision of Information ............................................................................................................ 50
14.12.4
Route Surveillance ...................................................................................................................... 51
14.12.5
Line Walk Survey ......................................................................................................................... 52
14.13
WATER QUALITY MONITORING ............................................................ 54
14.13.1
Parameters and limits ................................................................................................................. 54
14.13.2
Frequency of Sampling and Water Quality Monitoring...................................................... 54
14.14
RECORD KEEPING .................................................................................. 59
14.15
REPORTING FORMAT ............................................................................. 68
14.15.1
Daily Report on Operation and Maintenance........................................................................ 68
14.15.2
Monthly Report on Operation and Maintenance of 403 MLD Water Treatment Plant 71
14.16
SPECIAL ACTIVITIES .............................................................................. 73
2370 of 2461
14.17
MMRDA
ELECTRICAL............................................................................................ 74
14.18
OPERATION & MAINTENANCE PRACTICES (INSTRUMENTATION,
CONTROL & AUTOMATION) ................................................................................. 83
14.18.1
General Maintenance .................................................................................................................. 83
14.18.2
Preventive Maintenance ............................................................................................................. 84
14.18.3
Concurrent Maintenance............................................................................................................ 86
14.18.4
Reliability Cantered Maintenance ............................................................................................ 86
14.18.5
Operations and maintenance documentation ...................................................................... 87
14.18.6
O & M SCHEDULE: Excess Electricity Consumption........................................................ 87
14.18.7
Spare parts stocking ................................................................................................................... 88
14.18.8
Utilities & Consumables............................................................................................................. 89
14.18.9
Technical support ........................................................................................................................ 89
2371 of 2461
MMRDA
SUB-SECTION 6C : 14: OPERATION AND MAINTENANANCE OF WATER

SUPPLY SYSTEM
14.1
General
This section describes to the specifications of materials used for
operation
and
maintenance,
preventive maintenance,
the
workmanship,
periodical
and
parameters and standards for the
acceptable quality of treated water, maintenance of records, and

responsibilities during operation and maintenance period.
The
Contractor shall operate and maintain the Intake with raw water
pumping station, water treatment plant, clear water pumping station.
complete pipeline including allied valves, pipe appurtenances
from
Intake to MBRs at Kashid Kopar for VVCMC & Chene near

Ghodbunder for MBMC , MBRs with allied systems at Chene and
Kashidkopar, 132 kV/ 6.6 kV/ 415 V substations at Intake and WTP,
instrumentation,
Central and local
SCADA systems,
all ancillary
buildings, campus area, for period of eight years and to prevent any
further sudden failure or breakdown through maintenance works on
plant operation and its operation works. It is essential that Employer
and contractor need to have sufficient information on operational
issues under normal and emergency condition.
14.2
Obligation of the Employer and Contractor
14.2.1
Obligation of the Employer

(i)
The Employer shall provide only raw water which shall be lifted
from Kawdas pickup weir. The cost of raw water shall be paid by
the Employer to the concern authority
(ii)
Complete power cost payments for operation and maintenance

of complete plant shall be borne by the Employer.
SECTION 6C.14: OPERATION AND MAINTENANCE OF WS SYSTEM
2372 of 2461
PAGE 1 of 90
14.2.2
MMRDA
Obligation of the Contractor

(i)
The contractor shall obtain all statutory, legal permissions,

Licenses to operate and maintain the complete plant and
systems including Substations, Chlorination system.
(ii)
Procurements of spares, consumables, oils, lubricants and

chemicals in sufficient quantity storage and use, Consumption &
Stock record required for water treatment and other purposes
shall be the contractors responsibility.
(iii)
The obligation of contractor is to provide treated water meeting

all the specifications and requirements as indicated, mentioned
in IS 10500: 2012.
(iv)
The frequency of Testing of water quality parameters from

Intake, Clarifier, Filtration, post chlorination, Re-chlorination,
MBRs shall be as per details mentioned in the table, as per
requirements & directives of Employer.
(v)
The contractor shall update operation and maintenance manual

every year indicating every year Edition number as
Edition
number 1, Edition number 2 etc.

(vi)
The contractor shall organize training and deployment of

advisors as details in Employers requirement.
(vii)
Insurance: The Contractor shall, without limiting his or the

Employers obligations and responsibilities, insure;
a. The work together with material and plant for incorporation
therein, to the full replacement cost (term cost in this context
shall include profit).
b. The Contractors equipment and other things brought onto
2373 of 2461
PAGE 2 of 90
MMRDA
site by the Contractor, for a sum sufficient to provide for their

replacement at the site.
c. The insurance shall be in the joint names of the Contractor
and the Employer at the Contractors cost and shall cover the
Employer and the Contractor against all losses or damages
from whatsoever cause arising from the start of the O&M until
the date of completion of O&M in respect of the facility or any
section or part thereof as the case may be.
d. Any amount not insured or not recovered from the insurer
14.3
Definitions of Operation and Maintenance
14.3.1
Operation Work
This work consists of operation work and monitoring work:
Operation work is executing the plant operation based on the
scheduled process and procedure to meet designed criteria including
set up or adjust the operational index or data according to the water
quality or demand.
Monitoring work is to confirm the operation data, and readout its
measurement value on panels, and checkup the working performance
of plant appropriately, as well as keep the records of the output.
14.3.2
Maintenance Work
The work consists of inspection work and maintenance work as
mentioned below:
Inspection work, that includes physical appearance, inspection and

measurement with testing equipment to verify and survey that the
2374 of 2461
PAGE 3 of 90
MMRDA
plant performance whether operation in normal or not
The inspection work shall be daily executed by each technical

specialist as a routine and/or regular inspection and shall be
recorded each time. The evaluation on the collected data shall be
immediately reviewed by the chief operational engineer to instruct
the staff member for the operation on the same day and/or make a
plan of detail inspection and/or make repair schedule to make sure
continuous plant operation without any problem.
Maintenance work, for which main task-work shall include activities,

such as lubrication, overhaul, replacement of parts
14.3.2.1
Preventive Maintenance
Preventive maintenance consists of all the regular work carried out in
order to sustain the conditions necessary or smooth operation of the
plant and to keep the performance of the equipment as close as
possible to its original performance level. Its purpose is to reduce the
probabilities of failure of deterioration of equipment of the plant. In
simple terms, preventive maintenance involves the elementary
operations such as lubrication, mechanical servicing, electrical and
instrumentation servicing.
14.3.2.2
Corrective or Remedial Maintenance

Corrective or remedial maintenance consists of all works needed to reestablish the conditions necessary for an apparatus or set of
equipment to operate properly after rectification subsequent to failure
or deterioration of the results observed from the equipment. It includes
the following operations,
Dismantling or equipment
Replacement of parts
2375 of 2461
PAGE 4 of 90
MMRDA
The work may be scheduled for the short or medium term in

accordance with the checks carried out as part of the preventive
maintenance procedure, the number of hours as apparatus has been
operating, or an alarm factor (abnormal noise, repeated cut-out,
weakening of the insulation, etc.) or may be dictated by an unexpected
breakdown
Maintenance covers all the techniques and systems which, by means
of regular monitoring of equipment and scheduled maintenance
procedures, prevent failures and, in the event of problems, enable
repairs to be carried out with the minimum disruption of the process.
Maintenance is therefore a combination of technical, administrative,
and management activities. Maintenance consists of preventive and
corrective procedures.
14.4
Specification
The specification of materials used for repairs shall be the same as
have been used in the original work. Specifications for any materials
which were not used during construction shall be approved by the
Employers Representative prior to commencement of the operation
and maintenance period and must be incorporated in the O&M manual.
Without being limited by this clause, during O&M period the Contractor
shall use appropriate material for repairs even if material required for
such repairs has not been approved earlier, and no delay in making
such repairs shall be subjected to such limitation.
However, subsequent to use of such material the Contractor shall
submit proposals for the approval of specifications of such material.
The approved material will subsequently form a part of the O&M
manual.
14.5
Strategy for Good Operation and Maintenance
2376 of 2461
PAGE 5 of 90
14.5.1
MMRDA
Introduction
The minimum requirements for good operation and maintenance are:
1.
Preparation of a plan for operation and maintenance.
2.
Providing required personnel to operate and maintain.
3.
Providing
Capacity
building
programmers
for
the O&M
personnel.
4.
Availability of spares and tools for ensuring maintenance.
5.
Preparation of GIS based maps of the system.
6.
Preparation of a water audit and leakage control plan.
7.
Maintaining MIS records on the system including history of

equipment, costs, life etc.
14.5.2
8.
Action Plan for energy audit for saving on energy.
9.
Establishing a sound financial management system.
Preparation of a Plan
A program or a plan has to be prepared for operation and maintenance
of every major unit to be specifically written for that particular unit. The
overall operation and maintenance plan of an organization is made up
of collecting operation and maintenance programs of various individual
units. This plan has to contain procedures for routine tasks, checks and
inspections at intervals viz. daily, weekly, quarterly, semi-annually or
annually.
2377 of 2461
PAGE 6 of 90
MMRDA
The individual plans must be prepared for all units and all pieces of
equipment. Each unit must have a plan to fix responsibility, timing of
action, ways and means of achieving the completion of action and
contain what objectives are meant to be achieved by this action.
Generally, actions recommended by the manufacturer or by the
engineer who has installed the equipment or who has supervised the
installation can be included. Often the contractors recommended
operation and maintenance procedures at the time of design or
construction will be a good starting point for writing a sound
Programme. This plan has to be followed by the operation and
maintenance staff and also will be the basis for supervision and
inspection and also can be used for evaluation of the status of
operation and maintenance.
If the labor costs for operation and maintenance are high compared to
replacement cost, the latter course of action will be preferable. The
managers shall realize that most of the operation and maintenance can
be carried out without more staff. The existing operation and
maintenance staff with little training can do the operation and
maintenance work without any extra expense. Similarly, record keeping
and analysing does not require any additional cost. However, costs
have to be provided in the budgets for spares, tools and plants, training
to operation and maintenance staff and any specialized services for
important equipment.
Briefly the plan shall contain what actions are required, when these
actions are to be taken, who has to take these actions, how these
actions are to be achieved and why these actions are required. The
nature of maintenance can be described in a separate maintenance
manual and related by numbers in the plan for reference, so that the
maintenance staff know as to how to carry out the numbered actions.
Checklists can be prepared for use by the supervision or inspecting
officers to ensure that the actions indicated in the operation and
maintenance plan are carried out promptly and properly. Check lists for
various units of O&M of water supply and treatment are listed in the
2378 of 2461
PAGE 7 of 90
MMRDA
respective chapters.
14.5.3
Categories
The O&M function is performed by:
(a)
operating staff and
(b)
supervisory staff. While the former actually run the system, the
latter monitor the operations and provide managerial support. It
is difficult to propose a rigid organizational structure model for
use at all places. It is likely to vary from place to place due to
factors like site-specific requirements, availability of suitable
manpower and age-old practices.
14.5.4
Job Description
When the plan or programme containing procedures to be adopted or
actions to be taken is prepared for each piece of equipment, the person
to carry out this action is to be identified. This persons job description
should contain reference to the maintenance plan/programme. The job
description of operating personnel shall clearly define the limits up to
which these personnel can carry out normal maintenance. The job
description of the Supervisor/Manager shall include the requirement
that they shall ensure that the operating personnel conform to these
limits and thus ensure the safety of the equipment.
14.5.5
Training
The personnel who are already available or chosen to carry out the
actions contained in the programme may have to be trained through
special courses or by on the job training to ensure that these
personnel are thoroughly trained to carry out the actions listed in the
plan
of
maintenance.
This
training
is
essential
to
prevent
experimentation by operating personnel to meddle with equipment

2379 of 2461
PAGE 8 of 90
MMRDA
since often these operating personnel may not be capable to take up

the required maintenance. On the job training is preferred to class
room training. The supervisors can be trained initially and they can
later train their operators.
i)
Supervisory organization of engineers, accountants, managers

belonging to the O&M agency.
ii)
Day to day operation and maintenance of units like treatment

plant, pumping stations and large transmissions with private
agencies
iii)
Day to day operation and maintenance of transmission mains

and distribution system with private agency.
iv)
Repairs with private agencies: such as meter repairs, upkeep of

chlorinators, chemical dosers, and instrumentation repair,
maintenance and calibration.
v)
Supply of chemicals and spares to be arranged by O&M agency.
vi)
Payment of energy charges, raw water charges, telephone bills

etc. to be made by O&M agency directly.
vii)
The organization itself can decide to hand over to private

agencies such duties which cannot be discharged by it
economically/efficiently.
14.5.6
Availability of Tools & Plants and Spares

