AppH-1 SES

STANDARD ENGINEERING SPECIFICATIONS (SES) WASTE WATER GENERAL CONTENTS
Section
Title
Included
1 2 3 4 5 6 7 8 9 10 11 12
GENERAL REQUIREMENTS MATERIALS EXCAVATION, BACKFILLING AND RESTORATION CONCRETE AND FORMWORK CONSTRUCTION OF PIPELINES, TUNNELS AND ANCILLARY WORKS BUILDING WORKS TESTING AND DISINFECTION ROADWORKS SEWER AND WATER MAIN RENOVATION PROTECTIVE COATINGS TO METAL WORK DESIGN MECHANICAL WORKS
13 ANNEX A ANNEX B ANNEX C
ELECTRICAL SPECIFICATIONS List of Preferred Brands of Electrical and Instrumentation Equipment and Components Waste Water Standard Drawing Waste Water Facilities Standard Paint Color
MWC Standard Engineering Specifications
Waste Water
CONTENTS General Notes Section Title Clause Number 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20 1.21 1.22 1.23 1.24 1.25 1.26 1.27 1.28 1.29 1.30 1.31 1.32 1.33 1.34 1.35 1.36 1.37 1.38 2 MATERIALS 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 Clause Heading Page
GENERAL REQUIREMENTS
Entry Onto the Site Survey of Highways, Properties, Lands and Crops Site Fencing Level and Reference Points Accommodation for the Site Manager Billposting and Advertising Interference with Land Interests Interference with Access to Properties and Apparatus Procedure for Complaints and Claims for Damage Protection Against Damage Facilities, Highway Authorities and Others Traffic Requirements Tidiness of Site Works Affecting Water Course Contamination of Water Supply Safety in Sewers and at Sewage Work Emergency Arrangements Explosives and Dangerous Substance Electricity Distribution on the Site Design Calculations Drawings Quality Management System Safety Maintaining Flow in Sewers Control of Noise and Vibration in the Work Manuals for Buildings and Structures Plant Operation and Maintenance Manuals Spares and Special Tools Tests to be Witnessed Before Delivery Delivery Equipotential Bonding Sanitary Precaution and Control Signs Personal Safety Equipment Fire Precautions Dust Abatement Uniform SURVEYING AND SETTING OUT WORK Standards and Submission of Materials Storage and Stockpiling of Materials Handling and Use of Materials Topsoil Turf Grass Seed Fertilizer Trees and Shrubs Aggregates for Concrete
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12 12 12 13 13 14 14 14 14 14 15 15 16 16 16 17 17 17 18 18 18 25 26 26 26 27 27 28 28 28 28 28 29 29 29 29 29 30 32 32 33 33 33 33 33 33 33
2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19 2.20 2.21 2.22 2.23 2.24 2.25 2.26 2.27 2.28 2.29 2.30 2.31 2.32 2.33 2.34 2.35 2.36 2.37 2.38 2.39 2.40 2.41 2.42 2.43 2.44 2.45 2.46 2.47 2.48 2.49 2.50 2.51 2.52 2.53 2.54 2.55 2.56 2.57 2.58 2.59 2.60 2.61 2.62
Cement Admixture for Concrete and Grout Sand Pipe Surround Materials Dowel Bars Steel Sheet Piles Trench Backfill Materials Selected Sandy Materials Bank Run Gravel Crushed Stone Bedding Embankment Materials Lime for Mortar Cement Grout Steel Reinforcement Joint Filler Materials Tying Wire Formwork Cover Blocks and Spacer for Reinforcement Waterstop Bricks and Blocks Mortar Joint Sealant Cast Iron Pipes and Fittings Cast Iron Soil Pipes Ductile Iron Pipes and Fittings Steel Pipes and Fittings Unplasticized Polyvinyl Chloride Pipes and Fittings (uPVC) for Water Unplasticized Polyvinyl Chloride Pipes and Fittings (uPVC) for Sewer Polyethylene Pipes and Fittings Fiberglass Pressure Pipes Marker Tapes Joint Sealant and Lubricants Flanges for Pipes Gaskets for Flanged Joints Valves Pre-cast Concrete Manholes Manhole Frames and Covers Manhole Step Iron (Ladder Rungs) Vitrified Clay Pipes and Fittings Reinforced Concrete Pipes and Fittings Unreinforced Pipes and Fittings Hydrants Electrodes, Filler Rods and Wires for Welding Precast Concrete Segment for Tunnels and Shafts Bituminous Jointing Strip Packing for Tunnels Grummets Nut, Screws, Washers and Bolts Sleeve Type Coupling Brass Fittings Saddles Rubber Gaskets for Mechanical and Push-on Joints Valve Boxes
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34 34 34 34 35 35 35 35 36 36 36 36 36 37 38 38 38 38 38 39 39 40 40 41 41 42 42 43 43 44 45 45 45 45 45 46 46 46 46 47 47 47 47 47 48 48 49 49 49 49 50 50 50
2.63 2.64 2.65 2.66 2.67 2.68 2.69 2.70 2.71 2.72 2.73 2.74 2.75 2.76 2.77 2.78 2.79 2.80 2.81 2.82 2.83 2.84 2.85 2.86 2.87 2.88 2.89 2.90 2.91 2.92 2.93 2.94 2.95 2.96 2.97 2.98 2.99 2.100 2.101 2.102 3 EXCAVATION, BACKFILLING AND RESTORATION
Plastic Sheeting Structural Steel Aluminum and Aluminum Alloy Timber for Carpentry and Joinery Glass for Glazing Paints and Painting Materials for Building Water Fasteners Handrails and Ballusters Safety Gate Chains Liquid Chlorine Sodium Hypochlorite Calcium Hypochlorite Aggregate Subbase Course Aggregate Base Course Crushed Aggregate Base Course Lime Stabilized Road Mixed Based Course Portland Cement Stabilized Road Mixed Based Course Asphalt Stabilized Road Mixed Based Course Portland Cement Treated Plant Mix base Course Aggregate Stockfile Aggregate Surface Course Bituminous Prime Coat Bituminous Tack Coat Bituminous Seal Coat Bituminous Surface Treatment Bituminous Penetration-Macadam Pavement Bituminous Road Mix Surface Course Bituminous Plant Mix Surface CourseGeneral Bituminous Plant Mix Surface Course-Cold Laid Bituminous Plant Mix (Stockpile Maintence Mixture) Bituminous Concrete Surface Course-Hot Applied Portland Cement Concrete Pavement Curb and Gutter Sidewalk Thrust Blocks MISCELLANEOUS STAINLESS STEEL METAL WORKS ALTERNATIVE PIPE MATERIAL FOR SEWER PIPES AIR- VACUUM AND AIR-RELEASE VALVES EPOXY PAINTS FOR CONCRETE TANKS
50 50 51 51 51 52 52 52 52 52 52 52 53 53 53 53 53 53 53 53 53 53 53 53 53 53 54 54 54 54 54 54 54 54 54 54 54 54 55 55 56
3.1 3.2 3.3 3.4 3.5 3.6
Excavation Clearing and Grubbing Test Pits Trench Excavation Headings, Tunnels and Shafts Excavation in Carriageway/Roadways
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56 57 57 57 58
3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22 3.23 3.24 3.25 3.26 3.27 3.28 3.29 3.30 3.31 3.32 3.33 3.34 3.35 4 CONCRETE AND FORMWORK 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 4.20 4.21 4.22 4.23 4.24 4.25
Miscellaneous Turf for Relaying Topsoil for Re-use Dealing with Surface and Ground Water Temporary Drains Backfilling Backfilling Above Ground Reinstatement of Maintainable Highways Reinstatement of Non-Maintainable Highways Reinstatement of Unpaved lands Trees Land Drains Blasting Reinstatement of Walls, Fences and Hedges Piling Closure and Demolition of Redundant Assets Filling Operations Disposal Operations Field Density Test Sheeting and Bracing Structural Fill Lines and Grades Slopes, Slides and Geological Overbreak Re-use of Excavated Materials Stockpiling of Materials MATERIAL FOR PIPE BEDDING AND TRENCH FILLING BEDDING FOR PIPES BACKFILLING TO PIPES STANDARDS OF COMPACTION Concrete Quality Small Construction Concrete Ready Mixed Concrete Concrete Mixes Mortar Mixes Cement Grout Testing Porous No-Fines Concrete Air-Entrained Concrete Chloride Content Workability Transporting, Placing and Compacting Concrete Temperature Protection and Curing Records of Concreting Construction of Formwork Cleaning and Treatment of Forms Stripping of Formwork Sloping of Formwork Cutting and Bending of Reinforcement Fixing of Reinforcement Surface Condition of Reinforcement Laps and Joints Welding of Reinforcement Built-In Items
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58 58 58 58 59 59 60 60 61 61 62 62 63 63 64 64 64 64 64 64 65 66 66 67 67 67 67 68 68 70 70 70 71 71 72 72 73 74 74 74 74 75 75 76 76 77 77 77 77 77 79 79 79 79
4.26 4.27 4.28 4.29 4.30 4.31 4.32 4.33 4.34 4.35 5 CONSTRUCTION OF PIPELINES, TUNNELS AND ANCILLARY WORK
Construction Joints Surface Finishes Produced Without Formwork Surface Finishes Produced With Formwork Tie Bolts for Formwork Tolerance for Concrete Surfaces Marking of Precast Concrete Components Concrete Cast Against Rock Concrete Cast Against Previously Placed Concrete Acceptance Criteria CONCRETE DIRECTLY IN CONTACT WITH SEWAGE
79 80 80 80 81 81 81 81 82 83
85 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16 5.17 5.18 5.19 5.20 5.21 5.22 5.23 5.24 5.25 5.26 5.27 5.28 5.29 5.30 5.31 5.32 5.33 5.34 5.35 5.36 5.37 5.38 5.39 General Pipe Bedding Concrete Protection to Pipes Completion of Pipe Surround Pipelaying in Headings Thrust Blocks Pipe Jointing Generally Welded Joints in Plastic Pipes Butt Fusion Jointing in Polyethylene Pipelines Flanged Joints Ogee Joints Welded Joints in Steel Pipes Cement Mortar Joints Run Lead Joints Protection of Ferrous Pipes, Joints and Fittings Cutting Pipes Precast Concrete Manholes Precast Concrete Segmental Manholes Brick and In-Situ Concrete Manholes and Chambers Inverts and Benching Pipes and Joints Adjacent to Structures Watertightness of Manholes and Chambers Setting Manhole Covers and Frames Connections to Existing Sewers Sewers and Manholes to be Abandoned Pipe Jacking Shafts Openings in Shafts and Tunnels Segmental Shaft and Tunnel Linings Unbolted Concrete Tunnel Segments Bolted Concrete Segmental Linings Grouting of Segments Caulking Pointing of Joints Shafts and Tunnel to be Watertight Recording Information Junctions and Laterals on Sewers Marker and Indicator Posts Tolerances for Pipelines, Shafts and Tunnels
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86 86 86 86 87 87 87 87 99 99 99 99 100 100 101 101 101 102 102 102 102 102 102 103 103 105 105 105 105 106 106 106 106 106 107 107 107 107
5.40 5.41 5.42 5.43 5.44 6 BUILDING WORKS 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15 6.16 6.17 6.18 6.19 6.20 6.21 6.22 6.23 6.24 6.25 6.26 6.27 6.28 6.29 6.30 6.31 6.32 6.33 6.34 6.35 6.36 6.37 6.38 7 TESTING AND DISINFECTION
Sleeve Type Coupling Jointing for Bell and Spigot Rubber Rings Interconnection between Pipes Pipe Supports Service Connections Brickwork and Blockwork Generally Brickwork and Blockwork, Jointing and Pointing Damp Proof Course Corbelling Bonding to Concrete Underpinning Centering and Lagging Preparation for Plastering Cement Plastering Other Floor, Wall and Ceiling Finishes Carpentry and Joinery Structural Steelwork Roofs Timber Floors Door Frames Windows Glazing Painting Roof Coverings Lightweight Concrete Roof Screed Asphalt Roofing Bitumen Felt Roofing Surface Treatment to Flat Roofs Plumbing Opening in Walls, Floors and Ceilings Tolerances for Building Works Nailing Steel Casement and Awning Windows Illumination Clean-Up th Warranty Inspection on 11 Month Welding ACCESS AND SUPPORT FACILITIES SITE DEVELOPMENT OR RESTORATION WORKS WOOD DOORS Fire protection Architectural finishes Schedule of doors and windows
107 108 108 109 109 111 111 112 112 112 112 112 112 112 113 117 118 119 119 119 119 119 122 123 124 124 124 125 125 125 125 125 125 132 132 133 133 133 133 134 135 135 135 137
7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8
139
Cleansing of Pipelines Precautions Prior to Testing Pipelines Notification of Test Testing of Non-Pressure Pipelines Water Test for Non-Pressure Pipelines (Exfiltration) Air Test for Non-Pressure Pipelines CCTV Inspection for Non-Pressure Pipelines Infiltration
137 137 137 137 138 138 138
Waste Water
7.9 7.10 7.11 7.12 7.13 7.14 7.15 7.16 8 ROADWORKS 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 9.13 9.14 9.15 9.16 9.17 9.18 9.19 9.20 9.21 10 PROTECTIVE COATINGS TO METAL WORK
Testing of Pressure Pipelines Swabbing of Watermains Disinfection of Watermains Cleansing of Structures Testing of Concrete Structures Designed to Retain an Aqueous Liquid Testing of Roofs Disinfection of Structures for Potable Water Pressure Testing Polyethylene Pipelines General Clearing and Grubbing Removal of Structures and Obstructions Excavation Road Formations and Subgrade Preparation Sub-Base and Base Course Construction Surfacing Curbs and Gutters Sidewalks Tolerances for Finished Roadway Surfaces Isolation of Flows Preparatory Survey Preparation of Existing Sewers and Watermains Jointing Generally Connections Intermediate Chambers Release of Curing Water Annulus Grouting Generally Inspection After Grouting Lining Through Valves Inspection After Renovation Bringing Renovated Water Mains Into Service Lining Template Tolerances for Preformed Lining Cutting of Sewer Linings Treatment of Sewer Linings at Intermediate Manholes Placement of Sewer Lining-General Placement of Cast Polyester Resin Linings (In-Situ Form) Sliplining Void Grouting Core Sampling
138 139 139 139 139 139 139 140 142 142 142 142 142 142 143 143 143 143 144 144 144 145 145 145 145 145 146 146 146 146 146 147 147 147 147 148 148 148 149 150
SEWER AND WATER MAIN RENOVATION
10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8
Coating System Generally Blast Cleaning Cleaning Paints Painting Metallic Coatings Touching Up and Repair Quality Plan
153 153 153 153 154 154 154
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11
DESIGN
11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 11.9 11.10 11.11 11.12 11.13 11.14 11.15 11.16 11.17 11.18 11.19 11.20 11.21 11.22 11.23 11.24 11.25 11.26 Part 1 12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 12.9 12.10 12.11 12.12 12.13 12.14 12.15 12.16 12.17 12.18 12.19 12.20 12.21 12.22 12.23 12.24
Application Design Standards Sliding Overturning Flotation Settlement Concrete Structures Building Design Structural Steel Work Masonry Timber Flooring Handrails and Balusters Stairs and Ladders Hydraulic Design Pipelines Drainage Manholes Overflows Outfalls Roads Landscaping Foundations Ground Anchors Bunds to Chemical Tanks Working Room GENERAL SPECIFICATIONS SCOPE OF WORK REFERENCES DEFINITIONS CASTINGS AND FORGINGS LUBRICATION, BEARINGS, SEALS AND GEARBOXES FIXING MACHINERY ALIGNMENT, LIFTING, DISMANTLING, NOISE & VIBRATION BOLTS, SCREWS, NUTS, STUDS AND WASHERS PIPEWORK SYSTEMS PENSTOCKS ACTUATORS PRESSURE GAUGES SURGE VESSELS AERATION PIPEWORK / HIGH PRESSURE DUCT WORKS SLUDGE STORAGE TANKS - GENERAL PUMPS VENTILATION AND AIR CONDITIONING SUSPENDED CEILINGS HANDRAILING, WALKWAYS, FLOORING AND LADDERS PORTABLE FIRE EXTINGUISHER AIR CONDITIONING GAS DETECTION AND ALARM SYSTEMS FIRE ALARM AND FIRE EXTINGUISHER SYSTEMS ESCAPE ROUTES
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162 162 162 162 162 162 162 163 163 163 163 163 163 164 164 164 164 165 165 165 165 166 169 169 169 170 172 172 172 173 174 174 175 176 177 177 178 179 180 181 181 183 186 199 201 201 203 203 205 206 207
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MECHANICAL WORKS
12.25 12.26 PART 2 12.27 12.28 12.29 12.30 12.31 12.32 12.33 12.34 12.35 12.36 12.37 12.38 12.39 12.40 PART 3 12.41 12.42 12.43 12.44 12.45 12.46 12.47 13 ELECTRICAL SPECIFICATIONS PART 1 13.1 13.2 13.3 13.4 13.5 13.6 13.7 13.8 13.9 13.10 PART 2 13.11 13.12 13.13 13.14 13.15 13.16 13.17 13.18 13.19 13.20 13.21
LIFTING FACILITIES SUBMITTAL PRODUCT SPECIFICATIONS COARSE RAKED BAR SCREENS SCREENINGS TRANSPORTATION AND TREATMENT MECHANICAL FINE 3 MM SCREENS GRIT/GREASE REMOVAL SYSTEM SCREENING AND GRIT DISPOSAL SUBMERSIBLE MIXERS AIR DISTRIBUTION PIPEWORK POSITIVE DISPLACEMENT (ROTARY LOBE) AIR BLOWERS CENTRIFUGAL AIR BLOWERS BLOWER PIPEWORK & DUCTING DECANTING CENTRIFUGE POLYMER PREPARATION AND DOSING SYSTEM SODIUM HYPO-CHLORITE SYSTEM STANDBY GENERATOR EXECUTION HEALTH AND SAFETY TESTING OF PLANT BEFORE DELIVER INSTALLATION Plant Operation and Maintenance Manuals Tools Spares Guarantees GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS COLOR AND IDENTIFICATION INSTALLATION ELECTRICAL DRAWINGS/SUBMITTALS POST CONTRACT DRAWINGS AND DOCUMENTATION TESTING CALIBRATION INSTRUMENT ENVIRONMENTAL PROTECTION COMMISSIONING TRAINING PRODUCTS SPECIFICATIONS LOW VOLTAGE SWITCHBOARD MEDIUM VOLTAGE SWITCHGEAR OUTDOOR LOAD INTERRUPTER SWITCHGEAR MOTOR CONTROL CENTRES DISTRIBUTION BOARDS/CONTROL PANEL COMPONENTS SOFT STARTER LOW VOLTAGE FREQUENCY DRIVE DRY TYPE TRANSFORMER EARTHING POWER TRANSFORMERS
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207 209 209 209 211 211 213 214 214 215 217 218 220 222 226 228 229 235 235 235 235 236 237 237 237 238 238 241 244 259 262 265 273 273 274 274 274 274 278 284 286 289 290 295 299 303 304 305
13.22 13.23 13.24 13.25 13.26 13.27 13.28 13.29 13.30 ANNEX A B C
MOTORS WIRES AND CABLES LIGHTING AND SMALL POWER INTERIOR WIRINGS CONDUITS AND BOXES INSTRUMENTATION AND CONTROLS PROGRAMMABLE CONTROLLERS (PLC) CCTV LIGHTNING PROTECTION List of Preferred Brands of Electrical and Instrumentation Equipment and Components Waste Water Standard Drawing Waste Water Facilities Standard Paint Color
312 318 320 324 326 328 334 338 338 343 344 372
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SECTION 1 GENERAL REQUIREMENTS 1.1 ENTRY ONTO THE SITE 1. Prior to the commencement of operations, MWC shall supply to the Contractor the names and addresses of relevant owners and occupiers. The Contractor shall notify MWC in writing in advance of his intention to start work within each area of ownership or occupation. 2. The Contractor shall keep records of the dates of his entry onto and departure from all property and lands of each owner and occupier, together with the dates of the erection and removal of all enclosures, and shall furnish copies of these records when required by MWC. He shall keep and furnish copies of similar records in respect of roads, footpaths and thoroughfares. 3. The Contractor shall obtain all necessary permits and licenses from the local government unit or other public or private authorities concerned for the proper implementation of the Contract. Any payments or deposits for such permits and licenses shall be borne by the Contractor 4. The Contractor shall be responsible for obtaining and servicing a site compound, which shall be of sufficient size to accommodate MWCs site office, and the Contractors own office and storage requirements. The Contractor shall provide MWC with full details of its proposals for review. 5. All temporary buildings the Contractor proposes to erect on site shall be subject to the approval of MWC in respect of size, construction and position. 1.2 SURVEY OF HIGHWAYS, PROPERTIES, LANDS AND CROPS 1. Where appropriate, MWC shall arrange for surveys to be carried out, in conjunction with the Contractor and the Highway Authority, owners, occupiers, properties, lands and crops which may be affected by the Works. Two sets of photographs dated and titled shall be made. 2. Before any work affecting such highways, properties, lands or crops is commenced, the Contractor shall confirm in writing to MWC that the relevant survey is a true and accurate record of their condition. 3. A survey, including a pictorial record, of the condition of the site prior to the commencement of any works shall be made by the Contractor and agreed by MWC. 1.3 SITE FENCING 1. Where the type and locations of temporary site fencing are described in the Contract, the Contractor shall erect such fencing as soon as he is given possession of the relevant portion of the Site. The Contractor shall regularly inspect and maintain all such fencing, any defects being made good without delay. Access shall be provided in temporary site fencing as necessary for the use of the occupiers of adjacent lands. Temporary site fencing shall remain in position until either it is replaced by permanent fencing or the Works are sufficiently completed to enable that portion of the Site to be brought into use. 2. Fences to compounds in highway shall have lights at the top of each fence post. 3. The Contractors offices, workshops and storage compounds, camp area and all construction areas, where exclusion of unauthorized personnel is necessary for safety and security, shall be adequately fenced, gated and guarded. A central guardhouse shall be established at the
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main entrance to the Site. The Contractor shall employ a sufficient force of properly trained security guards at the Site of the Work. 1.4 LEVELS AND REFERENCE POINTS 1. The Contractor shall supply to MWC details of the value and location of the temporary benchmarks and reference points, which he proposes to use. Temporary benchmarks shall be located within 60 m of the Site and shall have the agreed value recorded on them. 2. The Contractor shall satisfy himself that the existing ground levels as indicated in the Contract are correct. Should the Contractor wish to dispute any levels he shall submit to MWC a schedule of the position of the level considered to be in error and a set of revised levels. The existing ground relevant to the disputed levels shall not be disturbed before MWCs decision as to the correct level is given. 3. The Contractor shall preserve and keep accessible or free from sight obstruction the benchmark of the basic survey provided by the Contract Drawings and those provided by him. 1.5 ACCOMMODATION FOR THE SITE MANAGER 1. The Contractor shall clean and maintain, until the completion of the Works, accommodation for MWC as described in the Contract Specific Document. Offices and other accommodation shall be erected, furnished, equipped and ready for occupation and use within 7 days of the Works Commencement Date, and fully serviced within 28 days of that Date. The room shall be provided within the Contractors office for the exclusive use of the Engineer and Project Management Consultant 2. Where movable offices are required by the Contract, these shall be relocated from time to time as directed by MWC. 3. Where the Contract requires telephone facilities for MWC, such facilities shall have separate connection direct to a public telephone exchange with privacy of conversation for MWC. 4. MWC Office. The office is described as follows: The Engineers accommodation shall have floor area of 30 square meters and be weather proofed, insulated, lines inside with plywood and painted internally. Floor to ceiling height shall be at least 2.5 meters. The office shall be well lighted and air conditioned. The office shall be provided with the following brand new office furnishings: 4- Standard double pedestal desk (lockable) 4- Swivel desk chair 2- 3x6 white board 2- 4 drawer steel cabinet 2- Personal Computer (Laptop) 1- DeskJet Printer 5. Within thirty (30) calendar days following the issuance of the Certificate of Completion, the Contractor shall, with MWCs approval, remove all temporary facilities. After this period, the use of the office by MWC will cease and equipment and furnishings will revert to the Contractor
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6. Reinstatement. Upon completion of the Works and removal of the accommodation the area of any site offices shall be fully reinstated to a standard no less than that appertaining prior to commencement of the works unless shown otherwise in the documents. 1.6 BILLPOSTING AND ADVERTISING 1. The Contractor shall not undertake or allow billposting or advertising of any kind upon the Works without the written consent of MWC. 1.7 INTERFERENCE WITH LAND INTERESTS 1. The Contractor shall confine his constructional operations within the Site, or such other areas of land as may be negotiated, and shall instruct his employees not to trespass. 2. Subject to any unavoidable disturbance, which may be necessitated by the execution of the Contract, the Contractor shall not interfere with any sporting, fishing or other rights, which may be enjoyed on or near the Site. 3. Before exercising any right negotiated by him in connection with wayleaves or accommodation outside the Site, the Contractor shall notify MWC in writing of such arrangements. 4. The Contractor shall not be permitted to bring animals onto the site. 1.8 INTERFERENCE WITH ACCESS TO PROPERTIES AND APPARATUS 1. Before interfering with access to any property, the Contractor shall provide alternative arrangements. The Contractor shall notify MWC and the relevant occupiers in writing 14 days in advance of any such interference and shall confirm to MWC that alternative arrangements have been agreed. 2. The Contractor shall not obstruct access to any manhole or other surface cover. 1.9 PROCEDURE FOR COMPLAINTS AND CLAIMS FOR DAMAGE 1. Details of all claims or warnings of intended claims, which the Contractor may receive in respect of matters against which is required by the Contract to indemnify the Employer shall be notified without delay to MWC, who shall likewise pass to the Contractor any such claims or warnings which may be submitted directly to MWC or Employer. 2. A similar exchange of information shall also be made in relation to all complaints, which may be received. 3. The Contractor shall notify MWC in writing immediately following any damage or injury arising out of the execution of the Works. 1.10 PROTECTION AGAINST DAMAGE 1. The Contractor shall take all necessary precautions to avoid causing any unwarranted damage to roads, properties, trees and other features and, during the currency of the Contract, shall deal promptly with any complaints by owners or occupiers. 2. Where any portion of the Works is close, across, or under any existing facilities, the Contractor shall temporarily support and work round, under or adjacent to all facilities in a manner designed to avoid damage, leakage or danger, and to ensure uninterrupted operation.