The availability of spare parts for repairs and replacements is to be
ensured by ordering and delivery of spare parts by organising an
inventory system. Efficient management of stores is required to ensure
that the required spare parts are available at all times. The list of spare
parts to be procured can be drafted on the basis of manufacturers
2380 of 2461
PAGE 9 of 90
MMRDA
recommendations in the absence of which a list of spare parts can be

prepared from the records of spare parts actually used in the previous
years.
A good starting part is to start with the maintenance program and list
item wise likely spares to be ordered for repairs and replacements.
Spare parts which are difficult to be procured i.e. delivery times are
longer shall be identified and the list of spares shall contain as to when
these are to be ordered. Managers will have to review the list and take
advance actions to ensure that spare parts are on hand when they are
needed. Alternatively, the required spares for five year periods are
procured at the time the equipment is initially installed. The next
important task is to ensure the availability of tools necessary to
properly repair and correct both the routine problems and for facilitating
repairs and replacements. Hence a list of tools and plants has to be
prepared, again starting from the plan of maintenance for each unit and
the final list of tools and plants is prepared to cover repairs of all the
pieces of equipment. It will be also necessary to arrange for routine
maintenance of tools and plants, for ensuring that they are in a fit state
to be used when repairs and replacements are taken up.
A well organised stores unit shall be available, and accessible at all
times to the operation and maintenance staff from which all required
spare parts, tools etc., to enable the operation and maintenance staff to
carry out the servicing, repairs or replacement, contained in the
maintenance plan.
14.5.6.1
List of Tools
List of Tools All the tools listed below shall be preserved with
contractor for the use of
in Construction phase, Water supply system
operation and maintenance period. All these tools shall be returned by

the Contractor to the Client in good condition after O&M period is over.
2381 of 2461
PAGE 10 of 90
MMRDA
Table 14.1: Mechanical

S.
Name of the Equipments
Quantit
Uni
Rate
Cost
in Rs
in Rs
welding
set
Gas Welding & cutting Equipments and
set
No
.
1
Welding
Machine
with
equipments
2
safety equipments
3
Trolley mounted DG set 15 kVA
set
Dewatering pumps set Diesel operated
set
set
(7.5 kW to 9.3 kW)

5
Dewatering
pump
set
electricity
operated not less than 7.5 kW

6
Mobile Workshop VAN/ Vehicle
No.
Truck mounted silt removal Machine
No.
Set
with jetting facility for Desilting ponds,

lakes, river passage etc.
8
Tripod
with Chain pulley block
Minimum 3T capacity
9
Tarpaulins Tents
No.
10
Lifebuoy /Life saver rings
No
s
11
Safety equipments including Helmets,
12
set
set
Set
set
gloves, goggles, ropes, suit etc.

12
Cupboards, Breathing apparatus with

Mask / cylinder sets
13
Portable Air compressor suitable rating

with
air
breathing
receiver,
air),
(specially
pressure
for
gauge,
connecting arrangement with cylinder

14
Chlorine
leakage
arresting
kit
Tonner Valve leakage arresting kit,

Tonner surface leakage arresting kit.
Tonner safety plug leakage arresting
2382 of 2461
PAGE 11 of 90
S.
MMRDA
Name of the Equipments
No
Quantit
Uni
Rate
Cost
in Rs
in Rs
.
kit
15
First aid box with component
12
set
16
Portable furniture sets
set
s
17
Special tools like vacuum cleaners,
portable blowers
18
Set
s
Spanner sets (6mm to 32 mm) Ring
12
set
set
spanners set, Flat spanner set Box

spanner set
19
Spanner sets (32mm to 56 mm) Ring

spanners, Flat spanner (32mm to
56mm)
20
Torque wrenches set
set
21
Pipe wrenches 12 inch, 24 inch
set
22
Screw driver set (6 inch, 12 inch) flat
12
set
set
end, screw driver set cross ends

23
Dial gauge set suitable for horizontal

pumps, Air Blowers
24
Vibration measuring instrument
No
25
Noise measuring instrument
No
26
Speed /RPM measuring instrument
No
No
(Non-contact type)
27
Temperature measuring instrument
s.
28
14.5.7
Spirit Level measurement (metallic)
No.
Maintenance of Records
The necessity for good maintenance records is often overlooked. The
maintenance plan programme contains as to what should be done and
when. But to decide as to how long an equipment is to be allowed to be
2383 of 2461
PAGE 12 of 90
MMRDA
kept in service requires information as to when it was installed, what is

its normal life etc. Budgets for operation and maintenance can be
prepared only on the basis of records of previous years maintenance.
The managers shall realise that most of the maintenance can be
carried out without more staff. The existing operation and maintenance
staff with little training can do the operation and maintenance work
without any extra expense. Similarly, record keeping and analysing
does not require any additional cost. However, costs have to be
provided in the budgets for spares, tools and plants, training to
operation and maintenance staff and any specialised services for
important equipment.
Good record system shall include the following minimum information to
ensure the required maintenance.
1.
Name of equipment and location of equipment
2.
Number available or installed
3.
Serial number
4.
Type and class
5.
Date of procurement/installation
6.
Cost of procurement and installation
7.
Name of manufacturer with address and telephone No.
8.
Name of distributor/dealer if purchased through them with

address and telephone number.
9.
Name of servicing firm with address and telephone number.
10.
Service manuals
2384 of 2461
PAGE 13 of 90
MMRDA
11.
Descriptive technical pamphlets
12.
Major overhauls: Details of date, nature of cost
13.
When next overhaul is due.
14.
Date, type and cost of repairs and replacement
15.
Cost of spares and cost of labour for repairs.
14.5.8
Plant and Machinery Register
14.5.8.1
Details of locations of equipment, machinery

The plant and machinery register shall be maintained separately for:
1)
Intake and Raw Water Pumping system and pumping main up to

WTP.
2)
Water treatment plant.
3)
Clear water pumping station and pumping main up to Break

pressure tank.
4)
Break pressure tank and gravity main from BPT to Kashid kopar
junction.
5)
Gravity
piping
main
Kashidkopar
junction
to
MBR
at
Kashidkopar, Master Balancing reservoir at Kashidkopar,

6)
Gravity piping main Kashidkopar junction to Chene MBR and

master balancing reservoir at Chene.
14.5.8.2
Details, Information for Equipment /Machinery
2385 of 2461
PAGE 14 of 90
MMRDA
The complete Plant and Machinery shall be maintained by the

operator.
According to design life of structures, plant and equipments
depreciation cost shall be calculated and mentioned annually in the
plant and machinery register The field, actual site machinery will be
verified and audited annually by the Auditor appointed by the client.
Annually report for audit shall be submitted by the contractor to
Employer /Client.
The Plant and Machinery Register Shall be maintained by the
contractor which shall include the following data/information
1.
Name of equipment and location of equipment.
2.
Number available or installed.
3.
Serial number.
4.
Type and class.
5.
Date of procurement/installation.
6.
Cost of procurement and installation.
7.
Name of manufacturer with address and telephone No. / Mobile

No.
8.
Name of distributor/dealer if purchased through them with

address and telephone number/Mobile number.
9.
Total number of major failure of equipment.
10.
Total expenditure done on equipment during the year.
2386 of 2461
PAGE 15 of 90
11.
14.6
MMRDA
Depreciation value of equipment.
Activities during O&M Period

General
Within the framework of the Contractors responsibilities given above,
the Contractor shall carry out the following activities. However, these
shall not limit the requirement for other activities which otherwise are
required as per term and conditions of Contract or to fulfill the
Contractors responsibilities or are essential as per good industrial
practices. The Contractor shall be responsible for, but not limited to,
the following:
a)
Providing water with quality as specified and at the flow rates on

22 hr/ day 403 ML/day i.e. 218 ML/day at Chene MBR & 185
ML/day at Kashidkopar MBR or as directed by, Employers
Representative.
b)
Providing the required staff of specified qualification and

experience, but not less than the minimum specified numbers,
for operation and maintenance and additional staff as per
requirement for repairs.
c)
Providing all consumables, spares, oils, lubricants, etc. required

for functioning of plant and equipment including chemicals.
d)
Maintenance of 132 kV/ 6.6 kV/ 415V substations etc. at the

pumping
stations,
water
treatment
plant,
administrative
buildings, Chemical house, MBRs pipelines, tunnels etc.
(all
works constructed in this Contract) in neat and clean condition.

e)
Entering into AMC contracts with system / equipment suppliers,

as necessary. It is mandatory to enter into an agreement for an
2387 of 2461
PAGE 16 of 90
MMRDA
8-year maintenance contract with the PLC and SCADA system

supplier or the authorized system integrator, whosoever has
executed the work for this project and their representative
should be available at site within 24 hours.
f)
Maintenance of the lighting fixtures and the lighting system of all

areas and replacement of all non-functional lighting fixtures
within 24 hours.
g)
Maintaining the following;
Repair
history
of
all
mechanical,
electrical
and
instrumentation control equipment in pumping stations, water

treatment plant, and communication instruments, Complete
Pipe line and allied valves;
Logbooks through PLC system;
Every day power availability, input voltage and current,

frequency, power factor, kWh meter readings and kW
reading for Substation at Intake Raw water pumping station,
Water Treatment plant and clear water pump house, MBRs
at Kashidkopar & Chene;
Daily log of operations of all the important equipment such as

Intake, Raw water pumping station, Water treatment plant
System
pumping
and
equipment,
station,
Pre-Chlorination
Post-Chlorination,
Clear
dosing,
water
electrically
actuated valves, Flow measurements, Power supply, MBRs

etc. with time tag;
Hourly levels of sumps at Raw water pumping station, Clear

water Pumping station;
Hourly readings of pressure on the manifold, flow rate in
2388 of 2461
PAGE 17 of 90
MMRDA
manifold and integrated quantity of water;
Raw and clear water quality test results on turbidity, residual

chlorine levels and other process parameters;
Daily list of alarms with time tag;
Logbook format and the data to be included in the logbook

shall be decided during commissioning in consultation with
Employers representative;
Last periodic maintenance done for all equipment/buildings

of the system;
Observation made during patrolling of the pipe line and

roads;
In addition to maintenance of above logbooks the Contractor is

required to maintain one inspection registers and complaint
registers at each pumping station and WTP and MBRs. The
complaints
entered
in
the
complaint
register
must
be
investigated and remedial measures must immediately be taken.

h)
Providing required spares, special tools and test equipment and

maintaining adequate inventory of required accessories or
equipment itself for repair of system so that the electrical,
mechanical, instrumentation and control system, pipe and the
communication system
can
work
efficiently as
per the
guarantees given or minimum required efficiencies asked for in

the Contract, without any additional costs to employer.
i)
Providing manpower for the required repairs of all facilities along

with the manpower and materials for repair of the roads,
buildings and campus area utilities.
2389 of 2461
PAGE 18 of 90
j)
MMRDA
Maintaining the drinking water supply facilities at Intake & Raw

water Pumping station, WTP campus, Clear water Pumping
station, Reservoirs and all its units.
k)
Maintaining
stores
for
the
electrical,
mechanical
and
instrumentation and control equipment as well as that for the

chemicals and laboratory consumables at the filter plant. The
maintenance of stores will include but shall not be limited to:
Loading / unloading of materials received and issued for

works;
Proper arrangement of material in stores to ensure its safety

and easy availability;
Maintaining store areas in a neat and tidy condition;
Keeping records and accounting for the incoming materials,
Keeping records and accounting for the consumed materials.
The Contractor shall be solely responsible for the safety and

security of the goods in the store and will be responsible for any
loss or damages in stores for any reason.
He may opt for
insurance cover against the value of the goods to be stored

without any additional costs on the Employer.
l)
Periodic routine maintenance of structures/buildings of campus

areas of treatment plant and others built in the Contract. Such
maintenance must ensure adequate cleanliness, ventilation,
illumination and structural safety. In addition to this, the general
hygienic
standards
must
be
maintained
and
adequate
plantation, horticultural activities must be taken up to maintain

the total environment of the campus / buildings pleasant.
2390 of 2461
PAGE 19 of 90
m)
MMRDA
Updating and periodic submissions of the operation and

maintenance manual. The Contractor shall take up all periodic
maintenance works provided in the approved O&M manual.
n)
Providing transportation facilities between various areas from