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3. Should any leakage or damage be discovered, the Contractor shall at once notify MWC or owner concerned, as appropriate and the Contractor shall afford every facility for the repair or replacement of the facilities affected. 1.11 FACILITIES, HIGHWAY AUTHORITIES AND OTHERS 1. The Contract drawings indicate what are believed to be the positions of the existing facilities close to the Works, but no warranty is given as to the accuracy or completeness of this information. In particular no service connections to individual properties are shown. 2. The accepted program of Works shall show information necessary to enable MWC to arrange for all diversions, or removals, of existing facilities described in the Contract to be carried out at the appropriate time. 3. The Contractor shall liase with all relevant utility agencies and other owners of the existing facilities before commencing any excavations and shall satisfy himself as to the exact position of existing facilities which may affect or be affected by the construction of the Works. 4. The Contractor shall notify MWC in advance of any diversion or removal of existing facilities, which he may require for his own convenience or because of his proposed method of working and shall comply with any requirements of MWC with respect to them. 5. Should any facilities found to exist which is not indicated, or not as indicated in the Contract, the Contractor shall at once give written notification to MWC. 6. The Contractor shall comply with the requirements of any public or private body whose plant, facilities or equipment is affected by the Works. 7. The Contractor shall consult with the relevant body prior to the removal of any services, which are either indicated as being abandoned on the drawings or will be made redundant by service diversions arranged by MWC. 1.12 TRAFFIC REQUIREMENTS 1.21.10 The Contractor shall comply with the relevant ordinances of the Metro Manila Development Authority (MMDA) and the requirements of DPWH and the police. The Contractor shall also comply with the legitimate requirements of any public or private body (barangay etc.) upon whose land the works are to be carried out. 2. Before any work in or affecting the use of any highway is commenced, the Contractors proposed method of working shall be agreed with, and confirmed in writing to MWC and other government agency concerned. 3. Throughout the execution of the Works and the guaranteed period, the Contractor shall cooperate with the relevant government agencies concerning works in, or access to the highway. The Contractor shall inform MWC of any requirements of, or arrangements made. 4. Where the Works temporarily necessitates the diversion of any existing carriageway, footway or public right of way, the Contractor shall provide and maintain an alternative, which shall be operational before interference with the existing way. 5. Where ramps are required, they shall be provided and maintained to a standard suitable in all respects for the class or classes of traffic or pedestrians requiring to use them. 6. The Contractor shall take all reasonable steps to prevent vehicles entering and leaving the Site depositing mud or other debris on the surface of adjacent roads or footways, and shall remove expeditiously any material so deposited. In particular the Contractor shall only wash down plant and machinery within the designated site compound.
MWC Standard Engineering Specifications 15 Waste Water
7. No Contractors site employees' private vehicles are to be parked on the highway. The Contractor shall arrange off-street parking for his employees private cars. 8. Where the volume of traffic and/or parked cars impede the progress of the Works, the Contractor shall bring this to the notice of MWC, and continue with the next available portion of the Works. 1.13 TIDINESS OF SITE 1. The Contractor shall be responsible for the tidiness of the Site in accordance with the Conditions of Contract. 1.14 WORKS AFFECTING WATER COURSES 1. The Contractor shall notify MWC in writing 14 days in advance of his intention to start at any part of the Works affecting a watercourse, canal or lake. 2. The Contractor shall be responsible for maintaining watercourses within the Site in effective working condition at all times. 3. The Contractor shall take all practicable measures, which shall be to the prior approval of MWC, to prevent the deposition of silt or other material in, and the pollution of, any existing watercourse, canal/sewer, lake, reservoir, borehole, aquifer or catchment area, arising from his operations. 4. Concreting within a watercourse shall only take place after separation of the working area by a bund. Alternatively the watercourse can be diverted down a temporary course for the duration of the crossing. The first flush of water over a structure constructed of concrete or containing cementitious material will require treatment. 5. Prior to commencing any work on site, the Contractor shall consult with MWC, the Environment Agency (EA) and local government units and Department of Public Works and Highways (DPWH), in respect of any measures necessary to protect the land drainage water resources, water quality and/or fisheries interests and obtain all necessary consents with respect to his method of working, temporary discharge from the site, etc. 1.15 CONTAMINATION OF WATER SUPPLIES 1. Before any person is engaged on work described in the Contract as involving restricted operations, he shall be notified of the need for personal hygiene and the dangers of contamination, shall complete a medical questionnaire provided by the Employer and, where there is a need, shall be tested to indicate that he is not a carrier of typhoid or other waterborne disease. The Contractor shall notify MWC of any person who has been certified by a doctor as suffering from an illness associated with looseness of the bowels, and no such person shall be employed on such work until the Employers medical adviser is satisfied that it is safe for him to be so employed. 2. When undertaking connections into existing water mains the Contractor shall take such measures as are necessary to prevent ingress of water into the water main. MWC shall be informed immediately if any ingress of water takes place. 3. Immediately prior to making a connection, a solution of 20 ppm chloros (sodium hypochlorite) shall be sprayed:i) ii) inside and outside the existing pipework into and outside the new pipework within the excavation
16 Waste Water
iii)
around the excavation
4. When undertaking work in reservoir catchments, adjacent to watercourses or around existing water treatment facilities, the Contractor shall take measures to ensure that water supplies (either raw or treated water) do not become contaminated. 5. When undertaking work in reservoir catchments, adjacent to watercourses or around existing water treatment facilities, the Contractor shall take measures to ensure that water supplies (either raw or treated water) do not become contaminated. In particular: i) ii) 1.16 Refuelling of plant shall be carried out adjacent to the fuel storage areas Where plant will be traversing steep slopes, fuel tanks shall be filled to such levels that fuel cannot overflow from the tanks.
SAFETY IN SEWERS AND AT SEWAGE WORKS 1. Where the work will involve entry or work on sewers or at sewage works, the Contractors Construction Safety and Health Program shall include full details of the relevant safety measures it proposes to implement. 2. The Contractors safety policy shall, as a minimum, comply with MWCs own procedures for safe working in confined spaces, sewers and sewage works. Details of these will be made available to the Contractor on request.
1.17
EMERGENCY ARRANGEMENTS 1. The Contractors submitted safety policy shall detail arrangements to be made in the event of an emergency arising.
2. The Contractor shall acquaint himself and his employees with any relevant local arrangements, which are in existence for dealing with emergencies.
3. The Contractor shall make the necessary arrangement with hospitals and medical clinics that will give medical attention to such emergencies.
1.18
EXPLOSIVES AND DANGEROUS SUBSTANCE
1. No explosive or other dangerous substance shall be brought onto the Site or used for any purpose unless the Contractor has previously obtained the written approval of MWC.
2. The location of each explosives magazine and store of any other dangerous substance on the Site shall be approved in writing by MWC.
3. The storage of blasting explosives shall be in accordance with the security measures established by the Chief, Firearms and Explosives Unit and the relevant provisions of the Philippine Bureau of Mines and Mines Safety Rules and Regulations.
1.19
ELECTRICITY DISTRIBUTION ON THE SITE 1. All electrical installations forming part of the Temporary Works, including site offices cabins, shall comply with the relevant provisions of the latest Philippine Electrical Code the rules and regulations of relevant national and local undertakings including requirements of the local electricity distribution company (e.g. MERALCO) telecommunications companies (e.g. PLDT, Globe etc). and and the and
2. The Contractor shall submit for approval by MWC, full details of proposed electrical installations. The submission shall be in the following form: Distribution Diagram Plan showing cable routes Design calculation sheets
Electrical installation shall not proceed until approval is obtained. 3. Installations shall be tested in accordance with National and Local Ordinances or Laws governing the installation of electrical works. 4. A distribution drawing shall be mounted adjacent to the main supply point. This drawing shall be revised as necessary when an extension or modification is carried out. The name and telephone number of the electrical installer shall be displayed at this point. 5. Each site office or cabin shall be equipped with an isolating device, fitted to the outside adjacent to the main doorway, connected to isolate the whole electrical installation within the individual office or cabin. 1.20 DESIGN CALCULATIONS 1. If the Contractor is to be responsible for the design of all part of the Permanent Works the extent of his responsibility will be defined in the Contract Specific Specification. 2. For the elements of the Permanent Works for which the Contractor has design responsibility, it shall submit 2 copies of fully checked and signed off calculations as specified in the Contract Specific Specification to MWC for information. Calculations shall be in English on A4 (210mm x 297mm) or Letter (11"x8.5") paper; full references and details of any computer programs used shall be given. 3 The Contractor shall be responsible for the structural design of the sewer lines and the complete design of the Sewage Treatment Plant and Facilities covered by this Contract all in accordance with SES 11, 12 and 13.
4. All design calculations and drawings shall be submitted for review prior to procurement, fabrication or construction. 1.21 DRAWINGS 1. Electrical Drawings supplied by MWC are as listed elsewhere in the Bid Documents. 2. Drawings submitted by the Contractor shall be provided on an on-going basis to an agreed schedule as the design proceeds. They shall contain a title block of a format agreed with MWC. Drawings shall be to scale and include a graphical scale. All dimensions shall be given in metric units. All relevant drawings shall show plant references. All drawings submitted by the Contractor shall be fully checked and signed off prior to submission and include the drawings status e.g. Draft/For Approval etc.
3. Drawings submitted by the Contractor shall be categorized during the duration of the Contract as follows: Design submitted for review and approval. Design drawings of approved status and other drawings used by the Contractor for the construction of the Works (No paper prints shall be submitted to MWC) Construction drawings incorporating any changes made prior to the issue of a taking over certificate (4 No paper prints shall be submitted to MWC).
Construction-
As-built
4. Electronic Drawings submitted by the Contractor shall be prepared in a format readable by AutoCAD (latest version) and shall not exceed A1 size. Amended drawings shall have their amendments highlighted by indicating the version number within a triangle next to the amendment. 5. The design drawings and other information to be submitted by the Contractor shall be tabulated in the Contract Specific Document. 6. In addition to requirements specified elsewhere in this specification, the clause shall apply. requirements of this
The Contractor shall prepare detailed working drawings of the whole of the Works to be carried out in this Contract. All drawings shall be to an acceptable and professional standard. Poorly prepared or insufficiently detailed drawings will be rejected. Drawings which have not been initialed or signed as having been checked by a responsible member of the Contractors organization will also be rejected. The Contractor shall submit in advance the drawing index/table of content that will be generated with description/title and drawing numbers as per approval of MWC. The drawing documents will be filled up on status basis together with the drawing. Where appropriate, the drawing scale must be shown. The drawing shall also include a graphic scale to facilitate scaling when a sheet is reproduced at a different size to the original. Plant room layout drawings are to be prepared to a scale of 1:50 or larger. Equipment detail drawings shall be drawn at a scale of 1:20 or larger. All Drawings shall include the Manufacturers detail or serial number of all plant/equipment so that sufficient information is available for the ordering of replacement parts. All drawings shall be created using AutoCAD, release 2000 in A1 size unless noted otherwise. Graphical symbols used on drawings shall comply with the symbols contained in the current version of the appropriate standard (PEC, NEC or IEC). Cross-references shall be marked on all schematic diagrams to show where a coil has its contacts and where contacts have their coils. This referencing shall apply to all types of equipment shown on more than one drawing. Drawing Sheets, Numbering and Scales All drawings shall be on sheet with sizes and borders complying with the Preferred series of sheets, with filling margins. All electrical wiring and circuit diagrams shall be A3 size and all electrical layouts shall be on A1 size.
7.
Standard Drawing Scales: General Plan: Plans/Sections: Mechanical/Electrical/Structural: Line and Profile:
1:300 1:400 1:50 1:100 1:30 1:50 1:100 (Vertical) 1:500 1:1000 (Horizontal)
Drawing Sequence as follows: WWTP 0XX/XXXXX / 4000 / S001 Contract Number
Drawing Nos. Discipline Code Discipline Code C - General/Civil Project Code A - Architectural/ Landscaping S - Structural M - Piping/Mechanical P - Process/Sanitary E - Electrical
8.
CAD Standards Set-Up
Drawings shall be created with ACAD.DWG as the prototype drawing. Titleblock shall be a block containing attributes for the Titleblock Information (MWCI title block) Title block must not be exploded. Drawing origin shall be set to 0,0.
Border and Titleblock origins shall be set at the lower left-hand corner. Border and Titleblock shall be inserted at location 0,0 in Layer Titleblock. Limits shall be the Sheet size or the Border extremity.
Colors
Pen Number 1
Pen Color Red
Pen Thickness 0.20
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2 3 4 5 6 7
Yellow Green Cyan Blue Magenta White
0.50 0.40 0.05 0.30 0.10 0.60
Linetypes All linetypes shall be selected from the Autocad Standard Linetypes.
Text Styles All font style shall be Roman Simplex with the following text heights.
A1 Size Application Height Titles, Drawing Numbers 6 0.60 Sub-titles 4 0.40 General Notes, Material Lists Dimensions, others 2.5 0.20 2 3 Thickness Height 4
A3 Size
Thickness
0.40
0.30
0.20
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Line Number
All drawings for MCCs, Switchgear and Control Panel shall have the following line number allocation.
AC Distribution 1001 3000 DC Distribution 3001 5000 Control Wiring Diagram 5001 7000 Termination Diagram 7001 9000
Line number shall be used for wiring and terminal identification.
9.
Assembly Drawings
Drawings of assemblies of mechanical and electrical plant and machines shall include, where appropriate: Overall dimensions and mass (including the mass of the heaviest lift for maintenance); Finished sizes and tolerances of all wearing parts; Terminal point details; Expansion limits; Lubrication points; Minimum clearances; Welding preparation and procedures; For plant or plant items subject to pressure and temperatures higher than ambient; Design pressures and temperatures; Working pressures and temperatures; Test pressures and temperatures; Insets, where necessary, to ensure every item of the assembly is clearly shown; All points of support; All points of attachment of the plant to piping, conduits or other items supplied by others; Location of holding-down bolts or other points of support or anchorage. 10. Electrical Drawings
Graphical symbols used on drawings shall comply with the symbols contained in the current version of the appropriate standard (PEC, NEC or IEC).
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Electrical schematics for the installation shall include the following: Single Line and Block Diagrams are to describe the process control in simple terms using single line diagrams for instrumentation, controls, protection and control sequence, Including load schedule and calculation. Plant Layout Drawings shall show the location of all electrical equipment in relation to the plant. Equipment Layout Drawings and Cross sections shall show clearly the location, layout, labeling of the equipment mounted in switchgear, control boxes etc. and the location of cables supporting routing. Schematic Diagram Drawings shall show in schematic form all wiring and electrical equipment supplied under this Contract, together with all other circuitry to which this equipment is interconnected. Any relevant reference data supplied by the shall be incorporated. Drawings shall be in Ladder diagram format. Connection Diagrams/Termination Diagrams shall include all control panel and junction box connection diagrams and also interconnection diagrams. Bill of Materials/Parts List - All apparatus shall be listed in the Bill of Materials showing quantity, description, manufacturer and type, order number, installed location. Short Circuit Calculation of the whole system. Cable Routing Diagrams or Cabling Lists shall be supplied and shall show all cables involved in the contract together with cable identification number, cable type, length and connection positions. Cable lists may also be used.
11.
Mechanical Drawing
The Contractor shall submit detailed shop drawings and data prepared and organized by the Instrument Manufacturer who was designated at the time of bidding. These drawings and data shall be submitted as a complete bound package at one time within 60 calendar days after date of execution of contract, and shall include:
Data Sheets of Each Component, Together with a Technical Product Brochure or Bulletin The data sheets shall show: a. Component functional description used herein and on the Contractor's Drawings; b. Manufacturer's model number of other product designation;
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c.
Project tag number used herein and on the Contractor's Drawings;
d. Project system or loop of which the component is a part; e. Project location or assembly at which the component is to be installed; f. Input and output characteristics;
g. Scale range and units (if any) and multiplier (if any); h. Requirements for electrical supply; i. j k. Requirements for air supply (if any); Materials of component parts to be in contact with, or otherwise exposed to, process media; Special requirements or features.
A complete index shall appear in front of each bound submittal volume. A separate technical brochure shall be indexed in the submittal by system or loop. If, within a single system or loop a single instrument is employed more than once, one data sheet with one brochure or bulletin may cover all identical uses of that instrument in that system. System groups shall be separated by labeled tags.
Drawings Showing both Schematic and Wiring Diagrams for Control Circuits and/or Instruments Complete details on the circuit interrelationship of all devices within and outside each control board shall be submitted first, using schematic control diagrams. Subsequent to return of this first submittal by MWC, piping and wiring diagrams shall be prepared and submitted for review by MWC; the diagrams shall consist of component layout drawings to scale, showing numbered terminals on components together with the unique number of the wire to be connected to each terminal. Piping and wiring diagrams shall show terminal assignments from all primary measurement devices, such as flow meters, and all final control devices, such as samplers, pumps, valves, and chemical feeders. The Contractor shall furnish all necessary equipment suppliers shop drawings to facilitate inclusion of this information by the Single Instrument Manufacturer.
Assembly and Construction Drawings for each Control Board and for other Special Enclosed Assemblies for Field Installation These drawings shall include dimensions, identification of all components, surface preparation and finish data, nameplates and the like. These drawings shall also include other details including prototype photographs, to define exactly the style and overall appearance of the assembly; a finish treatment sample shall be included.
Installation, Mounting and Anchoring Details for all components and assemblies to be field-mounted, including conduit connection entry details. Complete and Detailed Bills of Materials including each field mounted device or assembly as well as cabinet assemblies and sub-assemblies. Bills of Materials shall include all items within an enclosure.
12.
As Built Manufacturing Drawings/Information
The drawings shall be supplied in loose-leaf binders with index to simplify location of a particular drawing.
Immediately following final successful works testing/commissioning, the Contractor shall revise all appropriate drawings and incorporate any modifications found necessary as a result of the tests. The Contractor shall then forward three (3) white copies, one (1) reproducible copy, and an electronic copy on diskette in AutoCAD 2000 format, of all documentation and drawings applicable for the installation. The Contractor shall also submit three (3) fair copies of test certification applicable to the installation. 13. Document List A document list shall be produced to show all documents being supplied under this Contract. This list shall show the document name, document number, paper size, latest revision number and highest sheet number used.
14.
Execution
No site work, other than standard equipment or controls, will proceed until such drawings or specifications have been reviewed and marked as satisfactory or released. Approved code numbers are only for engineering review and prior for approval for construction drawing. The Contractor shall seek permission for work order prior to approval of MWC.
Works not included in the scope of works shall proceed upon approval of variation order together with approved cost proposal.
1.22
QUALITY MANAGEMENT SYSTEM 1. The Contractor shall have in place a Quality Management System.
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2. The Contractor may be requested to submit copies of the Quality Management System operating procedures, working instructions and proforma that will be used during the Contract. 3. MWC reserve the right to audit or review the Quality Management System operated by the Contractor, or his Sub-Contractors, particularly as applied to the Contract. 4. The Contractor shall submit the initial version of their Quality Plan during the precommencement stage. The plan shall cover, but not limited to, the following: Policy statement Procedures and instructions to be used or developed for the Contract Organizational structure Authority and responsibility schedule Co-ordination of suppliers and interface management Inspection and test and commissioning plan
5. The Contractor shall seek endorsement of their Quality Plan to MWC prior to commencing work on site. All subsequent revisions shall be submitted to MWC for comment or information. 1.23 SAFETY 1. The Contractor shall submit a copy of the Construction Health and Safety Plan approved by the Bureau of Working Condition, Department of Labor and Employment, on the date agreed during the pre-commencement meeting. 1.24 MAINTAINING FLOW IN SEWERS 1. When the work is required on, to or adjacent to an existing live sewer, the Contractor must take all necessary measures, including standby provision if required, to deal with and maintain the flow in the sewer so as not to cause damage or inconvenience. 1.25 CONTROL OF NOISE AND VIBRATION FROM THE WORKS 1. The Contractor shall carry out the work in accordance with any enactment relating to noise. 2. Noise levels permissible during construction are given in the table below and are to be measured at 1 meter from the face of any noise sensitive building. For the purposes of this Contract, a noise sensitive building is classed as a) b) c) Boundary walls or fence of a single domestic dwelling; External face of building of a condominium or similar building; External face of building of a hospital/medical center. Time Period (24 hr clock) 0800-1800 1800-2200 2200-0800 0800-1200 1200-2400 All day
26
Day of Week
Overall Max (dB) 70 50 40 70 40 40

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Allowable 5 Minute Max (dB) 85 55 45 85 45 45
Monday-Friday Monday-Friday Monday-Friday Saturday Saturday Sunday

3. Noise assessments shall be included in method statement.
1.26
MANUALS FOR BUILDINGS AND STRUCTURES 1. All manuals shall be A4 or letter (8.5"x11") sized, hard bound, loose-leaf type. 2. The Contractor shall supply three copies of the manuals for approval by MWC. The period for review and approval shall be not less than 3 months. 3. The Contractor shall supply four copies of approved manuals prior to issue of the Taking-over Certificate. 4. The manuals shall contain as a minimum: a) Design i) ii) iii) Design Criteria Design limitations and durability considerations Construction history including site photographs
b) Location of Services i) Details of the location and nature of utilities and services, including heating and ventilation, emergency/fire fighting systems and emergency escape routes.
c) Requirements for Inspection and Maintenance i) ii) Itemization of those areas requiring periodic inspection and maintenance and frequency of such inspections and maintenance, including heating and ventilation. Description of hazardous areas and precautions to be taken during access to such areas.
d) Materials i) List and Specification of all materials and products used in the construction of the buildings together with names, addresses and telephone numbers of manufacturers, suppliers and sub-contractors.
e) Guarantees and Warranties i) The Contractor shall obtain copies of manufacturers guarantees and design warranties relevant to all building components and materials used in the construction.
f)
Demolition and replacement i) Details of any special measures required for demolition shall be provided where potential hazards are built into the structure, such as pre-tensioned beams or suspended floors.