Intake to MBRs
o)
Submission of monthly report
Co-ordination with other contractors and/ or agencies

responsible for the execution, operation and maintenance of
the Substations, Raw water pumping station, Water
treatment plant, clear water pumping plant, MBRs including
all electric supply company and other government agencies
The Employers representative shall be entitled to audit any

aspect of the system and the contractor shall ensure
remedial action as directed
Safety reporting: Necessary reporting of all accidents and

hazardous incidents of all accidents and hazardous
incidents including descriptions of cause, extent of injuries,
action taken, as per prescribed format detail information
required to submit to Employer, Client, government
agencies and precautions instituted to prevent repetition of
such events
14.7
Operations and Maintenance Manual

Operation
and
Maintenance
manual
shall
incorporate all
the
equipments, technical information for following systems/ units/

structures
1. Intake
2391 of 2461
PAGE 20 of 90
MMRDA
2. Substations
3. Raw water Pumping Station
4. Rising Main
5. Water Treatment Plant
6. Chlorination System
7. Clear Water Pumping Station
8. Rising Main with Break Pressure Tank
9. Gravity Main
10. MBR at Kashidkopar
11. MBR at Chene
14.7.1
Contents of O&M Manual

The comprehensive manual shall be submitted before the operation
and maintenance period, as specified. It shall be periodically updated
to incorporate the best practices experience gained while carrying out
the O&M activities, broadly on the principals listed below:
1. Up-dating any changes in the procedures set out in the O&M
manual, as deemed necessary based on any limitations observed
during the maintenance period, including incorporating additional
procedures for maintenance of other repairs/break downs not
incorporated in the maintenance manual but faced during O&M
period.
2. Procedures for repair of leaks/burst in different types of pipes must
2392 of 2461
PAGE 21 of 90
MMRDA
be provided, with supporting drawings. The O&M manual must be

updated if any differences are observed during O&M period.
3. Frequency of spares used in maintenance of valves (air-valve,
sluice valves and butterfly valves), expansion joints, equipment
installed for surge protection and protection against corrosion must
be recorded for updating the contents of the manual.
4. Records of trouble shooting points and details of events causing
trouble (breakdowns) during maintenance of inlet chamber,
chemical mixing unit, flash mixer, clariflocculator, filter bed(s),
sludge thickener and drying beds, pre-chlorinator and any other part
of the treatment plant must be maintained and used for updating the
contents of the manual.
troubles (break downs) during maintenance of pumps / motors /
measuring equipment(s) / electric panel and accessories there in
must be maintained and used for updating the contents of the
manual.
6. Records of locations and type of damages observed during
maintenance of road which are of recurring nature must be used in
updating the manual.
trouble (breakdowns) during maintenance 132/6.6 kV /415 V substation, etc., must be maintained and used for updating the contents
of manual.
8. Records of Inventory used must be maintained and the relevant
portion of O&M manual must be updated to list out the inventory
requirements for maintaining the system for 12 months.
9. Records of the raw water quality, as monitored during very day of
2393 of 2461
PAGE 22 of 90
MMRDA
the O&M period, must be maintained and handed over after the
expiry of Contract period. The chemical requirement in the worst
conditions of operation must be identified and incorporated in the
manual. Though not a parameter of the raw water quality, the
Contractor shall keep records of pre-chlorination requirement to
check the algae growth in the plant to be incorporated in O&M
manual. Record keeping must be sufficient so as to assist in
forming a relationship between the chemical dosages required for
treatment with respect to the raw water input quality.
10. The provisions in the manual must incorporate every aspect of good
industrial practices even if not elaborated here or in other parts of
the bid document. The provisions in the approved operation and
maintenance document shall be valid and binding for both the
parties during operation and maintenance along with the additions
and deletions made.
11. The manual so prepared must be updated after the end of every
year of operation and maintenance, giving effect to the experience
gained and the observations made by the Department during the
maintenance period.
12. At the time of handing over after completion of O&M period, all the
equipment, including standby equipment, must be in good working
order.
14.7.2
Related Dimensions of O&M

The Contractor, before commencement of the Tests on Completion,
shall submit 8 (Eight) copies of the operation and maintenance
manuals for the pipe line, power supply systems including 132 kV/ 6.6
kV /415V overhead single circuit lattice tower line, water treatment
plant and pump stations Raw water , Clear water pumping station in
the English language, containing descriptions, illustrations, sketches,
drawings, sectional drawings, sectional arrangement view and
2394 of 2461
PAGE 23 of 90
MMRDA
manufacturers parts numbers to enable the connections, functions,

operation and maintenance of all components of the complete System
to be easily followed and for all parts to be easily identified to facilitate
ordering of the replacement parts. Exploded views of the items/ works
where appropriate shall be used for clarity. The Contractor shall
provide the contact address and telephone number (Hotline) in the
manual.
Technical data of all equipment and their performance. Including

name plate
Instructions for servicing and overhauling
Particulars of lubricating oil and grease to be used, also alternative

indigenous commercial lubricating oils suitable for use
Performance curves for all units regarding efficiency loading and

output
Performance curves for the motors
List of tools mounted on wall panels
List of spares provided in the spare box
Spare parts list, with manufacturers part numbers
Operators log
List of the photographs of the plant and machinery as fabricated by

the manufacturer
The maintenance manual shall also include the following:
Procedures for maintenance
2395 of 2461
PAGE 24 of 90
14.7.3
MMRDA
Preventive maintenance procedures for all the equipment
Emergency maintenance management of the plant and equipment
History Sheet
History of major equipments shall be maintained for all mechanical,
electrical equipment like transformers, Switchgears, important relays,
Vertical turbine pumps & its motors, Air Blowers, Ventilation system,
pipeline Air valves, line valves and scour valves major instrumentation,
SCADA and measuring instruments with calibration in Intake, Raw
water pumping station, Water treatment plant, Clear water pumping
station, MBR at Kashid kopar, & Chene
14.8
Experience and Qualification of Staff

For all operation and maintenance works, the Contractor shall provide
skilled staff, which has
adequate
qualifications
and sufficient
experience of similar works. CV of All managerial staff will have to be

got approved from the Employers representative. Out of 6 assistant
managers and 14 Jr. Managers Minimum 40% shall be of Mechanical,
Electrical and instrumentation discipline.
Table 14.2: Staff
S.
Category
No
Installation
Substation,
Manager
Assistant
WTP
Total
Substatio
Intake &
n&
RWPS
CWPS
MBR
KK
Trun
Chen
main
1
1
Manager
1
1
14
(in
shifts)
Jr. Manager
2396 of 2461
PAGE 25 of 90
MMRDA
(in shifts)
4
Operator (in
32
16
36
80
15
shifts)
5
Fitter
Helper
(in
shifts)
7
Electrician
(in shifts )
Mechanic
Helper
18
24
(Elect)
(in
shifts )
10
Security
Guard
(in
shifts )
11
Chemist
12
Assistant
lab
15
Clerk /Typist
16
Accountant
17
Store keeper
18
Sweeper
38
72
38
17
16
43
224
chemist
13
Lab
Assistant (in
shifts )
14
Helper
(in shifts )
Note:
1. The above requirement is minimum only. The Contractor will
arrange extra work force, as and when required, so as to smoothly
run
the
operation
maintenance,
repairs
and
etc.
maintenance
and
general
2397 of 2461
including
preventive
cleanliness
of
the
PAGE 26 of 90
MMRDA
installations.
2. The Contractor will have to maintain adequate transportation
facilities for daily patrolling of the pipe line from Kawdas to
Suryanagar WTP to Kashidkopar MBR, & Chene MBR and will
ensure regular watch on pipe line. Minimum 4 jeeps /vehicles shall
be provided, 3 for patrolling of pipeline and one for maintenance of
pipeline.
3. The above staff strength is exclusive of leave reserve required for
different category of staff. The Contractor shall ensure availability of
the personnel given in the above table for all seven days in a week.
4. The
Contractor
shall
make
appropriate
arrangements
for
maintenance of items like road work, buildings, arboriculture,

patrolling and maintenance of civil structures, vehicle operations
and other activities defined to fulfill its obligations under O&M
Contract.
5. Deployment of staff will be with prior permission of MMRDA
6. Internally deployment will be approved by MMRDA
14.9
General Requirement for Operation and Maintenance
14.9.1
Intake System
i) Operation of stop logs (inlet arrangement) / gate, Manual operated
gantry, chain pulley block with its periodical maintenance including
provision of required manpower for routine operation.
ii) Screen Cleaning of Screen daily and its periodical maintenance.
iii) Operation of Sluice gates and its operating arrangement with its
periodical maintenance including provision of required manpower
2398 of 2461
PAGE 27 of 90
MMRDA
for routine operation.

iv) Intake structure
14.9.2
Pumping Stations
i) Operation of plants as required, including provision of required
manpower for routine operation of pumping station.
ii) Periodic upgrading, as required, of the impellers and wearing rings
by replacement with the intermediate impellers and wearing rings,
and subsequently with the final impellers and wearing rings, for the
clear
water
pumping
station
(replacement
impellers
and
accessories to be provided as a part of the Contract).

iii) Maintaining the pumping station PLC, including hardware and
software along with all instruments, in proper working condition. The
downtime of the control system shall not exceed 2 hours. During the
downtime, the Contractor shall continue to operate the pumping
station in manual mode using the local panel controls and the
readings from local instruments.
iv) Routine and periodic maintenance of the entire control system and
instruments as per the manufacturers recommendations.
v) Replacement of damaged control, communication cables, and
power supply cables.
vi) Repair or replacement, as required, of all instruments such as flow
meters, pressure sensors, pressure gauges, level sensors, float
level switches, temperature scanners, vibration sensors, noise
meter, data loggers along with all other equipment. The down time
of any individual instrument as referred above shall not exceed 24
hours.
2399 of 2461
PAGE 28 of 90
MMRDA
vii) Periodic site calibration of all measuring/metering equipment at

every 6 months minimum or as recommended by the manufacturer.
The calibration at the manufacturers works/ independent laboratory
shall be carried out only in case of major failure of the instrument.
viii)Preparation and submission of daily and monthly customized
reports, produced from the local SCADA system
ix) Repair or replacement, as required, of damaged electrical
equipment/ parts for proper functioning of electrical system.
x) Maintenance of the cooling and lubricating systems.
xi) Routine maintenance of the pumps/ motors as per recommendation
of the manufacturer.
xii) Replacement of bearings, damaged impellers and other damaged
parts so that the operation of pumps ensures the guaranteed
efficiencies with desired noise and vibration levels.
xiii)
Routine and periodic maintenance of the EOT cranes as per the

manufacturers recommendations.
xiv)
Breakdown
maintenance
of
all
electrical,
mechanical,
instrumentation and control equipment, EOT crane, etc.

xv)
Re-painting of the exposed mild steel components of pipe line,

ladders, railings etc. in the pump house in the 3rd and 5th year
of O&M to keep them in good shape &appearance.
xvi)
Maintaining the surrounding areas of the pumping stations free

from shrubs, weeds, grass and other unplanned vegetation.
xvii)
Routine
monitoring
of
substation
equipment
and
taking
preventive measures as required

2400 of 2461
PAGE 29 of 90
xviii)
Routine
MMRDA
maintenance
of
VFD
as
per
manufacturers
recommendation.
xix)
Keeping the hourly records of:
Status of pumps
Current
Voltage
Frequency
Active and reactive power
Water level at suction reservoir
Suction and delivery gauge readings
Rate of flow
Pump head
Keeping daily records of:

o Total number of hours of operation
o Total quantity pumped
o Total energy(kWh) consumption
xx)
Disposal of screened material.
xxi)
Providing all consumables such as grease, oil, stationery, water

for gardening, etc.
xxii)
Providing office furniture for operating and maintenance staff.
xxiii)
Providing safety accessories such as gloves, shoes, first aid box
etc.
xxiv) Ensuring safety of plant and equipment.
xxv)
Furnishing required information to Employer.
xxvi) Any compensation charges levied by Electricity providing

company, MSEDL, towards low power factor, overloading or any
2401 of 2461
PAGE 30 of 90
MMRDA
other such penalties will be borne by the Contractor.

xxvii) Contractor will be given a minimum of 15 days advance notice
by the Employers Representative for changing the impellers
when required.
14.9.3
Specific Requirements of Pumping Station Maintenance

Table 14.3: Maintenance Schedule for Pumping Stations
Activity
Frequency
Removal of clogged materials from screens
Daily 6 times
(only for raw water pumping station / plant)

Temperature
of
WTI/OTI
w.r.t
ambient Daily 4 times
temperature
Oil level in the conservator
Daily 3 times
Oil level in the bushing
Daily 3 times
Temperature of RTD, BTD in motors w.r.t. Daily 3 times

ambient temp.
Watering garden around plant, if provided
Daily 3 times
Checking of dis-connectors operation
Weekly
Operation of crane for all motions
Weekly
Cleaning of level sensors
Weekly
Housekeeping plant and its surroundings
Daily
(Includes removal of dust, dirt, cobweb etc.)