1.27
PLANT OPERATION AND MAINTENANCE MANUALS 1. Requirements for Plant Operations and Maintenance Manuals, if required, shall be as specified in Mechanical and Electrical Technical Specifications.
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1.28
SPARES AND SPECIAL TOOLS In sufficient time to allow the items to be ordered and delivered before the Works are taken over, the Contractor shall provide the spares reference, the manufacturer, the manufacturers reference for the spare, the number used in the Works and the plant reference on which they are used. Spares supplied shall be suitably packaged for long term storage in an unheated store with the packaging clearly marked with the spares reference number. Spares shall be manufactured from the same materials as the originals. Spare Parts List The Contractor shall submit to MWC three (3) identical sets of spare parts lists for all equipment supplied or installed. The lists shall be headed by equipment name and numbers indicated in the as-built drawings and shall include the following: i. Current list price of each spare part. It shall be limited to those spare parts which each manufacturer recommends to be maintained by MWC in the inventory, and; The name, address, and telephone numbers of the nearest suppliers of the parts The spare parts lists shall be bound in standard size, lever arch file hard cover binders suitable for bookshelf storage. Binder ring size shall not exceed 75 mm.
ii. listed.
1.29
TESTS TO BE WITNESSED BEFORE DELIVERY 1. The Contract Specific Document lists the tests for equipment that MWC requires to witness before delivery.
1.30
DELIVERY 1. Where equipment is to be delivered to site, at least five working days before equipment is delivered to site, two copies of a written application for authority to deliver shall be submitted to MWC. The application shall show the items to be delivered and the proposed delivery date. 2. If delivered equipment is not to be immediately incorporated in the Works it shall be suitably protected, packed and stored. Each package shall have a list of contents on it and two copies of the lists submitted to MWC.
1.31
EQUIPOTENTIAL BONDING 1. It shall be demonstrable that equipotential bonding of equipment is carried out in accordance with the current regulations.
1.32
SANITARY PRECAUTION AND CONTROL 1. The Contractor shall employ the services of a licensed Sanitary Engineer to direct and supervise all Sanitary Engineering work in accordance with the provisions of Republic Act No. 1364 known as the Sanitary Engineering Law. 2. The Contractor shall be responsible for, and shall exercise all sanitary precautions and control at the job site to safeguard the public health and the living conditions of his men.
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1.33
SIGNS 1. The CONTRACTOR shall furnish, erect and maintain MANILA WATER COMPANY project identification signs for each working area. All signs shall be placed at strategic location designated by MWC. 2. The sign shall be 3M Scotchlite reflective sticker material or approved equivalent 4 feet by 8 feet in size and shall be posted in front of the construction site. The sign shall be placed and sticked on a Galvanized Iron sheet gauge #16 mounted on a steel frame acceptable to MWC. Layout plan and other information are shown in SD_MWC/450/C002. 3. For pipelaying and other excavation activities, the CONTRACTOR shall furnish a 3M Scotchlite reflective sticker material or approved equivalent 2 feet by 1.5 feet in size. It shall be sticked on aluminum or galvanized iron sheet gauge #16 and shall be placed and hang on a galvanized pipe A-Frame structure shown in the contract drawing SD/WSB/001. A minimum of two signs for every one hundred meters of open excavation shall be displayed while the construction is on going. Additional sign shall be placed on the corner of every street where there is change in the direction of the excavation activities. Layout plan and other information are shown in SD_MWC/450/C003. 4. Templates of MANILA WATER COMPANY logo and mascot are attached, SD_MWC_LOGO and SD_MWC_MASCOT respectively. 5. The CONTRACTOR shall submit layout to MWC before fabrication of any is made. The Corporate Department of the MANILA WATER COMPANY shall approve all layouts. 6. Upon completion of the work, all signs installed shall be removed from the site. 7. These signs shall be separate and distinct to the requirement of the MMDA, DPWH, LGU, Police and other safety signs.
1.34
PERSONAL SAFETY EQUIPMENT 1. The Contractor shall provide its personnel and visitors with appropriate safety equipment, such as helmets, safety footwear, gloves, waterproof clothing, dust masks and safety belts. The use of such safety equipment shall be compulsory. 2. Emergency equipment such as gas masks, signaling devices, flashlights in good working condition, etc. shall be stored in the Contractors office.
1.35
FIRE PRECAUTIONS 1. The Contractor shall organize a fire brigade equipped for the fighting of any fire that may break out on the construction site, in temporary structures, etc. An adequate number of fire extinguishers shall, at all times, be available at each construction site or camp and shall be maintained in satisfactory working order. Fire protection facilities shall be of the gas, dry powder or other suitable chemical or pumped water type.
1.36
DUST ABATEMENT 1. During the performance of the work and any associated operations, the Contractor shall carry out proper and efficient measures, acceptable to MWC, to reduce dust nuisance and to prevent any damage to crops, dwellings or causing nuisance to persons. The Contractor shall be held liable for any damage resulting from dust originating from his operations.
1.37
UNIFORM
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1. All employees of the Contractor working at the site shall be in uniform with the following color scheme: a. Supervisor b. Other workers White Manila Water Blue
2. The uniform may be a T-shirt and shall be painted with companys name and address and the MWC logo. 1.38 SURVEYING AND SETTING OUT WORK 1 The Drawings show the available survey information for the sites included in this Contract. Should the Contractor have any disagreements with this basic survey information and the relevant drawings, it shall inform MWC in writing not later than two (2) weeks after the Notice to Proceed. The Contractor shall perform all calculations, surveys and setting-out necessary to establish the accurate location of the structures as shown on the Drawings. The Contractor shall submit to MWC for review in advance of any setting-out work, a description of the methods and procedures it intends to use. The Contractor shall entrust the surveying works only to persons who, by their training and experience, have sufficient qualifications and knowledge to ensure proper fulfillment of the survey tasks assigned to them. For the performance of the survey, the Contractor shall provide a sufficient number of reliable and accurate instruments. If the Contractor chooses to use triangulation points or bench marks other than those furnished by MWC, he shall do so at its own expense and risk.
3 4
Bench Marks 6 The Contractor shall preserve and keep accessible or free from sight obstruction the benchmark of the basic survey provided by the Bid Drawings and those provided by him. Any accidental damage shall immediately be brought to the attention of MWC. Benchmarks shall be of stainless steel or cast iron. In softer soil, the steel bolt shall be embedded in a block of concrete of suitable size, and stable. Inscriptions shall be durable and clearly legible. Coordinate points may be marked by steel pipes or pegs, subject to the review of MWC. Every newly fixed point shall be checked, as far as possible through other elements than those served to establish the point.
8.
Auxiliary Works 9 The Contractor shall perform auxiliary works with regard to survey which include, but shall not be limited to, the following: a) Perform all necessary calculations with clear presentation of calculations and results in order to facilitate verification; b) Expose covered bench marks; c) Provide bench marks in lieu of and/or in addition to those of the Engineer; d) Remove machinery and obstructions from the required sight-lines;
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e) Stop all machinery, drilling, driving and other work causing ground vibration, stopping all smoke, dust, gas, etc. hindering clear view or causing refraction; f) Restrict or stop traffic of persons and vehicles near instruments or in sight-lines during instrument observations; g) Provide adequate lighting or cut-off sources of interfering light to ensure the necessary clear view; h) Provide an adequate number of laborers with experience as surveying aides, and materials as deemed suitable by the Engineer for control and auxiliary i) Remove all obstructive accumulation of water; j) Carry out additional topographic surveys in cases where the existing topographical data is insufficient for accurate measurement of the work; k) Carry out all necessary topographical surveys for the incorporation of measuring equipment, instruments, etc.; and l) Carry out all necessary topographical surveys for the observation of the behavior of structures during construction. Checking of Contractors Survey Work by the Engineer 10 The Contractor shall provide MWC the opportunity to check the construction survey work and shall, if required, assist MWC at any time in the performance of the control work. The Contractor shall, in due time, apply for these checks. Checks will usually be made during work breaks, but in cases of urgency, the Contractor shall restrict or stop affected work without being entitled to any reimbursement. Any checks by MWC shall not relieve the Contractor of his full responsibility for the accuracy of structures and parts of them with regard to their position and dimensions.
11 12
Damage to Crops and Vegetation 13 No trees or crops of economic value existing on the Site shall be damaged or removed by the Contractor during survey and cross-sectioning works prior to their enumeration and evaluation by MWC. As soon as a section of work has been defined and valued, the Contractor shall delineate the boundaries of the areas to be cleared by approved markings. The Contractor shall be responsible to secure permits and clearances for any trees or crops to be affected by the proposed project.
14. 15
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SECTION 2 MATERIALS 2.1 STANDARDS AND SUBMISSION OF MATERIALS 1. All materials shall bear the seal or mark of the agency that verified the suitability or compliance of said materials to the specific standard. 2. Shop drawings and samples of materials to be used shall be submitted for MWC approval. 3. After the Contract has been awarded, the Contractor shall submit to MWC for approval a list of his proposed suppliers and sources of materials required for the execution of the work. 4. The materials subsequently supplied shall conform to the quality of samples, which have been approved by MWC. 5. Names of additional suppliers and sources of materials may be submitted by the Contractor during the execution of the Contract, but no supplier and source shall be changed without the approval of MWC. 6. The contractor may submit for MWC approval an equivalent or better alternative materials than those specified in this specification.
7. All standards referred to herein shall mean the latest edition of that standard at the time of the issuance of the document.
8. Product and substance, which may come in contact with raw water to be treated or potable water, shall not be used unless they have prior approval of MWC.
Unless otherwise specified, at least three (3) samples of each material shall be submitted a minimum of fourteen (14) working days prior to ordering such material or equipment. Submission shall be in an orderly sequence so that dependent materials or equipment can be assembled and reviewed without causing delay in the work.
10 All samples shall be individually and indelibly labeled or tagged indicating thereon all specified physical characteristics and manufacturers names for identification. Upon receiving approval, one set of samples will be stamped and dated by MWC and returned to the Contractor for safe keeping in the site office until completion of the work. Unless otherwise specified, all colors and textures of specified items shall be selected by MWC from the manufacturers standard colors and standard product lines. 11 All materials to be used under this contract shall be ISO certified and applicable for industrial applications under Class D environment
2.2
STORAGE AND STOCKPILING OF MATERIALS 1. Materials and components shall be stored and stockpiled in such a manner as to preserve their quality and condition to the standards required by the Contract.
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2. The quantity of materials stored and stockpiled on the site shall be consistent and sufficient as required for the efficient implementation of work as scheduled. 2.3 HANDLING AND USE OF MATERIALS 1. Materials and components shall be handled in such a manner as to avoid any damage or contamination and in accordance with all applicable recommendation of the manufacturers.
2. Unless otherwise specified in the Contract, the use, installation, application or fixing of materials and components shall be in accordance with all applicable recommendations of the manufacturers. Where appropriate, the Contractor shall make use of any technical advisory services offered by manufacturers. 2.4 Topsoil 1. Topsoil shall be of a loamy character, free from roots, hard clay, coarse gravel, stones larger than 50 mm in size, coarse sand, weeds and other deleterious substances. It shall be capable of sustaining vegetation and shall be subject to the approval of MWC. 2.5 Turf 1. Turfs shall be 300mm wide and of uniform thickness not less than 40mm and length not exceeding 1 meter. 2. Where turf becomes unsuitable for relaying it shall be replaced with new. 2.6 Grass Seed 1. Grass seed shall be a mixture of grasses indigenous to the locality, free from undesirable types and weeds. The Contractor shall furnish MWC with full details of the mixture he proposes to use for acceptance. 2.7 Fertilizer 1. Fertilizer shall consist of compounds containing urea nitrogen, phosphoric acid and potash, commercially available. For general purposes, the constituents will be in the following properties: Urea Nitrogen 5%; Phosphoric Acid 15%; Potash 15%. 2.8 Trees and Shrubs
1. Trees and shrubs shall comply with the relevant provisions of the appropriate DENR standards.
2. No tree shall be cut without approval from DENR and MWC. 2.9 Aggregates for Concrete 1. Fine and coarse aggregates for concrete shall comply with the relevant provisions of ASTM C33.