Checking vibration and noise level of pump sets
Daily
Fully closing and opening of sluice gates and Monthly

valves
Submission
of
report
on
maintenance
to Monthly
Employer
IR and PI values of motors
Monthly
Condition of silica gel in breather and
Monthly
replacement (if required)

Replacement of bearings
Within
day
of
breakdown
2402 of 2461
PAGE 31 of 90
MMRDA
Activity
Frequency
Replacement of bulbs, lamps etc.
Within
day
of
breakdown
Tightening of gland
When leakage
increases beyond
acceptable limit
Greasing, oiling
As per manufacturers
recommendation
Attending breakdowns
As and when it occurs
Preparation of list of spares for satisfactory Half-yearly

operation
Transformer oil sample checking
Half-yearly
Inspection of switchboard, cable box, etc.(i.e. Halt-yearly

visual inspection, tightness of nuts and bolts, IR
values, earthing contacts, checking tightness of
terminal block, etc.)
Measurement of earth resistance
Yearly
Checking of relays/ alarm (trough secondary Yearly

injection)
Condition
of
gasket
and
replacement
(if Yearly
required)
14.9.4

i) Operation and maintenance of all the water treatment process
facilities from inlet chamber to clear water reservoirs.
ii) Providing required manpower for routine operation of flash
mixtures, clariflocculators, filter beds, inlet and outlet channels of
filters, backwash pump sump and tank, compressor room, HV/LV
switchgear room, PLC control, all motors and valves in the system,
and laboratory.
iii) Maintaining the PLC, including the hardware, software and all
instruments, in good working condition. The downtime of entire
2403 of 2461
PAGE 32 of 90
MMRDA
control system shall not exceed 2 hours. During the downtime, the
Contractor shall continue to operate the water treatment plant in
manual mode using the local panel controls and the readings from
local instruments
iv) Routine and periodic maintenance of the entire control system and
instruments as per the manufacturers recommendations.
v) Replacement of damaged controls, communication cables and
power supply cables.
vi) Repair or replacement, as required, of all instruments such as flow
meters,
pressure
transmitters,
pressure
gauges,
level
sensors/transmitters, float type level switches, on-line pH meters,

turbidity meters, on-line residual chlorine meters and laboratory
instruments along with all other equipment. The downtime of any
individual instrument as referred above shall not exceed 24 hours.
vii) Periodic site calibration of all measuring/metering equipment or as
recommended
by
the
manufacturer.
The
calibration
at
manufacturers works shall be done only in case of major failure/

repairs of the instruments.
viii)Preparation and submission of daily and monthly customized
reports produced by the local SCADA system.
ix) Provision and maintenance of all consumables for printing without
any additional costs to the Employer.
x) Inspection of each clariflocculator at least once in a year after
complete dewatering for damages caused to the moving parts, steel
structures, and the RCC structure. Subsequently the repairs,
cleaning and disinfection must be done.
xi) Maintaining all filters in good and proper operating condition
2404 of 2461
PAGE 33 of 90
MMRDA
irrespective of the inflow and outflow rates, except for filters under
repair or periodic inspection.
xii) Maintenance of the filter beds and under drainage system in good
and proper operating condition including providing gravel and sand
as required.
xiii)Weekly lubrication of all gears of reduction motors, motorized
valves, gates and other parts of the system.
xiv)
Periodic operating and checking check all valves and gates for
their manual and electric operation. Operation of valves must be

checked from local control console, switchgear and through PLC
system. Any defect observed must be made good.
xv) Ensuring environmentally friendly disposal of sludge at approved
site(s), within a radius of 10 kilometers from the treatment plant.
xvi)
Operation and maintenance of all circuits and buildings
associated with the treatment works.

xvii)
Breakdown maintenance of all electrical, mechanical and

instrumentation equipment.
xviii)
Routine monitoring of substation equipment and take preventive

measures (as required)
xix)
Routine maintenance works of lighting and earthing system.
xx) Re-painting of the exposed mild steel components of pipeline,

ladders, railings etc. in the filter plant in the 3rd and 5th year of
O&M to keep them in good shape.
xxi)
Maintaining the surrounding areas of the filter plant free from
shrubs, weeds, grass and other unwanted vegetation.

2405 of 2461
PAGE 34 of 90
xxii)
MMRDA
Annual cleaning and disinfection of the clear water reservoirs.
The raw water shall be used for watering plant and washing.
xxiii)
Providing safety accessories, e.g. gloves, shoes, first aid box,
etc.
xxiv) Ensuring fire and safety equipment.
xxv)
The Contractor shall have to provide necessary chemicals such

as Alum, Chlorine and Polyelectrolytes etc. The Contractor will
take three quotations from reputed suppliers of required
consumables and procure the material from the lowest quoted
rate supplier. The Employer will reimburse the actual cost of
these chemicals within two weeks of producing the bill.
However, the Employer may supply the chemicals, which will
have to be used by the Contractor. Minimum 15 days stock shall
have to be maintained to ensure that quality of water does not
suffer. The Contractor will use chemicals to ensure their most
economic consumption and minimize wastage
14.10
Indicative Maintenance Schedules for Intake and CWPS

Following schedule for maintenance is only indicative and for reference
only. The contractor shall prepare the maintenance schedule as per
system and equipment manufacturers recommendation and submit for
approval to Employers representative.
14.10.1
Stop Log Gates

Monthly:
Check operation (lowering & raising) of stop log by

lifting equipment
Annually:
Check the rubber seal condition and replace if
necessary.
2406 of 2461
PAGE 35 of 90
MMRDA
- Place stop log gates in position and remove

14.10.2
Screen
Daily:
Check clogging and differential level across the

screen (morning and evening
Clean if level difference is 100 mm or higher.
Monthly:
Raise each screen to cleaning platform level, clean

and lower
Check the condition of screen, report if any
damage and rectify, otherwise write OK
14.10.3
Sluice gate
Monthly:
Check operation (opening and closing).

Check condition of gate, report if any damage and
rectify if
14.10.4
necessary otherwise write OK
Ventilation system
Monthly:
Check operation of each fan and noise level

Check condition of duct
Check effectiveness to restrict temperature rise
within the limit or otherwise
Annual
Dismantle
rotating
element
and
do
servicing
14.10.5
Civil works:
2407 of 2461
PAGE 36 of 90
Six monthly:
14.10.6
MMRDA
Check condition and rectify damage if any
Silt deposition in Pump well

Remove silt before and after monsoon
14.10.7
Maintenance of Pumps
PERIODIC INSPECTION AND TEST
The maintenance schedule should enlist items to be attended to at
different periods, such as daily, semi-annually, annually, etc.
14.10.7.1
Daily Observations
A log book should be maintained to record the observations, which
should cover the following items.
(i) timings when the pump was run during the previous 24 hours,
(ii) at the time: of observation, whether the leakage through the stuffing
box is alright,
(iii) whether any undue noise or vibration,
(iv) reading so f pressure, voltage and current.
14.10.7.2
Semi-Annual Inspection
(i)
free movement of the gland of the stuffing box,
(ii)
cleaning and oiling of the gland bolts,
(iii)
inspection of the packing and repacking, ft. necessary,
2408 of 2461
PAGE 37 of 90
MMRDA
(iv)
alignment of the pump and the drive,
(v)
cleaning of oil lubricated bearings and replenishing fresh oil. If

bearings are grease lubricated, the condition of the grease
should be checked and replaced/replenished to correct quantity.
An antifriction beating should have its housing so packed with in
case that the void spaces in the bearings and the housing be 1/3
to 1/2 filled with greases. A fully packed housing will cause the
bearing to overheat and will result in reduced life of the bearing.
14.10.7.3
Annual Inspection
(i) cleaning and examination of all bearings for flaws developed, if
any.
(ii) examination of shaft sleeves for wear & scour.
(iii) checking clearances.
Clearances at the wearing rings should be within the limits
recommended by the manufacturer. Excessive clearances
cause a drop in the efficiency of the pump. If the wear is only
one side, it is indicative of misalignment. Not only that the
misalignment should be set right, but also the causes for the
disturbance of the alignment should be investigated when the
clearances have to be redeemed to the values recommended by
the manufacturers, some general guidelines detailed in 'l'able
would come handy.
If the clearance on wear is seen to be 0.2 or 0.25 mm more than
the original clearance, the wearing ring should be renewed or
replaced to get the original clearance.
In using the tolerance given in Table, below they are to be used
2409 of 2461
PAGE 38 of 90
MMRDA
unilaterally. For example, while machining the i.d. of the wearing

ring of basic size, say 175 mm the limits for machining would be
175.00 minimum and 175.04 maximum. For' the corresponding
O.D. at the hub of the impeller, the basic size will be with a
clearance of 0.35, hence 174.65 mm and the machining limits
will be 174.65maximum and 174.61 minimum.
Wearing Ring I.D. Diameter Clearance and Machining Tolerance
Inside diameter of
Diameter of
Machining
wearing ring in mm
clearance in mm
tolerance in mm
Up to 100
0.3
0.04
100-150
0.35
0.04
150-200
0.4
0.06
200-300
0.45
0.06
300-500
0.55
0.06
500-750
0.58
0.06
750-1200
0.69
0.08
1200-1500
0.79
0.1
(iv) Impeller hubs and vane tips should be checked for any pitting or
erosion.
(v) End play of the bearings should be checked.
(vi) All instruments and flow meters should be recalibrated.
(vii) Pump should be tested to determine whether proper
performance is being obtained. In the case of vertical turbine
pumps, the inspection can be bi-annual. Annual inspection is
not advisable, because it involves disturbing the alignment and
clearance
2410 of 2461
PAGE 39 of 90
14.11
MMRDA
Indicative maintenance schedule for WTP

a) Table14.4:
Typical Operation & Maintenance Items in
Flocculator and clarifier System
Daily
Frequenc
Periodic
Description
y
Daily
Frequenc
Improvement/Repair
Description
y
Verification of Annual
Verification
of
raw
operation
on
water
volume
Frequenc
Descriptio
various kind of
valve and gates
Daily
Verification
of
water level in
crack/degradatio
settler
n on concrete
structure
Daily
required
Chemical
dosing
of
coagulant for
proper settling
Daily
Verification of
outlet quantity
from
settler
system
Daily
Maintenance,
check up and
clean
up
Instrumentatio
n
devices,
water meters,
mixtures,
water
level
2411 of 2461
PAGE 40 of 90
MMRDA
gauges
b) Table 14.5 Typical Items in Filtration Plant

Periodic
Daily
Frequency
Daily
Improvement/Repair
Description
Frequency
Description
Frequency
Description
Verification
monthly
Verification
Annual
Clean up all
of water level
of the
system
in filter beds
performance
equipment,
of pumps
pipe
line,
valves
and
gates of filter
beds
Daily
Verification
Every
Verification
of amount of month
of
filtered
remains
effluent,
mud-balls in
filtration
sand
Annual
sludge
Maintenance
of air supply
equipment
rate/loss
Daily
Verification
of
Every
water month
Verification
Every 1
Maintenance
of air flow
Year
of
Back
quality
wash water
Wash Pumps
(Turbidity)
flow control
sets
equipment
system
&
performance
Daily
Verification
Every
Alignment of
Every 1
Maintenance
of equipment Week
equipments
Year
of
performance
nose&
blowers sets
vibration
&and system
Air
level,
2412 of 2461
PAGE 41 of 90
Periodic
Daily
Frequency
Daily
MMRDA
Improvement/Repair
Description
Frequency
Description
Frequency
Description
Verification
Every 1-2
Verification
Annual
Maintenance,
of amount of months
of water
check up and
backwash
level
clean
up
water
gauges, flow
back
wash
meters, air
pumps,
supply
blowers,
equipment
vacuum
Air
pumps,
motors,
valves
and
gates
Table 14.6: Indicative Maintenance Items in Chlorination facility

Items
Daily
Frequency
Storage tank
Every
times/day
Improvement / Repair
Description
Frequency
3- Yes, or no, chlorine A. N.