2. Fine aggregates shall be washed natural sand conforming to ASTM C33. 3. Coarse aggregates shall be well graded and shall conform to ASTM C33.
2.10
Cement 1. Portland cement shall be factory-produced by the cement manufacturer and shall comply with the provisions of ASTM C150. 2. Blended hydraulic cements shall comply with the provisions of ASTM C595. 3. Masonry cement shall comply with the provisions of ASTM C91.
2.11
Admixture for Concrete and Grout 1. An admixture to the concrete may be used if approved by MWC in writing. Accelerating, retarding and water-reducing admixtures for concrete or grout shall comply with ASTM-C494. Such admixture may be a hydroxylated carboxylic acid type or a hydroxylated polymer type but shall contain no calcium chloride. 2. Calcium chloride shall not be used in concrete which is to be reinforced, contains embedded metal, or has been designed to retain an aqueous liquid. However, when used with sulphateresisting cement or in concrete to be reinforced or contain embedded metal the chlorine ion content of admixture shall not exceed 2% by mass of the admixture or 0.03% by mass of the cement. Admixtures containing chlorides shall not be used in reinforced concrete designed to retain aqueous liquid.
3. Admixtures for the production of Air-Entrained concrete shall comply with the requirements of ASTM C260.
4. Fly ash and natural pozzolans for use in concrete shall comply with the requirements of ASTM C618.
5. Ground granular blast furnace cements, for use in concrete shall comply with the requirements of ASTM C989. 2.12 Sand 1. Sand for grout shall comply with the requirements of ASTM C 404. 2. Sand for mortar shall comply with the requirements of ASTM C 144. 3. Sand fill shall consist of clean, inert, hard, durable grains of quartz or other durable rock, free from loam or clay, surface coatings, and deleterious materials. The allowable amount of materials passing a No. 200 sieve shall not exceed ten percent (10%) by weight. The maximum particle size shall be 6mm. 2.13 Pipe Surround Materials 1. Bedding and pipe zone materials for buried pipelines shall comply insofar as applicable with the following standards and manuals:
PIPE MATERIAL CI/DI PVC

STANDARDS AWWA C600 AWWA M 23

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SP FRP PE
AWWA M 11 ASTM D3839 ASTM D2774
2. Pipe surround materials for metal and concrete pipes shall be graded as follows: Pipe Nominal Diameter (mm) Up to 100 Over 100 to 300 Maximum Particle Size (mm) 6 10 Suitable Processed Granular Materials 6mm nominal single-sized 10 or 14mm nominal single-sized or 14 to 5mm graded 14 or 20mm nominal single-sized or 14 to 5mm graded 14 or 20 mm nominal single-sized or 14 to 5mm graded or 20 to 5mm graded
Over 300 to 550
14
Over 500
20
3. Pipe surround materials for plastic pipes shall be sand fill consisting of clean, inert, hard, durable grains of quartz, free from loam or clay and other deleterious materials. The allowable amount of materials passing a No. 200 sieve shall not exceed ten percent (10%) by weight. The maximum particle size shall be 6mm. 2.14 Dowel Bars 1. Dowel bars for expansion joints shall conform to the requirements of AASHTO M31 (ASTM A615) or AASHTO M42. 2. Dowel bars shall be straight, free from burrs or other deformations restricting slippage in the concrete. Before delivery to the site of work, a minimum of one half (1/2) length of each dowel bar shall be painted with one coat of approved lead or tar paint. 3. The sleeve for dowel bars shall be metal of an approved design to cover 50 mm plus or minus 6.3 mm of the dowel, with a closed end of the sleeves at least 25 mm from the end of the dowel bar. Sleeves shall be of such design that they do not collapse during the construction. 2.15 Steel Sheet Piles 1. Steel sheet piles, forming part of permanent works shall, before being driven, be wire brushed to remove loose rust and other contaminants. They shall then be coated with black coal tar based paint of approximate thickness 30 microns. 2. Steel sheet piles, whether forming part of the permanent works or not, shall comply with the provisions of ASTM A 6M and ASTM A 328M. 2.16 Trench Backfill Material 1. Materials that are free from grass, roots, brush or other vegetation, boulders or rock pieces having maximum dimensions less than 75 mm may be used as backfill materials. Selected Sandy Material
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2.17
1. Material that is free of organic matter, does not contain stone or rock fragments larger than 10 mm in greatest dimensions and is non-cohesive shall be used as selected sandy material. Not more than 50% of the material shall pass the No. 200 Sieve. The material shall lend itself to ease of compaction and shall be placed at a moisture content approaching its optimum for compaction. 2.18 Bank Run Gravel 1. This material shall be a durable and graded soil aggregate conforming to Type I gradations A through D and/or Type II gradations E and F of ASTM D-1241. Before placing this material, the Contractor shall submit representative samples to MWC for approval. 2.19 Crushed Stone Bedding 1. Crushed stone bedding material shall be hard, durable crushed rock or gravel, free draining, free from organic matter and graded to comply with the following limits: CLASS A Sieve Size 25mm 20mm 15mm 10mm 5mm CLASS B Sieve Size 38mm 25mm 20mm 15mm 10mm 2.20 Embankment Materials 1. Embankment materials shall be free from brush, roots, grass or other organic materials. Cobbles and rock pieces having a diameter less than 150mm may be used. The amount of material passing the No. 200 sieve shall not exceed 50% by weight. 2.21 Lime for Mortar 1. Lime for mortar shall be in the form of putty complying with the relevant provisions of ASTM C207. 2.22 Cement Grout 1. Cement grout shall be mixed in the relevant proportions indicated in the following table, using the minimum quantity of water to ensure the necessary fluidity and to render it capable of penetrating the works.
Percent by Weight passing 100 90-100 10-50 0-20 0-5
Percent by Weight passing 100 90-100 10-50 0-20 0-5
Class G1 G2 G3
Nominal Mix by Mass Cement Sand 1 1 1 3 10
2. Cement grout shall be used within one hour of mixing except when containing retardant admixture. 3. Non-shrink grout shall be pre-bagged and conform to the requirements of ASTM C1107. 4. Admixture for concrete and grout shall comply with ASTM C494. 5. Sands for grout shall comply with ASTM C404. 2.23 Steel Reinforcement 1. Bar reinforcing steel shall be Hot-rolled non-weldable deformed, new billet bars conforming to ASTM A615, Grade 40 for bar <12 and Grade 60 for bar 16 unless otherwise specified on Drawing, or its equivalent under PNS-49. Steel reinforcement shall be free from loose mill and rust scale and from coatings that may destroy or reduce the bond. 2. Steel mats or fabric shall comply with ASTM A 185, ASTM A 497 or ASTM A 704M as detailed on the Drawings. 3. Steel reinforcement shall bear mill identification symbols and shall be tagged with the size and mark number so that different types may be identified. They shall be stored off the ground. 4. The following steel bar sizes shall be used for all reinforced concrete design: Bar Designation 10 12 16 20 25 28 32 36 Approximate Cross Sectional Area (mm) 78.54 113.10 201.06 314.16 490.88 615.75 804.25 1017.83 Approximate Unit Weight (kg/m) 0.616 0.888 1.578 2.466 3.853 4.834 6.313 7.990
5. Testing of steel reinforcement shall conform to PNS 49. 6. Every batch of steel reinforcement delivered to the site shall be tested to verify mass and tensile properties for every shipment of 5,000 kg or fraction thereof. 7. The test shall consist of 5 specimens. Abbreviated testing may be considered on a particular batch at the discretion of the Engineer. If the bar pattern of the specific diameter is acceptable for abbreviated testing the test shall consists of 3 specimens. 8. The specimen should be selected from different bars in the batch. A batch (lot) is defined as any quantity of bars of the size and grade manufactured by the same mill, covered by the same mill certificate and delivered to the site at any one time. Steel bars in more than one
delivery to the site within a short period may be considered as part of the same batch provided that the deliveries belong to one single consignment from the manufacturer and are covered by the same mill certificate. 9. Schedule of all reinforcement shall be for review and approval of MWC before fabrication. Bar cutting and bar lists shall be detailed in accordance with ACI 315. 2.24 Joint Filler Material 1. Pre-formed filler for joints shall conform to the requirements of AASHTO M33 (ASTM D994), AASHTO M153, AASHTO M213 or AASHTO M220, ASTM D1056, D1751 & D1752 2. Holes in pre-formed joint filler shall be accurately bored or punched out to accommodate dowel bars. 3. The material comprising the joint filler shall be of such quality that it can be satisfactorily installed in position at the joint. 4. Adhesives used to retain pre-formed joint fillers in place during construction shall have no harmful effects on concrete and shall be obtained from the manufacturer of the joint filler. 5. Pre-formed filler for joints in structures to retain aqueous liquids shall have a maximum water absorption of 0.30% by volume and a non recovered compression set of 20% of the original thickness, both tested in accordance with ASTM D3574. 2.25 Tying Wire 1. Tying wire for steel reinforcement shall be Gauge 16, GI wire conforming to ASTM- A82. 2.26 Formworks 1. Forms shall be of wood, plywood, steel, or other approved material, free from roughness and surface irregularities. 2. Except as otherwise expressly approved by MWC, all materials brought on the job site for use as forms, shoring or bracing shall be new material. 2.27 Cover Blocks and Spacers for Reinforcement 1. Cover blocks and spacers shall be designed to maintain the correct clear cover of concrete over steel reinforcement, shall be as small as possible, consistent with their purpose and of a shape acceptable to MWC. 2. Concrete cover blocks shall be manufactured with a 10mm aggregate size and otherwise produced to the same specification as the surrounding concrete. Wire cast in the block for the purpose of tying it to the reinforcement shall be Gauge 16 GI wire in accordance to ASTM A82. 3. Spacers shall be of rustproof material and shall not produce staining or otherwise be detrimental to the concrete or steel. 2.28 Waterstops 1. PVC waterstops shall be of plasticised PVC complying with the relevant provision of ASTM D412/D746/D747/D792. 2. Rubber waterstops shall have the following properties when tested in accordance with the relevant part of BS 903:
Part of BS 903 A1 A26 A2 A2 A16
Property
Requirements
3
Density Hardness Tensile Strength Elongation at break point Water absorption (48 hours immersion)
1100 kg/m (+ 5%) 60 70 IRHD 2 not less than 17.5 N/mm not less than 45% not exceeding 5%
PVC waterstop materials shall be an elastomeric plastic compound, the basic resin of which shall be polyvinyl chloride, and containing any additional resins, plasticizers or other materials needed for the material to comply with the requirements specified. PVC waterstop material shall meet the following physical requirements: Physical Property Tensile Strength min. MPa Ultimate Elongation min. ( %) Low Temp. Brittleness Stiffness in Flexure min. MPa Specific Gravity - max. Accelerated Extraction Effect of Alkalies Water Absorption max. (%) * U.S. Corps of Engineer Value 14.0 300 Pass 8.3 1.4 Pass Pass 0.5 ASTM Std. D412, Die C D412, Die C D746 D747 D792 CRD C572* CRD C572* D570
4 5
Waterstops shall be 210mm x 9mm thick multi-rib type with center bulb for construction, control and expansion joints. Waterstops for all joints shall be continuous around the corners and intersections, either in horizontal or vertical direction, as indicated on the Drawings. Field splices and joints shall be made in accordance with the water stop manufacturers instruction, using a thermostatically controlled heating iron.
2.29
Bricks and Blocks 1. Bricks shall comply with the provisions of the relevant standards in the table below: PURPOSE/USE General purpose building brick Facing bricks Concrete building bricks Sewer and manhole bricks ASTM C62 C216 C55 C32
2. Concrete hollow blocks shall comply with the provisions of PNS 16. 2.30 Mortar 1. Mortar shall be mixed only as and when required in the relevant proportions indicated in the following table, until its color and consistency are uniform. The constituent materials shall be accurately gauged, allowance being made for bulking of sand.