gas
solution
Repair
replacement
leakage
A. N.
Description
/ adjustment
Maintenance, check and clean up Instrumentation

devices, pipe, valves, meters, gauges etc
Chlorine
gas Every
cylinder
and times/day
room
3- Verification of no gas
A. N.
Repair
leakage, and no wet
replacement
or keep dray in the
adjustment
room
Every
times/day
3- Condition
of
the
A. N.
cylinder
Repair
replacement
adjustment
Every
3- Check-up pressure in
2413 of 2461
A. N.
Repair
/
PAGE 42 of 90
Items
MMRDA
Daily
Frequency
times/day
Description
Frequency
cylinder
Description
replacement
adjustment
3-times/day
Verification of room
temperature
A. N.
&
humidity
Daily
Daily
Repair
replacement
adjustment
Repair
equipment of cylinder
replacement
and hoist
adjustment
Check up and lifting
Classification
of
A. N.
A. N.
Repair
cylinder as new or
replacement
empty, and check the
adjustment
stock
A. N.
Maintenance,
check
up
and
clean
up
Instrumentation devices, pipe, valves, meters,

gauges etc
Chlorinator
Every
times/day
3- Check-up
solution
leakage
A. N.
and/or
chlorine gas
Every
times/day
Repair
replacement
adjustment
3- Check-up
gas
pressure
A. N.
gause,
vacuum gause,
flow meter,
gas
Repair
replacement
adjustment
water
pressure, water flow

Every
times/day
3- Check up ejectors,
chlorine
gas
A. N.
rate
valve at check valve

Every
times/day
3- Verification of dosing
Repair
replacement
adjustment
A. N.
rate / amount
Repair
replacement
adjustment
Valves / pipe
Every 2-6 hour Verification

/ days
Repair
performance of auto
replacement
inlet
adjustment
gas
of
valve
at
2414 of 2461
A. N.
PAGE 43 of 90
Items
MMRDA
Daily
Frequency
Description
Frequency
Description
Vaporizer
Every
times/day
3- Conformation of no
gas
leakage
pipe
A. N.
from
Repair
replacement
adjustment
connections,
valve
Neutralization
Every
equipment
times/day
3- Conformation
of
performance
A. N.
of
safety valves
Every 3 days
Repair
replacement
adjustment
Conformation
of
A. N.
Repair
solution leakage from
replacement
the tank / equipment /
adjustment
pipe / valve
Every
times/day
3- Check
up
solution
A. N.
level
Repair
replacement
adjustment
Daily
Check
up
performance
of
A. N.
splays, pumps
Daily
Daily
equipment
Check
up
performance
of
replacement
A. N.
Repair
replacement
adjustment
Check
up
performance
of
chlorine
gas
detectors
and
sensors,
adjustment
exhaust blower
Safety
Repair
A. N.
Repair
replacement
adjustment
Ventilation
system
Every
3- Check up sequence
2415 of 2461
A. N.
Repair
/
PAGE 44 of 90
Items
MMRDA
Daily
Frequency
Description
times/day
of
auto
Frequency
replacement
manual
mode
Air
supply
Blowers
operation
of
noise,
/Compressors)
adjustment
Conformation
( When
Description
A. N.
smell,
vibration,
loosen
Repair
replacement
adjustment
drive belt
When
Check
up
operation
pressure,
shaft,
air
A. N.
lubricant,
Repair
replacement
adjustment
heating air/oil
filters,
voltage/ampere
Every 2 days
25. Check up drain
A. N.
Repair
replacement
adjustment
Table
14.7:
Indicative
Maintenance
in
Electrical
and
Instrumentation Facility
Daily
Frequency
Periodic
Description
Frequency
Transformer Verification of KVA, V, Amp, Every 6

current
Incoming
Panels
protection,
oil Months
Description
Verification of oil,
abnormal sound,
temperature
performance
Verification of kVA, V, Amp, Every 6
Verification
lamp
test
/replacement, Month
of
switch
On/Off,
moisture cut heater, current
Fuse,
abnormal
protection,
sound,
burned
smell,
remove water
condenser,
relays,
protection
2416 of 2461
PAGE 45 of 90
MMRDA
Daily
Frequency
Periodic
Description
Frequency
Description
devices,
earthling,
wiring
and connection
Control
Verification of V, Amp, lamp Every 6
Panels
test & replacement, moisture Month
switch
On/Off,
cut
Fuse,
abnormal
heater,
overload
Verification
protection, operation mode,
sound,
burned smell, remove water
condenser,
of
relays,
protection
devices,
earthling,
wiring
and connection
Lighting
Panels
Verification of Amp, light test & Every 6

replacement,
moisture
cut Month
Verification
of
switch
On/Off,
heaters, overload protection,
Fuse,
abnormal
remove water
sound,
condenser,
relays,
protection
devices,
earthling,
wiring
and connection
Meters
reading
Verification of V, Amp,
overload protection
Every 6
Verification
Month
over
of
load
protection
indication, switch
On/Off,
accuracy,
damage
Motors
Verification of burned smell,

heating, vibration
Every 6
Verification
Month
switch
2417 of 2461
of
On/Off,
PAGE 46 of 90
MMRDA
Daily
Frequency
Periodic
Description
Frequency
Description
earthling,
insulation
resistance,
rpm,
damage,
temperature
Generators
Verification of kVA, V,
rpm,
air/oil filter, hours
oil level,
coolant level,
of
governor
loose bolts /
electrolyte
water
level/water
tighten,
temperature,
abnormal
Verification
tension pulley, 1200 hours motor/battery
cooling fan,
Nuts/
Amp, Every 250
oil
pump/starting
leakage,
sound,
switching
unit
motor/
electric
wiring/
piston/
exhaust
pipe,
replace
fuel
injection
pump/
fan
belt,
overhaul engine,
earthling,
insulation
resistance,
rpm,
damage, control
panel
System
Verification of system
sequence ON/OFF
Every 6
Verification of All
Month
system,
insulation
resistance
Cable line
Verification
of
short
circuit, Every 6
cable color, damage
Month
Verification
wire
of
droop,
degradation,
insulation
resistance
2418 of 2461
PAGE 47 of 90
MMRDA
Table 14.8 : General Monthly Checking Schedule

Parameters
Description
System/operation High raw turbidity / color, Over-flow, Flash mixing, Flocculation,

settling,
Filtration
and
its
backwash,
Sludge
thickening,
Settlement removal, Dewatering, , etc.

Unit process
Power switch, Mechanical performance, Over load, Noise,
(Mechanical)
Vibration, etc.
Unit process
Transformers, Meters, Over load-Motors Moisture cut heaters,
(Electrical)
Overload protection, Wiring and connection, Lamp test etc
Precaution,
Handling Chlorine / Alum solution and its emergency measure /
Safety &health
first-aid treatment,
Handling heavy load,
Physical damage,
Shock hazard
14.12
Transmission System
14.12.1
Checks to be Carried out

Programme has to be prepared for complete transmission system
which shall contain procedures for routine tasks, checks and
inspections at intervals i.e. Daily, weekly, quarterly, semiannually or
annually. This plan shall fix responsibility, timing for action ways and
means of completing the action as to when and who shall take the
action and need to take these actions. The check list can be prepared
for the use of managerial and technical staff shall be prepared to
ensure that the O & M staff have completed the tasks assigned to
them.
Table 14.9: Check List

S.
Checks Required /Undertaken
Status
No.
1
Frequency
Attended
by /Sign
Check the operation of valves is smooth
2419 of 2461
PAGE 48 of 90
without
any
abrupt
MMRDA
stoppage
during
closure.
2
Check the closure of valves results in

complete stoppage of flow or if any flow
passes the valves
Check for status of scouring and then

proper closure of washout valves
Check for leaks through pipes
Check leakage from glands , nut bolts or

any other place
Check
for
leakage
through
appurtenances including flange adaptor

/dismantling joints/expansion joints
7
Check for signs of corrosion of pipeline
Check
the
status
of
functioning
of
cathodic protection
9
Check the status of manhole covers over

the chamber for corrosion and physical
condition
10
Inspect for any possibilities of pollution of

the transmission system
11
Check the status of outfall drain of scour

valves and chances of contamination at
scours
12
Assess the need of corrosion protection

for exposed piping work
13
Check availability of spares for valves

flange adaptors , expansion joints
and
pipes and jointing material

14
Review of pressures
15
Review of flows
16
Check the age of pipes / c value s of

pipes
2420 of 2461
PAGE 49 of 90
MMRDA
17
Check for corrosive water
18
Study and report inflows and outflows into

the reservoirs linked to transmission
system
19
Identify the source of leakages
20
Status and calibration of flow meters
21
Availability
of
updated
transmission
system layout /map

22
Check village tapings valve for leakage

and proper working of flowmeter
23
Check the Railway crossing pipeline

transmission system status and leakages
etc
24
Check bridge / river /nallah /road crossing

pipeline transmission system status and
leakage
14.12.2
Safe Operating Limits (SOL) and Maximum Operating Pressure (MOP)

Prior to operating a pipeline, it is essential to establish appropriate safe
operating limits based on the pipeline design, test pressure, and any
operational constraints that may need to be applied.
The SOL for
pressure will be related to the declared maximum operating pressure

(MOP).
The operator must ensure that the pipeline is maintained
within these limits.

These SOLs, along with the declared MOP should be periodically
reviewed and redeclared as part of a procedure designed to confirm
continued fitness for purpose of the pipeline.
14.12.3
Provision of Information
The operator is required to provide those involved in operating,
maintaining, inspecting, modifying and repairing a pipeline with
sufficient written information as needed to perform their duties correctly
2421 of 2461
PAGE 50 of 90
MMRDA
and safely.
It is important that owners and occupiers of land through which a
pipeline is routed, and third parties who may require to work in the
vicinity, are reminded of, or made aware of, the pipelines location.
Regular contact with owners and occupiers is essential
In order to assist third parties, the operator should make available
pipeline location plans of a scale suitable to identify the approximate
location of the pipeline. Use of one-call systems such as Line search
should be considered.
The pipeline route should be marked with location markers at all road,
rail and river crossings. It is noted that the operator should provide
information on the location of the pipeline, the installations of markers
along the route to identify the accurate location of the pipeline should
be adequate for surveillance purposes and provision of general
information to 3rd parties.
14.12.4
Route Surveillance
It is essential to take all reasonable precautions to reduce the risk of
pipelines being struck or damaged by third party activities. The risk of
damage to a pipeline or pipeline system needs to be assessed in order
to determine appropriate surveillance methods and frequencies.
Route surveillance is employed to ensure that there are no unknown
activities being carried out in the vicinity of pipelines that could cause
damage to it. It should also be used to monitor building developments
that may result in proximity or population density infringements. Where
infringements do occur, they should be subjected to a risk assessment
in order to determine if any additional protection or surveillance needs
to be undertaken to reduce the risk posed by the pipeline to the
surrounding population.
2422 of 2461
PAGE 51 of 90
MMRDA
Where activities are being carried out by third parties in the vicinity of a
pipeline, with the consent of the owner, it is necessary to monitor the
activities and ensure agreed working methods and procedures are
being adhered to.
construction of any building work which may infringe proximity or
population density criteria
any previously unknown third-party activity on or adjacent to the
pipeline
the condition of pipeline marker posts
fires of any description including straw burning
discolouration of vegetation or other evidence of leakage
blasting or mineral extraction
ground movement
erosion and changing water courses
soil removal
tipping
vegetation overgrowth on easement
14.12.5
Line Walk Survey

Regular contact should be maintained with owners, tenants, occupiers
and managers of land through which a pipeline runs. Contact with
local authorities, statutory bodies, and selected contractors are also
2423 of 2461
PAGE 52 of 90
MMRDA
recommended. The purpose of this is as a reminder of the existence of

the pipeline, to establish future intended work in the vicinity of the
pipeline, and as an aid to updating records of those responsible for the
land.
Table 14.10: Activity & Frequency
Activity
Recommended Frequency
Line walk
Every 4 years
Owner/occupier
Annual
liaison
River crossing survey
Every 1 5 years, depending upon type
Road/rail crossings
Every 1 4 years depending upon type
In-line inspection
Every 10 years (if not integrity/risk based)
CIPPS
Every 5 years
Pearson/DCVG
As indicated by CIPPS
survey
Valves
Every year
Protective devices
Every year
Sleeve/casing
Every year
assessment
Pig traps
Prior to use
Infrastructure survey
Every 4 years
2424 of 2461
PAGE 53 of 90
MOP declaration
MMRDA
Every year
Programme
14.13
Water Quality Monitoring
14.13.1
Parameters and limits

The WTP is designed to achieve treated water quality as per table
below.
Table 14.11 : Water Quality
Parameters
Units
Required Output
NTU
Standard
10
Turbidity of filtered water
NTU
< 1.0
Color
(Units
Turbidity of the Effluent from the

Treated Water Quality Parameters
on Platinum
cobalt scale)
-
Taste and Odor

pH
14.13.2
Unobjectionable
7- 8.5
Fecal Coliforms
No. per 100
Total Coliform Organisms
No. per 100
Total Iron as Fe
mg/L
0.1
Residual Aluminum as Al
mg/L
0.03
Manganese as Mn
mg/L
0.05
Chlorides as (Cl)
mg/L
200
Sulphates as (SO4)
mg/L
200
Fluorides as (F)
mg/L
1.00
Nitrates (NO3)
mg/L
45.00
Alkalinity
mg/L
200
Frequency of Sampling and Water Quality Monitoring

Typical parameter for water analysis in order to achieve treated safe
2425 of 2461
PAGE 54 of 90
MMRDA
water quality it is essential to monitor treated water as vital process

units as detailed below.
Table 14.12 : Frequency of sampling
Location and Sampling/Analysis Points for Water Quality
Parameter
s
Frequ
Raw
ency
Water
Aer
Clarifier/
of
at
atio
settler
testin
Intake
Inlet
Outle
Clear Water
Filtration
Inlet
Outlet
MBR
MBR
Kashi
Chene
dkop
ar
t
A) Physical Examination
Two
Colour
Turbidity
Temperatu
re
Two
Two
Hourly
Hourly
Hourly
Hourly
Two
Hour
-
Two
Hourl
Two
Hourly
ly
Hourly
Hour
Hourl
Hourl
Hourly
Hourl
ly
One in
One
One in
in 8
hours
hours
One
One in
in 8
hours
hours
One
One in
in 8
hours
hours
Two
Two
hours
One in
Taste
One in
hours
8 hours
One in
Odour
Hourly
One in
hours
8 hours
B) Chemical Examination
Two
pH
Two
Two
Hourly
Hourly
Two
Hourl
Two
Hourl
Two
Hourl
Hourl
Hourly
Hourly
Hourly
Daily
Daily
Hourly
Daily
Daily
Elec.
Conductivit
y
Hourl
Daily
Hourly
Hourl
Hourly
Hourl
Turbidity
Daily
Hourly
y
Hourl
Hourly
2426 of 2461
PAGE 55 of 90
MMRDA
Parameter
s
Frequ
Raw
ency
Water
Aer
Clarifier/
of
at
atio
settler
testin
Intake
Inlet
Outle
Clear Water
Filtration
Inlet
Outlet
MBR
MBR
Kashi
Chene
dkop
ar
Total
Daily
Daily
Coliforms
one
one
Daily
Daily
Three
Three
Daily
Daily
Three
Three
Weekl
Weekly
y one
one
Weekl
Weekly
Calcium
y one
one
Magnesiu
Weekl
Weekly
y one
one
Weekl
Weekly
Weekly
Iron
y one
one
one
Manganes
Weekl
Weekly
Weekly
Weekl Weekl
y one
one
one
y one
Weekl
Weekly
Weekly
Weekl Weekl
y one
one
one
Weekl
Weekly
Weekly
Weekl Weekl
y one
one
one
y one
Weekl
Weekly
Weekly
Weekl Weekl
y one
one
one
y one
Weekl
Weekly
Weekly
Weekl Weekl
y one
one
one
y one
Weekl
Weekly
Weekly
Weekl Weekl
y one
one
one
y one
Weekl
Weekly
Weekly
Weekl Weekl
y one
one
one
y one
Acidity
Alkalinity
Hardness
Copper
Zinc
Aluminum
Sulphates
Fluorides
chlorides
Daily
Daily
Daily
one
one
one
Daily
Daily
Daily
Three
Three
Three
Daily
Weekl Weekl
Three
y one
Weekly
Weekl Weekl
one
y one
Weekly
Weekl Weekl
one
y one
Weekly
Weekl Weekl
one
2427 of 2461
y one
y one
y one
y one
y one
Weekl Weekl
y one
y one
y one
y one
y one
y one
y one
y one
y one
y one
PAGE 56 of 90
MMRDA
Parameter
s
Frequ
Raw
ency
Water
Aer
Clarifier/
of
at
atio
settler
testin
Intake
Inlet
Outle
Clear Water
Filtration
Inlet
Outlet
Weekly
nitrites
y one
one
Total
Weekl
Weekly
dissolved
y one
one
Weekl
Weekly
y one
one
MBR
Kashi
Chene
dkop
ar
Weekl
MBR
Weekly
Weekl Weekl
one
y one
Weekly
Weekl Weekl
one
y one
Wee
Weekly
Weekl Weekl
kly
one
y one
y one
y one
y one
solids
Suspended
solids
Week
Weekl
ly one y one
-
one
C) Tests for efficacy of treatment

Chlorine
Daily
Daily
demand
Two
Two
Free
Daily
Daily
Daily
Daily
Daily
Daily
chlorine
Two
Two
Two
Two
Two
Two
Combined
residual
chlorine
Hour
Hourl
Hourly
Hourly
ly
requiremen
Daily
Daily
Daily
Daily
one
one
one
one
Residual
Daily
Daily
Aluminium
three
three
Hourly
Hourly
Daily
Daily
Daily
three
three
three
Coagulant
optimum
-
Daily
-
three
Table 14.13: Chemical parameters indicative for pollution

Total
Daily
Daily
Daily
nitrogen
one
one
one
Daily
Daily
Daily
Ammonia
one
one
one
Nitrite
Daily
Daily
Daily
2428 of 2461
PAGE 57 of 90
MMRDA
Parameter
s
Frequ
Raw
ency
Water
Aer
Clarifier/
of
at
atio
settler
testin
Intake
Inlet
Nitrate
Phosphate
Outle
Clear Water
Filtration
Inlet
Outlet
MBR
MBR
Kashi
Chene
dkop
ar
one
one
one
Daily
Daily
Daily
one
one
one
Daily
Daily
Daily
one
one
one
Dail
DO
BOD
Daily
Daily
Daily
Daily
Daily
one
one
one
one
one
one
Dail
Daily
Daily
Daily
one
one
one
Daily
Daily
Table 14.14: Tests for toxic chemical substances
Lead
Arsenic
Mercury
Selenium
Chromium
cynide
Six
Six
Six
Monthl
Monthly
Monthl
y one
one
y one
Six
Six
Six
Monthl
Monthly
Monthl
y one
one
y one
Six
Six
Six
Monthl
Monthly
Monthl
y one
one
y one
Six
Six
Six
Monthl
Monthly
Monthl
y one
one
y one
Six
Six
Six
Monthl
Monthly
Monthl
y one
one
y one
Six
Six
Six
Monthl
Monthly
Monthl
2429 of 2461
PAGE 58 of 90
MMRDA
Parameter
s
Frequ
Raw
ency
Water
Aer
Clarifier/
of
at
atio
settler
testin
Intake
Inlet
Outle
Clear Water
Filtration
Inlet
Outlet
one
y one
Six
Six
Six
Monthl
Monthly
Monthl
y one
one
y one
Six
Six
Six
Monthl
Monthly
Monthl
y one
one
y one
Six
Six
Six
Hydrocarb
Monthl
Monthly
Monthl
ons
y one
one
y one
Six
Six
Six
Radioactivi
Monthl
Monthly
Monthl
ty
y one
one
y one
Pesticides
14.14
MBR
Kashi
Chene
dkop
ar
y one
Phenolics
MBR
Record Keeping
Suggested formats to be followed for proper recording of pumping and
treatment plant operations are given below. The format can be finalized
during execution stage.
Table 14.15: Daily Data

S.
Description / Data
Unit
Data
No.
Quantity
REMARKS
Output
2430 of 2461
PAGE 59 of 90
MMRDA
Mld
Mld
Kawdas weir water level
near stop log gates

2
Intake Sump level
Water input Quantity to

water treatment plant
Clear water sump level
MBR level kashikopar
Mld
MBR level Chene
Mld
Rainfall
mm
Temperature
0C
atmosphere at Kawdas
Plant Data
Raw water Pumping Station: and Clear water pumping station
Table 14.16: Plant Data
Date:
Tim
Voltag
Frequen
Speed
Energy
Flow
Head
cy
Rpm*
meter
readin
(m)
Hrs
Hz
reading
kWh
Cu.m
Signat
ure
1
2
3
4
5
6
7
8
9
10
11
12
13
2431 of 2461
PAGE 60 of 90
MMRDA
Tim
Voltag
Frequen
Speed
Energy
Flow
Head
cy
Rpm*
meter
readin
(m)
Hrs
Hz
reading
kWh
Cu.m
Signat
ure
14
15
16
17
18
19
20
21
22
23
24
Total =
* Applicable for
C.
section
Pump Operation
Raw water Pumping Station: & Clear water pumping station
Table 15.17: Pump Operation

Date:
Time
Pump no
Hrs
1
1
2
3
4
5
6
7
2432 of 2461
PAGE 61 of 90
MMRDA
Pump no
Time
Hrs
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Total
hours of
operatio
n
Mark X if pump is not available
Mark S, if pump is standby
Mark R if pump is running
Indicate Starting and Stopping time
2433 of 2461
PAGE 62 of 90
MMRDA
Power Statement
Pumping Station:
Month:
Table 15.18: Power Statement

Date
Dat
e
Theoretical
Allowance
Actual Power
Power
Consumption
Consumption
Difference
Signatur
e
(kWh)
(kWh)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
2434 of 2461
PAGE 63 of 90
Dat
e
MMRDA
Theoretical
Allowance
Actual Power
Power
Consumption
Consumption
Difference
Signatur
e
(kWh)
(kWh)
23.
24.
25.
26.
27.
28.
29.
30.
31.
MONTHLY REPORT
Pumping station:
Month and year
Table 15.19: Pump Operation Details

Pump No.
1
10
Number of hours
of operation
Vibration mm/sec
Noise level
dBA
Total quantity
pumped ml
Energy
consumption kWh
Total no of hrs of
power failure
Total no of pump
2435 of 2461
PAGE 64 of 90
MMRDA
Pump No.
1
10
set hrs not

available
Reason for nonavailability of
pump set
Action taken for
rectification
Non availability of
any other
equipment and
reason
Action taken for
rectification
Table 15.20: Chlorination Plant : Daily Status of Tonners
Full Chlorine Ton
Tonners in
Container Storage
Operation
Empty Tonners
1
2
.
.
.
30
31
Table 15.21: Chlorination Plant : Chlorinators Daily Operational

Record
Date
Time
Chlorinator in Service
Location
Booster Pump Set
Stand
Stand
Out of
in Service
by
by
Service
2436 of 2461
PAGE 65 of 90
MMRDA
Chlor
Boost
due to
inator
er
Failure
Pump
Set
Dose
Cl2
kg/hr Pressu
Vacuu
Wate
Flo
Curren
rpre
ss-
LP
ure
re
8.00
9.00
.
.
24.00
1.00
.
.
7.00
Total
24
hrs
Table 15.22: Filters Daily Operational Record

No.
Time
Hours Operated
Head Loss
Wash
Physical
Condition of
Filter
Star
Sto
Toda
Previou
Tota
Start
Sto
p
Min.
Lit
er
4
2437 of 2461
PAGE 66 of 90
No.
Time
MMRDA
Hours Operated
Head Loss
Wash
Physical
Condition of
Filter
Star
Sto
Toda
Previou
Tota
Start
Sto
Min.
Lit
er
10
11
12
No. of filter beds washed -
Average filter rate
Average Run Hours -
Maximum hourly rate
Total Wash hours -
Total water filtered
Percent of water filtered -
No. of filters operating
2438 of 2461
PAGE 67 of 90
No.
Time
MMRDA
Hours Operated
Head Loss
Wash
Physical
Condition of
Filter
Star
Sto
Toda
Previou
Tota
Average time wash-min -
Start
Sto
Min.
Lit
er
Filters out per wash -min

shift
II
III
Operat
or
14.15
Reporting format
Following indicative reporting format are specified which shall be
submitted to the Employers representative.
14.15.1
Daily Report on Operation and Maintenance

Table 15.23: Daily Report on Operation and Maintenance
A. Consumption Records
Sr.
Item
No.
A.1
Meter Reading
Daily
Avera
or other records
Quantit
ge per
m3 of
At 6:00
At 6:00
hrs of
hrs of
raw
reporti
previo
water
ng day
us day
Remarks
Raw water quantity

received
at
plant
inlet
A.2
Coagulant Quantity
consumed
A.3
Electrical
Power
consumed
2439 of 2461
PAGE 68 of 90
MMRDA
Table 15.24 : Quality Records