Class
Cement: lime Putty:Sand
Nominal Mix by Volume Cement: Sand with Plasticizer 1:2- /2 to 3 1:3 to 4 1:5 to 6 1:7 to 8
1
Class
Masonry Cement: Sand

1
M2 M3 M4
1:0 to :3 1 1 1: /2:4 to 4- /2 1:1:5 to 6 1:2:8 to 9
M5 M6 M7 M8
1:2 to 2- /2 1 1 1:2- /2 to 3- /2 1:4:5 1 1 1:5- /2 to 6- /2
2. All mortar shall be conveyed fresh to the work as required for use. Mortar which has begun to set or which has been site-mixed for a period of more than one hour in the case of Classes M1, M2, M5 and M6, and two hours in the case of Classes M3, M4, M7 and M8 shall not be used. 3. Mortar for making good holes cut through existing concrete walls shall be Class M2, with the addition of an epoxy compound, mixed in accordance with the manufacturers instructions. Alternatively, a proprietary ready mixed epoxy mortar may be used. In either case, the Contractor shall provide full details of his proposal to MWC for review. 4. Non-shrink grouts and mortars shall be a ready mixed proprietary brand, mixed and used entirely in accordance with the manufacturers instructions. The Contractor shall provide full details for MWCs review. 2.31 Joint Sealant 1. Joint sealant for concrete shall be all approved one component joint sealing compound on Polyurethane base and shore hardness of at least 35 after a 7 day curing period. The shore hardness shall be as defined in ASTM D2240. 2. Self-leveling type sealant shall be used in all horizontal joints in slabs. 3. Non-sagging type sealant for all wall and overhead joints. 4. Primer shall be a recommended by the sealant manufacturer. 5. The bond breaker (non-liquid) between sealant and joint filler shall be polyethylene or other release material approved by the engineer. 6. Joint sealant used for precast concrete shall be SIKAFLEX-T68 or approved equal. 2.32 Cast Iron Pipes and Fittings 1. Cast iron pipes and fittings shall conform to the requirements of ISO 13. 2. Fittings shall conform to AWWA C110. 3. Cast iron pipes and fittings and special castings shall be lined with cement mortar to conform to AWWA C104. 4. Pipes and fittings shall have an outside bituminous coating of coal tar base approximately 25 microns thick.
5. The nominal wall thickness of cast iron pipes shall not be less than as given in the following table:
NOMINAL DIAMETER MM 50 75 100 150 200 250
OUTSIDE DIAMETER MM
* Nominal Wall Thickness (mm) 7.2 7.5 8.3 9.2 10.0
98 118 170 222 274
* with tolerance = - (1 + 0.05t)
2.33
Cast Iron Soil Pipes 1. Cast iron soil pipes and fittings shall conform to the relevant provisions of ASTM A74. 2. The pipe and fittings shall be coated with coal tar or similar material. 3. Cast iron soil pipe and fittings shall have bell-and-spigot ends with rubber gaskets conforming to the requirements of Class Extra Heavy Cast iron soil pipes and fittings of ASTM A74.
2.34
Ductile Iron Pipes and Fittings 1. Ductile iron pipes and fittings shall comply with the relevant provisions of ISO 2531. 2. Pipes and fittings shall have an outside coating of coal tar base approximately 25 microns thick. 3. Ductile iron pipes and fittings shall be cement mortar lined to conform to either AWWA C104 or ISO 2531. 4. Wall Thickness for Ductile Iron Pipes
Nominal Diameter (mm) 50 75 100 150 200 250 300 350 400 500
Outside Diameter (mm) 98 118 170 222 274 326 378 429 532 635
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*Minimum Wall Thickness (mm) 6.0 6.1 6.3 6.4 6.8 7.2 7.7 8.1 9.0 10.0
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600 * Wall Thickness is strictly minimum, no negative tolerance is allowed. 2.35 Steel Pipes and Fittings 1. Steel pipes and fittings shall comply with the relevant provisions of AWWA C200. 2. Steel pipes shall be lined either in the shop in accordance with AWWA C205 or AWWA C210 or in place in accordance with AWWA C602. 3. Steel pipes shall be coated either in accordance with AWWA C203 (coal tar enamel) or AWWA C205 (cement mortar lining and coating). 4. Steel cylinder for pipe and fittings shall be fabricated from hot-rolled steel sheets or plates conforming to ASTM A283 Grade D, or ASTM A570 Grade C with a minimum yield point of 227.50 MPa. 5. Dimensions for steel fittings shall conform to AWWA C208. 6. Joints may be of the following types: a) b) c) d) Mechanical Type Push -on-type Welded joints Shop Welded flange
7. All requirements pertaining to the thickness, application and curing of lining specified for straight pipe shall also apply to fittings except that if the fitting can not be lined centrifugally, it shall be lined by hand.
8. Minimum Wall Thickness for Steel Pipes (for depth of cover of 1.20m to 2.5m only) shall be as follows: Nominal Diameter (mm) 400 450 500 600 750 900 1050 1200 9. Acceptable Joints a) 400mm to 500mm Joints shall be flanged, or shall be plain end on sleeve-type coupling. b) 600 and above Welded joints will be acceptable, provided the Contractor can demonstrate his ability to restore lining in-situ in advance of the work being undertaken. 2.36 Unplasticized Polyvinyl Chloride (uPVC) Pipes and Fittings Water Nominal Wall Thickness (mm) 4.76 4.76 4.76 4.76 6.35 7.93 7.93 8.10
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1. Unplasticized PVC pressure pipes and fittings shall comply with the relevant provisions of AWWA C900 and C905 and PNS-65.
2. Unplasticized PVC pressure pipes and fittings shall be extruded blue. 3. Pipe rating shall be Series 8 conforming to PNS-65.
4. Joints shall be push-on-type joints or plain end on couplings. 2.37 Unplasticized Polyvinyl Chloride (uPVC) Pipes and Fittings Sewer 1. Unplasticized PVC pipes and fittings for sewers and drains shall conform to the provisions of ASTMD2729, ASTMD 3034, ASTM F679 and ISO 4435. 2. The Standard Dimension Ratio (SDR) for unplasticized sewer and drainpipes shall be equal to or less than SDR 26 for pipe with an earth cover of 3-5 meters and SDR 34 for pipe with an earth cover less than 3 meters. 3. The tolerances for outside diameter and wall thickness for unplasticized sewer and drainpipes shall be in accordance with ISO 3606. 2.38 Polyethylene Pipes and Fittings 1. Polyethylene pipes and fittings shall be made from non-toxic materials and shall be colored blue. 2. Extrusion compounds for pipes and fittings shall be: a) HPPE - ELTEX TUB 124 - RIGIDEX 3100
b)
HDPE - KEMCOR HD 2468 - RIGIDEX PC 001-55 - DOWPLASTICS BG10150
c)
MDPE - KEMCOR 0898 - RIGIDEX MDPE
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Contractors may submit to MWC alternative extrusion compounds for consideration, however, the Contractor will have been expected to proposed such alternatives with its bid. Any such alternatives will be subject to third party testing, the successful results of which may lead to the inclusion of such alternatives to the approved compounds listed above.
3. Pipe and tubing rating and dimensions shall conform to ISO 161, SDR = 11. 4. Joints shall be selected from the following: a) Thermal butt fusion b) Flange assembly, which may consist of polyethylene stub-end, butt-fused to end of the pipe and metal slip-on-flange. c) Victaulic coupling with special stub-ends designed to accept the coupling butt fused to end of the pipes. d) Loose flange adaptors with polyethylene pipe anchoring facility. 5. Fittings for PE tubing shall have compression type joints. Composition, sampling and testing of fittings shall be in accordance with ASTM B584. 6. Threads of coupling shall be in accordance with ISO 228 and ISO 7. 7. Insert stiffeners shall be applied to all compression joints and shall be stainless steel type 304 or 316, as per ASTM A480M. 8. Inspection and testing of pipes and tubing shall be in accordance with ASTM D1248 and D241. 2.39 Fiberglass Pressure Pipe 1. Fiberglass pressure pipes and fittings shall comply with the relevant provisions of AWWA C950. 2. Testing .of pipes and fittings shall be in accordance with AWWA C950 or ASTM D3517. 3. Stiffness of Fiberglass Pressure Pipes shall be 10000 N/m or 15000 N/m depending on the design requirements. 4. Joints Joints shall be any of the following: a) b) c) d) Push-On Type Plain End to Bell Plain End to Fiberglass Coupling Flange Joint
2 2
5. The Contractor shall demonstrate the use of the suppliers product in similar circumstances. 6. Fiberglass pressure pipe shall only be used when ground conditions are suitable. The Contractor shall demonstrate that the ground conditions conform to the recommendations of the pipe supplier.
2.40
Marker tapes 1. Marker tape for buried water mains shall be colored orange PVC or polyethylene mesh or ribbon at least 50mm wide, incorporating a corrosion resistant tracing system. 2. The ribbon shall be printed with the words WATER PIPES BELOW" or SEWER PIPES BELOW in bold capital letters at intervals not exceeding 500mm.
2.41
Joint Seals and Lubricant 1. Elastomeric joint seals for water mains and drainage pipes for push-on and mechanical joints shall be generally stylene butadiene rubber (SBR), unless specified otherwise by the manufacturer and shall be obtained from the manufacturer. 2. Joint lubricants shall have no deleterious effects on either the joint rings or the pipe material and shall be unaffected by the conveyed liquid. In the jointing of water mains, lubricants shall be non-toxic, nor shall it impart taste, odor or color to the water and shall not support bacterial growth. The Contractor shall submit a non-toxicity test conducted by an independent laboratory acceptable to MWC at his expense.
2.42
Flanges for Pipes 1. Flanges for pipes and fittings shall comply with the standards given in the following table as applicable: PIPE/FITTING TYPE FLANGE SPECIFICATION STANDARD ISO 13 ISO 2531 AWWA C207
CI DI SP
2. Flange mating dimensions and drilling shall conform to ISO 7005. 3. Pressure rating for flanges shall be as stated in the Contract Specific Specification. 2.43 Gaskets for Flanged Joints 1. Gaskets for flanged joints shall generally be of the inside-bolt-circle type. They shall have a nominal thickness of 3mm and shall be EPDM Rubber or Neoprene. 2.44 Valves 1. Valves for pipeline installation shall comply with the relevant provisions of the appropriate AWWA standard as set out below: Type AWWA STANDARD AWWA 509
Resilient Seated Gate Valve Air Valve
AWWA 500
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Check Valve Rubber Seated Butterfly Valve
AWWA 500 AWWA C504
2. Valves shall have flanged ends in accordance with ISO 7005. 3. All valves shall be coated and lined with 100% powder epoxy. 4. The pressure rating of valves shall be as stated in the Contract Specific Specification. 2.45 Pre-Cast Concrete Manholes
1. Pre-cast concrete sections shall conform to ASTM C76, Class IV Wall C or Wall B. Sections shall have tongue and groove joints. 2. Pre-cast concrete manhole units of circular section shall comply with the relevant provisions of ASTM C76, Class IV, Wall C/B. Units which bed into bases shall be designed and manufactured so that the imposed vertical loads are transmitted directly through the full wall thickness of the unit 2.46 Manhole Frames and Covers 1. Manhole covers and frame casting shall comply with the following: Type Cast Iron Casting Malleable Iron Casting Cast Steel Casting Standard Class 30C ASTM A48 Grade 35018 ASTM A47 Grade N2 ASTM A 27
2. Manhole covers and frames shall have a minimum clear opening of 600mm. All covers shall be non-rocking. 3. Locking keys and lifts handle or pry bar hole shall be provided with the frames and covers. 4. Frames and covers shall be designed to carry AASHTO H-20 traffic loading. 2.47 Manhole Step Iron (Ladder Rungs) 1. All ladder rungs shall be cross cut serrated stainless steel A 304 of 20mm diameter
2. Steps shall have a serrated drop section surface designed for non-slip use and fixed at 400mm vertical center, not more than 150mm from the top of the manhole chamber and not more than 400mm from the bottom. 2.48 Vitrified Clay Pipes and Fittings 1. Vitrified clay pipes and fittings shall comply with the relevant provisions of ASTM C700. The strength shall be as noted on the drawings.