B. Quality Records
Particulars
At 6:00
At 12:00 At 18:00 At 24:00
hrs
B.
Turbidity
raw water (6
hourly)
hrs
hrs
Average
hrs
Remar
ks
of
on
report day
B.
Turbidity
of
settled water
Clarifier-1
Clarifier-2
.
B.
Turbidity
of
Filtered Water
Bed-1
Bed-2
Bed-3
Bed-4
.
.
B.
Residual
chlorine
in
filtered water
Table 15.25: Filtration plant Output

C. Filtration Plant
C.
Quantity
filtered
from beds
of
Record at
Record at
water 6:00 hrs of 6:00 hrs of

reporting
Quantity
Average
Remar
ks
next day
day
Bed-1
2440 of 2461
PAGE 69 of 90
MMRDA
C. Filtration Plant
C.
Quantity
filtered
from beds
of
Record at
Record at
Quantity
water 6:00 hrs of 6:00 hrs of

reporting
Average
Remar
ks
next day
day
Bed-2
..
..
Table 14.26: Status of Filter Beds and Clarifiers

S.
Unit
From hrs.
To hrs.
Total time
Remarks
No.
E.1
Filter
E.1.
Back Wash
Bed No-1
Bed No-2
Bed No-3
E.1.
Down Time
Bed No-1
Bed No-2
Bed No-3
E.2
Clarifiers
E.2.
Operational
Clarifier-1
Clarifier-2
E.2.
Downtime
Clarifier-1
Clarifier-2
..
2441 of 2461
PAGE 70 of 90
S.
Unit
MMRDA
From hrs.
To hrs.
Total time
Remarks
No.
E.3
Other Units
E.3.
Downtime
E.3.
Downtime
E.3.
Downtime
14.15.2
Monthly Report on Operation and Maintenance of 403 MLD Water

Treatment Plant
Prepared by: [Name of Contractor]
Report For: [Month]
Table 14.27: Chemical consumption

A. Consumption Records
S.
Item
No.
Reading
Readi
Quanti
Average
on last
ng of
ty
per 1000
date of
month
daily
m3 of raw
month
water/day
month
A.1
Raw
water
Remarks
quantity
received at plant inlet

A.2
Chlorine
Quantity
consumed
For pre-chlorination
For post-chlorination
A.3
Alum / PAC
Quantity
consumed
A.4
Electrical
Power
consumed
2442 of 2461
PAGE 71 of 90
MMRDA
Table 14.28 : Water quality Records

B. Quality Records
Particulars
B.
Turbidity of raw water (6
hourly) on report day
B.
Turbidity
water
of
clarified
of
Filtered
Average
Maximum
Minimum
during
during
during
month
month
month
Remarks
Clarifier-1
Clarifier-2
.
.
.
B.
Turbidity
Water
Bed-1
Bed-2
Bed-3
Bed-4
.
.
B.
Residual
chlorine
filtered water
in
Table 14.29 : Quantity of Sludge output

D. Quantity of Sludge (by Storage Measurement)
Total during
Average daily
month
Average per
Remark
cum of treated
water
Clarifier-1
Clarifier-2
2443 of 2461
PAGE 72 of 90
MMRDA
D. Quantity of Sludge (by Storage Measurement)

Total during
Average daily
month
Average per
Remark
cum of treated
water
Table 14.30: Operational

S.
Unit
No.
E.1
Filter
E.1.
Down Time
Bed No-1
Total Time
Average
During Month
Daily
Remark
Bed No-2
Bed No-3
E.2
Clarifiers
E.2.
Downtime
Clarifier-1
Clarifier-2
..
14.16
E.3
Other Units
E.3.
Downtime
E.3.
Downtime
E.3.
Downtime
Special Activities
The cost of following special activities, work shall be included
2444 of 2461
PAGE 73 of 90
MMRDA
a) All structure shall be repainted every three years period.

b) All the equipments, pumps, motors, pipelines / common headers in
pumping stations, piping & equipments in chambers, EOT/Manual
cranes shall be repainted every three years period
c) Pump wearing rings of pumps shall be checked every two years if
found worn out it shall be replaced. After 4 years period wearing ring
of pumps shall be replaced.
d) For every two years period line shaft bearings of pumps shall be
replaced.
e) Oil, lubricants shall be replaced as per manufacturers
recommendation.
14.17
Electrical
Table 14.31: Electrical Indicative Maintenance Schedule
S.
No
1
Equipment
Maintenance Activity
Frequency
132 kV Substation
Connection, Insulators, clamps
Visual Inspection
Installed &
Running
conductors, support structures

for
any
damage,
cracks,
and
loose
deformation
connection.
Daily
SF6 breaker - Gas pressure

Earthing connection
hissing sound, corona, pre and
post imprison inspection
Visual Inspection
Offline
Operating
mechanism of all
equipments
Control
and
2445 of 2461
Power
cable
PAGE 74 of 90
S.
No
MMRDA
Equipment
Frequency
connection
Earthing
pit
and
Earth
connection
clamp connections, busbars, all
porcelain parts and bushings of
Transformer CT's, PT's, LA's,
breakers, isolators etc.
2
SF6 - CIRCUIT
BREAKER
Gas pressure, corona,
Visual Inspection
Installed &
bushings condition, loose
Running
connections, structural damage
Daily
, earthing connections
Offline
Operational check
Offline
General Inspection
Overhaul
period
Overhaul
period
Overhaul &
Cleaning
Post Fault
maint
Inspection &
Opening Device(trip)
Overhaul
period
Circuit- Breaker Enclosure
Offline
Gas System
Overhaul
period
Overhaul
period
Overhaul &
Offline
Sulphur hexafluoride gas
Post Fault
maint
Offline
Insulation
2446 of 2461
Overhaul &
Post Fault
PAGE 75 of 90
S.
No
MMRDA
Equipment
Frequency
maint
Offline
Local control kiosk
Pressure gauges
Pressure Switches
Main connection
Secondary wiring and fuses
Earth Connection
SF6 heater
Offline
Interpole linkages
main mechanism
Overhaul
period
Overhaul
period
Overhaul
period
Overhaul
period
Overhaul
period
Overhaul
period
Overhaul
period
Overhaul
period
Overhaul
period
Auxiliary switches indiacting
Overhaul
devices and interlocks
period
Overhaul &
interrupters
Post Fault
maint
Local air receives and pressure

vessels
Filter and desiccants
Offline
Overhaul
period
Overload devices and protective Overhaul

Relays
period
Instrument and Protective

Relays
2447 of 2461
PAGE 76 of 90
S.
No
MMRDA
Equipment
Control relay and contactor
Bus bar and Bus bar chamber
Frequency
Overhaul
period
Overhaul
period
Overhaul &
Offline
Final verification
Post Fault
maint
TRANSFORMER
Visual Inspection
Installed
&Running
Oil Level
Winding Temperature at WTI
Oil Temperature at OTI
Daily
Pressure at Pressure Gauge

Noise
Silica gel colour
Examine the transformer tank

and bushings for evidence of
leakage. Inspect the bushings,
insulators, and surge arrestors
b
Visual Inspection
Offline
for broken or damaged parts,

signs of overheating or arcing,
Half Yearly /
Yearly
or tracking. Clean all bushings,

insulators, and surge arrestors
of any dirt or dust accumulation
Tighten
c
Connection
Offline
all
conductor
connections in accordance with

manufacturers
Half Yearly /
Yearly
recommendations
Reading
Running
Voltage
2448 of 2461
Daily
PAGE 77 of 90
S.
No
MMRDA
Equipment
Frequency
Ampere
kVAr, kVA, Power factor at
132kV Metering Panel & for
Auxilary Transformer at 6.6kV
Panel.
Additional
suggested
includes
an
testing
insulation
resistance test and a power

factor test. These are nondestructive tests which can be
e
Insulation test
Offline
performed to track the condition

of the insulation over time.
Detailed
records
should
Yearly
be
maintained and analyzed to

identify undesirable trends that
may indicate the onset of an
insulation failure
Breakdown voltage
for Transformer Oil
SWITCH GEAR
Visual
Push Button
Bushing Tightness
Taking
offline
sample
of
offline
Transformer check BDV test of Yearly

oil sample and Filtration
Offline
cleanness
Running
Voltage, kwh , Kva & frequency
daily
Running
Indication Lamp
daily
Every 12
Months
Offline
Local/Remote & Stop/start

checking Tightness of all busing Every 12
connection
2449 of 2461
Months
PAGE 78 of 90
S.
No
Equipment
Contact
IR Test
MMRDA
connection and Damaged Due
to wear and tear to be replaced
insulation Resistance rest for
After
Test
Maintenance maintenance
Phase
Breaker
Visual Inspection
Test
after
check the operating speed
Mechanism
MOTORS
Sequence
after overhaul
Installed and
Running
Offline
Offline
Bus Bar
Phase Sequence
Frequency
6 Months
Inspection should look for:

Evidence of damage caused by
dirt, loose parts, or foreign
objects.
Verification that air inlets are not
blocked
Evidence of moisture and/or dirt
build-up
Unusual noises, leaking oil
seals, or high vibration
Evidence
of
degradation
of
foundation, bed plates, anchor

bolts
This data should be trended.

The
b
monitoring
Temperature
Installed and completed
monitoring
Running
loading
temperature
at
should
similar
and
to
be
motor
ambient
allow
6 Months
for
accurate trending.
of bearings and
2450 of 2461
PAGE 79 of 90
S.
No
MMRDA
Equipment
Frequency
windings
Vibration
Installed and Record

Running
and
trend
vibration
levels.
6 Months
This should be done by a

trained
and
experienced
technician,
preferably a qualified level II
technician
Record and trend all three

d
Running current
Installed and phase currents and verify the

Running
currents are balanced and do
Daily
not exceed nameplate rating.

Each phase should be within +/5% of the average of all three
phases
Perform
e
Insulation
Installed and
resistance(IR)
offline
IR
check
between
motor leads and ground. This

determines
ground
condition
insulation.
of
the
Record,
temperature correct and trend

6600 V Motors IR Value > 100
megohm
415V Motors IR Value > 5
megohm
Winding resistance
Installed and
offline
12 Months
24Months
A comparison of the line to line

resistances
of
the
motors
winding. This test should be
2451 of 2461
PAGE 80 of 90
S.
No
MMRDA
Equipment
Frequency
done at the motor terminals

using
meter
measuring
low
capable
of
resistance
(milliohms). A typical ohm meter

does
not
accuracy.
have
adequate
Record,
temperate
correct and trend.

Each phase should be within +/(3% - 5%) of the average of all
three phases
Stator visual
Inspection
Overhaul

coil movement
plugged vent holes
2 Yearly or
soft or degraded insulation
winding fault
coil bracing adequate and intact
tripping
lamination damage
partial discharge activity
tightness of wedges
Rotor / Shaft visual

Inspection
Overhaul

cracks in rotor bars
balance weights properly
secured
signs of bar movement
signs of rotor/stator rub or
lamination damage
2 Yearly or
major fault
tripping
cooling ducts clear

rubbing marks on shaft
keyway distortion
2452 of 2461
PAGE 81 of 90
S.
No
MMRDA
Equipment
Frequency
All parts should be cleanedand

Clean*, bake dry
i
and varnish (as
baked dry to remove all dirt and

Overhaul
needed)
contamination.
should
be
The
windings
reinsulated
as
appropriate.
Perform
IR
check
between
motor leads and ground. This

j
Insulation
resistance
Overhaul
determines
condition
of
the
ground insulation required IR

values shall be obtained as
mentioned below
6600 V Motors IR Value > 100
megohm
415V Motors IR Value > 5
megohm
CABLE
IR Value
Continuity
End termination
Installed &
offline
Installed &
offline
Insulation Resistance
Continuity test for cable
Installed &
End termination connection to
offline
be checked
COMMON
MAINTENANCE
7
FOR ALL
ELECTRICAL
EQUIPMENT
Maintenance as per
Preventive
maintenance
offline
manufacture's
Quarterly/Half
recommendations i.e.
Yearly/ Yearly
replacement of work out parts,
2453 of 2461
PAGE 82 of 90
S.
MMRDA
Equipment
No
Frequency
check permissible clearances,

calibrations etc.
Earth grid resistance
measurement and connections
Yearly
Maintain Records
Break down
maintenance
Fault detection and remedial

offline
measures, replacement of
damaged parts
Visual Inspection of all parts
As and when
Taking in to service and
Fault occurs
observe functioning
Recording of all events,
indications
14.18
Operation & Maintenance practices (Instrumentation, Control &
Automation)
14.18.1
General Maintenance
A comprehensive maintenance program is critical to attaining long-term
reliable performance of SCADA Systems / ICA systems. Periodic
device calibration, preventive maintenance, and testing allow potential
problems to be identified before they can cause mission failure. Prompt
corrective maintenance assures reliability by minimizing downtime of
redundant components.
The DBO contractor has to enter in to AMC contracts with system /
equipment suppliers of ICA, as necessary. It is mandatory to enter into
an agreement for a 8 years operation and maintenance contract with
the instrumentation, PLC and SCADA system supplier and wireless
communication
supplier
or
the
authorized
system
integrator,
whosoever has executed the work for this project.
2454 of 2461
PAGE 83 of 90
14.18.2
MMRDA
Preventive Maintenance
The SCADA system should be part of the overall preventive
maintenance (PM) program for the facility.
Table below provides a list of recommended maintenance activities
and frequencies for ICA systems and their components.
Preventive
subsystems
maintenance
should
schedules
be
for
coordinated
ICA
components
with
those
for
and
the
mechanical/electrical systems they serve to minimize overall scheduled

down time.
Table 14.32: Activity & Frequency
Activity
Frequency
Electrical Systems/Components/Instruments
Check Regulators and Filters
Monthly
Inspect Tubing and Piping
Monthly
Actuate Pressure Switches
3 months
Calibrate Switches and Sensors
Yearly
Calibrate Pressure Gauges
Yearly
Calibrate Level Transmitters
Yearly
Calibrate Flow transmitters
Yearly
Calibrate Pressure Transmitters
Yearly
Calibrate Thermometers
Yearly
Calibrate
Analytical
Instruments/Online 6 Months
Instruments(p H, Residual Chlorine, Turbidity ,etc.,)

Change Sampling solution of Analytical Instruments
As required
Electronic Systems
Lamp Test/Verify Indicators
Monthly
Inspect Enclosures for Dirt, Water, Heat
Monthly
Run PLC Diagnostics
3 Months
Calibrate Sensors and Transmitters
Yearly
Calibrate Meters
Yearly
2455 of 2461
PAGE 84 of 90
MMRDA
Activity
Frequency
PLC Communication Modules
Monthly
PLC Batteries
Yearly
Test Automatic control Sequences
Monthly
Verify Alarms
Weekly
Software Maintenance and Patching
3months
Anti-virus Definition Updates
Monthly
Inspect Wire, Cable and Connections
Monthly
Inter site Communication Network
Weekly
Dead Bus Relays
3 Months
UPS setting with SCADA
Weekly
PLC Redundant Power back up
Monthly
SCADA Redundancy
Monthly
Network Redundancy
Weekly
PLC Hot-Standby
Monthly
Historian Package(Capacity)
Monthly
Data Archiving
Monthly
a) Many components of SCADA systems, such as dead-bus relays,

are not required to function under normal system operating modes.
For this reason the system should be tested periodically under
actual or simulated contingency conditions. These tests should
approach as closely as possible the actual off- normal conditions in
which the system must operate.
For example, SCADA for Dual Redundant system should be tested
by interrupting the utility source as far upstream of the normal
service as possible.
b) Periodic system testing procedures can duplicate or be derived
from the functional performance testing procedures.
c) The SCADA software maintenance should include timely updates of
any new versions from the supplier and testing to verify proper
installation on the SCADA computer. In addition, software antivirus
2456 of 2461
PAGE 85 of 90
MMRDA
updates should be maintained. This should be performed any time

after the computer is connected to the Internet or the antivirus patch
should be downloaded as and when the updates are available.
Normal operation requires that the SCADA computer not be
connected to the Internet.
d) Faulty Instruments, sensors, transmitters, communication modules,
computer hardware should be replaced with new components.
Repair of the items would not be accepted.
14.18.3
Concurrent Maintenance
Concurrent maintenance is defined as testing, troubleshooting, repair
or replacement of a component or subsystem while redundant
component(s) or subsystem(s) are serving the load. The ability to
perform concurrent maintenance is critical to attaining the specified
reliability/availability criteria for facilities and must be designed into the
SCADA system. Where SCADA components are associated with
equipment that has redundancy and therefore are not themselves
redundant, their maintenance should be scheduled to occur during
maintenance of the associated equipment. SCADA components and
controllers that are redundant must be capable of being taken out of
service, repaired or replaced and tested without interfering with the
operation of the redundant component.
14.18.4
Reliability Cantered Maintenance

Reliability-Cantered Maintenance (RCM) is an approach for developing
an effective and efficient maintenance program based on the reliability
characteristics of the constituent parts and subsystems, economics,
and safety. RCM provides a logical, structured framework for
determining the optimum mix of applicable and effective maintenance
activities needed to sustain the operational reliability of systems and
equipment while ensuring their safe and economical operation and
support.
2457 of 2461
PAGE 86 of 90
MMRDA
A significant by-product of the application of SCADA systems to the

control of facilities is the large amount of operational data made
available through the trending and data storage features of the
SCADA. This operational data can be used for automated performance
monitoring of mechanical and electrical systems that can support a
RCM approach
14.18.5
Operations and maintenance documentation

The contractor should perform an O&M analysis to determine the O&M
data required to support maintenance of the SCADA system. This
analysis
should
be
coordinated
with
MMRDA
to
determine
maintenance parameters and O&M data that are available. Typical

O&M data requirements include the following items:
a. System documentation as defined in FDS, FAT & SAT documents
b. Minimum spare parts list.
c. Recommended spare parts list.
d. Recommended onsite test equipment.
e. Recommended O&M training.
f. Manufacturers Recommended O&M to be performed by contractor
14.18.6
O & M SCHEDULE: Excess Electricity Consumption

The monitoring of consumption of electrical energy for all the
installations shall be done at optimum level. The contractor shall
operate and maintain all the plants equipments in proper manner to
ensure the desired electricity consumption as per the bid offer at all the
2458 of 2461
PAGE 87 of 90
MMRDA
time. In case, contractors fail to do so and consume excess power for

getting the desired output then the charges towards the excess power
consumption shall have to be borne by the contractor. The charges
towards the same shall be worked out at the prevailing rate at that
time. All the motor feeders in the pumping stations are with
independent energy meters and same be used to record the power
consumption. In case of auxiliary load at pumping station, Sub-station
& WTP the arrangement/provision of measurement of
power
consumption shall be made during the design stage as required by the

contractor.
14.18.7
Spare parts stocking

An adequate on-site stock of spare parts is essential to obtaining high
availability of ICA systems.
All spare parts used for the equipment in the maintenance of the
system must be from the manufacturer of the equipment or, if the
equipment itself has been made with parts from other manufacturers,
the parts must be of the same make as used in the equipment supplied
and installed.
All spare parts shall be packed for long storage under the climatic
conditions prevailing at the Site. Each spare part shall be labelled on
the outside of its packing with its description, number and purpose and,
if more than one spare is packed in a single case, a general description
of the case contents shall be shown on the outside and a packing list
enclosed.
Minimum recommended stocking levels include the following. These
quantities may need to be increased for components which are used in
large numbers in the facility:
(1) Manufacturers recommended spare parts list.
2459 of 2461
PAGE 88 of 90
MMRDA
(2) One each of all line replaceable boards or modules.

(3) Six each power and control fuses used in the system.
(4) Tools required to terminate coaxial on fiber optic cables.
Automation:
(1) Laptop computer loaded with software required to access
controllers.
(2) Licenses for all software installed on the system.
(3) Permission to modify program code.
(4) Spare cables for connecting computer to controllers.
(5) PLC
CPU,
Power
supply
module,1
DI,DO,AI,AO
modules,
Communication module, protocol converter etc.

(6) PLC batteries, fuses, etc.
14.18.8
Utilities & Consumables

The contractor has to provide consumables for printers e.g.: Ink
cartridges (color & B/W), A4, A3, A1 size of paper, dot-matrix print
paper for a period of 8 years.
Downtime of the above system should not exceed more than 2 hours.
14.18.9
Technical support
2460 of 2461
PAGE 89 of 90
MMRDA
The Contractor should specify functional areas of the operating system

and/or equipment where a technical representative will be furnished by
the manufacturer for training, test, checkout, validation, or preoperational exercises.
Ongoing O&M of SCADA system software may require technical
support from the system vendor or from agency technical personnel not
located at the facility. Commercial SCADA software typically has
provisions for remote modem access that permit this type of support
from the vendors location or an agency central engineering group.
Such remote access provisions represent a vulnerability to hacking
and must be used with great caution. They should be monitored when
in use and physically disconnected when not in use.
Password protection policies for all SCADA systems, including PLCs,
shall be in compliance with Established policies and to be agreed with
the employers representative.
These policies require that the default password that came from the
control supplier be changed when Placed into operation at the facility.
2461 of 2461
PAGE 90 of 90

Part II

Enviado por

Dados do documento

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Part II

Enviado por

Direitos autorais:

Formatos disponíveis

MUMBAI METROPOLITAN REGION

WATER SUPPLY RESOURCE MANAGEMENT CELL

Part - II: EMPLOYERS REQUIRMENTS

SURYA REGIONAL BULK WATER SUPPLY SCHEME

Project Region and the MMRDA .................................................................................... 1

Surya Regional Water Supply Scheme........................................................................... 2

Project Background ................................................................................................. 2

Objectives of the Project ......................................................................................... 3

Source and location of Intake ........................................................................................ 4

Surya River ............................................................................................................... 4

Location of Intake .................................................................................................... 5

Service Areas and locations of MBRs ............................................................................ 5

Vasai-Virar Sub-Region ............................................................................................ 5

Location of Water Treatment Works............................................................................. 8

Incorporation of Break Pressure Tank (BPT) ................................................................. 9

Brief Description of Water Supply System .................................................................... 9

Scope of Contract ......................................................................................................... 11

Activities Included ................................................................................................. 11

Detailed Scope ....................................................................................................... 12

Other Incidental Works ......................................................................................... 15

Completeness of the Works and System............................................................... 16

SURYA REGIONAL BULK WATER SUPPLY SCHEME

SUB-SECTION 6A.1: PROJECT REQUIREMENTS

Project Region and the MMRDA

The project is in Mumbai Metropolitan Region (MMR) which comprises

SECTION 6A.1: PROJECT REQUIREMENTS

SURYA REGIONAL BULK WATER SUPPLY SCHEME

Figure 1.1: Expanse of Mumbai Metropolitan Region

Surya Regional Water Supply Scheme

SECTION 6A.1: PROJECT REQUIREMENTS

SURYA REGIONAL BULK WATER SUPPLY SCHEME

of the scheme is accordingly kept 403 ML/day. It is intended to give

Vasai -Virar City Municipal Corporation

Mira Bhayandar Municipal Corporation

27 villages in Vasai - Virar Sub-region not

Objectives of the Project

Manual on Water Supply and Treatment by CPHEEO

SECTION 6A.1: PROJECT REQUIREMENTS

SURYA REGIONAL BULK WATER SUPPLY SCHEME

WHO guidelines for drinking water quality

The system design, selection of process and material of construction

Supply safe and clear water treated to acceptable standard as per

Water conservation, low leakage and reuse wherever feasible

Design life as given in Manual on Water Supply and Treatment

Source and location of Intake

SECTION 6A.1: PROJECT REQUIREMENTS

SURYA REGIONAL BULK WATER SUPPLY SCHEME

Service Areas and locations of MBRs

Topography of the sub-region is moderately flat with ground level

SECTION 6A.1: PROJECT REQUIREMENTS

SURYA REGIONAL BULK WATER SUPPLY SCHEME

Figure 1.2: Vasai-Virar Subregion

The Sub-region includes Vasai Virar Municipal Corporation (VVMC)

SURYA REGIONAL BULK WATER SUPPLY SCHEME

Suitable plot for locating MBR is identified near existing MBRs.

The area lies between 191903 - 191612 N and

Topography of the sub-region is fairly flat with ground levels varying

SECTION 6A.1: PROJECT REQUIREMENTS

SURYA REGIONAL BULK WATER SUPPLY SCHEME

Figure 1.3: Mira-Bhayandar Sub region

Location of Water Treatment Works

Suitable large land about 20-25 Ha is required for water treatment

SURYA REGIONAL BULK WATER SUPPLY SCHEME

treatment works. The contours and variation in levels are appropriate