2. Joints for vitrified clay pipes and fittings shall be in accordance with the provisions of ASTM C425. 2.49 Reinforced Concrete Pipes and Fittings 1. Reinforced concrete pipes and fittings shall be designed in accordance with ASTM C76M. 2. Cement shall conform to ASTM C150 Type II and shall not contain more than 0.60% total alkali as determined in accordance with ASTM C14M. 3. Aggregates shall meet the requirements of ASTM C33 except the requirements for gradation shall not apply. 4. Steel reinforcement shall be either conforming to ASTM A82 or ASTM A496, welded wire mesh conforming to ASTM A185 or ASTM A497, or plain billet-steel bars conforming to ASTM A615M. 5. The pipe shall have bell and spigot type joints with a groove either on the bell or in the spigot to retain a rubber gasket. 6. Fittings for use in laying reinforced concrete pipe shall be of equal thickness of wall and minimum cover for reinforcement as required for pipe. Fittings shall be shop-fabricated unless otherwise specified or shown on the drawings. 2.50 Unreinforced Concrete Pipes and Fittings 1. Unreinforced concrete pipes and fittings shall comply with the relevant provisions of ASTM C14. 2. Fittings shall be of at least equal thickness of wall as required for pipe. 3. Cement shall conform to ASTM C150, Type II and shall not contain more than 0.60% total alkali as determined in accordance with ASTM C14M. 4. Aggregates shall meet the requirement of ASTM C33 except that the requirement for gradation shall not apply. 5. The pipe joints shall have bell-and-spigot joint with a groove either on the spigot or in the bell to retain a rubber gasket. 2.51 Hydrants 1. Unless otherwise indicated in the Drawings or Contract Specification, hydrants shall be either of the traffic model type or spring type, manufactured in accordance with AWWA. 2. For spring type hydrant, hinges, washers, bolts and valve keys shall be stainless steel as per ASTM A276 type 304. 2.52 Electrodes, Filler Rods and Wires for Welding 1. Electrodes, filler rods and wires shall be compatible with the grade of steel to be welded and shall be in accordance with the steel or plate manufacturers recommendation. 2.53 Precast Concrete Segments for Tunnels and Shafts 1. The minimum 28 day characteristic strength of concrete used in the manufacture of segments shall be 40 MPa.
2. Concrete shall be sampled and tested for compliance with the specified characteristic strength in accordance with the provision of ASTM C39. Sampling shall be at a rate of not less than one sample per 20 cubic meters of fresh concrete. All segments shall have the date of manufacture clearly marked in an appropriate position at the time of manufacture. 3. Segments shall not be removed from the moulds until the concrete cube strength has reached 10 MPa and no segments shall leave the place of manufacture or be used in the Work until 28 days after casting. Copies of test cube results shall be sent to MWC and segments shall not be incorporated into the Permanent Work until MWC is satisfied that the relevant test results confirm that the concrete complies with the specified characteristic strength. 4. Segments shall be cast with such accuracy and uniformity of dimensions that all similar segments shall be interchangeable, not only with individual rings, but with corresponding segments of other rings. All surfaces of the segments shall be free from cracking, honeycombing, or other blemishes. 5. Segments shall be manufactured to the following tolerances:
Nominal Dimension
Permissible deviation (mm) 1.5 3 3 (on back face only) 1.5
Circumferential length Radius of curvature Thickness Width
6. The Contractor shall ensure that segments can withstand handling, erection, and any shield thrust stresses, without cracking, spalling or distortion. 7. The clear cover of concrete over any steel reinforcement shall be not less than 12mm and spacers shall be of rustproof material. 8. All segment joint faces shall have a caulking rebate, which shall be of minimum size 20mm deep by 3mm wide for bolted segments and 10mm deep by 3mm wide for smoothbore segments. 9. Where grouting is described in the Contract, all segments shall have at least one grout hole of 50mm diameter. 10. Tapered segments for curves shall comply with the general requirements of this Clause, each segment having the radius and the location of the segment within the ring, clearly marked. Segments shall be symmetrically tapered. 2.54 Bituminous Jointing Strip 1. Jointing strip for pre-cast concrete tunnel and shaft segments shall be bitumen-based, 3 mm minimum thickness and be suitable for the size and type of segments with which it is to be used. Where boltholes are required, they shall accurately match, in size and position, the corresponding holes in the segments. 2.55 Packing for Tunnels 1. Packing pieces for joint gaps in bolted tunnels segments shall be band-sawn, knot-free preserved softwood.
2.56
Grummets 1. Grummets shall be of gel-impregnated hemp or plastic and have thickness before compression of not less than 10mm. Grummets shall have a tight fit on, and shall have an external diameter at least 25mm greater than the bolts on to which they are fitted.
2.57
Nuts, Screws, Washers and Bolts 1. Bolts, anchor bolts, nuts and washers shall be of low carbon steel, grade B of ASTM A307 and shall be hot-dipped galvanized in accordance with ASTM A153. Bolt head and nut shapes shall be hexagonal and shall conform to ISO 272. Each bolt shall be long enough to extend entirely through the nut but not more than four (4) threads beyond. Washers shall be provided under nuts and under the heads of bolts. 2. Bolt length shall be sufficient to ensure that nuts are full threaded when tightened in their final position. 3. Stainless steel nuts, screws, washers and bolts when submerged shall comply with the relevant provisions of ASTM F593 and ASTM F594. 4. Where bolting is incompatible with the material being fixed, suitable isolating washers and sleeves shall be used.
2.58
Sleeve Type Coupling
1. Sleeve type coupling shall be in accordance with AWWA M11. The middle ring and followers shall be coated internally with coal tar epoxy seal coat in accordance with AWWA C 210.
2. The coupling shall be coated and lined with 100% powder epoxy.
2.59
Brass Fittings 1. Brass fittings shall be manufactured of leaded red brass with the following analysis: Metal Copper Tin Lead Zinc Component % 85 5 5 5
The composition, sampling and testing of the metal shall be in accordance with ASTM B 584. 2. Corporation stops, straight coupling adaptors and ferrules shall be male threaded on the inlet ends tapered ISO 7 and compression joint at the outlet end.
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3. Service stops and angle valves shall be female threaded ISO 7 tapered threads on the outlet end and compression joint at the inlet end. 4. Compression joints for tubing shall be provided with stainless steel stiffener and lock ring to prevent pull out. 2.60 Saddles 1. Saddles for uPVC pipe shall be made of cast iron. Saddles for cast iron and ductile iron shall be made of cast iron with single or double strap. Straps shall be made of red brass or of steel coated with epoxy or hot-dip galvanized in accordance with ASTM A 153. Welded straps shall not be accepted. 2. Saddles shall be constructed from one or a combination of the following metals: a) Ductile Iron - Minimum tensile strength of 415 MPa in accordance with ASTM A 536. b) Red Brass - 85-5-5-5 in accordance with ASTM B 584. c) Cast Iron - Gray Iron in accordance with ASTM A 48, Class 30.
5. Saddles for all pipe materials shall be shaped to fit various pipe diameters. Gaskets shall be provided for all saddles and shall be either Buna N or Neoprene rubber. 2.61 Rubber Gaskets for Mechanical and Push-On Joints 1. Rubber gaskets for mechanical and push-on joints shall be continuous ring-type, made of special composition rubber in accordance with the respective pipe standard specifications. Each gasket shall have a dense, homogenous section, a smooth surface free of blisters, pits and other imperfections and shall be of sufficient volume to fill the groove when the joint is assembled to make the joint watertight. 2.62 Valve Boxes 1. CI Valve boxes shall be installed where required or as determined by MWC. Valve boxes shall be of the telescopic slide type or screw type with hinge cover installed. CI shall conform to ASTM A126 Class B. 2.63 Plastic Sheeting 1. Plastic sheeting for waterproof underlay shall be free from tears and voids and shall be substantially free from pinholes and other discontinuities. It shall comply with ASTM D2103. 2.64 Structural Steel 1. Structural steel sections shall comply with the relevant provisions of the following standards, as detailed on the drawings: Structural Steel, ASTM A36 Welded and Seamless Steel Pipe, ASTM A53, Grade B High-Strength Low-Alloy Structural Steel, ASTM A242 High-Strength Low-Alloy Structural Manganese Vanadium Steel, ASTM A441 Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes, ASTM A500 Hot-Formed Welded and Seamless Carbon Steel Structural Tubing, ASTM A501 High-Yield Strength Quenched Tempered Alloy Steel Plate, Suitable for Welding, ASTM A514 Structural Steel with 290 MPa Minimum Yield Point, ASTM A529
Hot-Rolled Carbon Steel Sheets and Strip, Structural Quality, ASTM A570, Grades D and E High-Strength Low-Alloy Columbian-Vanadium Steels of Structural Quality, ASTM A572 2 High-Strength Low-Alloy Structural Steel with 345 Mpa Minimum Yield Point to 100 mm Thick, ASTM A 588 Steel Sheet and Strip, Hot-Rolled and Cold-Rolled, High-Strength, Low-Alloy, with Improved Corrosion resistance, ASTM A606 Steel Sheet and Strip, Hot-Rolled and Cold-Rolled, High-Strength, Low-Alloy, Columbian and/or Vanadium, ASTM A607 Hot-Formed Welded and Seamless High-Strength Low-Alloy Structural Tubing, ASTM A618 2. The Contractor shall furnish MWC with affidavits stating that steelwork provided meets the required specification. 2.65 Aluminum and Aluminum Alloy 1. Aluminum and Aluminum alloys shall comply with the provisions of the appropriate standard, listed in the table below: USE/PURPOSE Aluminum Alloy Extruded structural pipe and tube Aluminum Alloy Rolled tread plate Aluminum Alloy Structural shapes Aluminum and Aluminum Alloy Drawn Seamless Tube Aluminum and Aluminum Alloy Drawn Tube, general purpose Aluminum and Aluminum Alloy Extruded bars, rods, wire shapes & tubes Aluminum and Aluminum Alloy Sheet and plate 2.66 Timber for Carpentry and Joinery 1. Timber shall be a seasoned, dry and free from large, loose and unsound knot, sap bleeding, shakes or other imperfections. All exposed timber shall be smoothly dressed and well sanded. 2. Generally timber species, unless otherwise indicated on the Drawings shall be as the following table: Use/Purpose Timber exposed to the weather, such as doorframes, window frames, and external joinery. Timbers in direct contact with masonry or concrete. Timber for general internal carpentry purposes, i.e. internal framing, joists, studs etc. Timbers to receive paint finishes. 2.67 Glass for Glazing 1. Unless otherwise indicated on the Drawings, glass shall be tinted plate glass, of thickness as shown in the drawings. 2. Glazing compound shall be non-setting and pigmented to match the colors of the glazed units. Species Guijo or Yakal ASTM B429 B632M B308M B210M B483M B221M B209M
Apitong Tanguile
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2.68
Paints and Painting Materials for Building 1. Ready mixed glass paints for buildings shall be external quality. Colors shall be as painting schedule as shown on the Drawings. 2. Boiled linseed oil for paints and varnishes shall comply with the requirements of ASTM D260. 3. Knotting, for use as an impervious covering for knots and resinous areas shall be site mixed and comprise equal parts, by volume, of shellac flakes and methylated spirits. 4. Stopping shall comprise a mixture of one-third white lead and two-thirds ordinary whiting and linseed oil putty, with a small quantity of gold size. 5. Paint remover shall be non-flammable, solvent based. 6. All paint materials shall be first class quality. The Contractor may select another bonafide and reputable manufacturers product, providing it first satisfies MWC that the selected product is equivalent in quality to those specified, and also receives approval in writing to use the substituted paint product. However, all paints shall be obtained from the same manufacturer as far as possible.
2.69
Water 1. Water for use with cement or in contact with potable water mains and installations shall be potable, clean and free from deleterious amount of acid, alkali, oil and organic matter.
2.70
Fasteners
1. Common Nails shall conform to UBC Standard 25-17 unless otherwise specified or shown. Nails shall be galvanized, aluminum or stainless steel as appropriate where exposed to weather.
2.71
Handrails and Balusters 1. Handrails and balusters shall be manufactured from material complying with the provisions of the appropriate Philippine Standards. 2. After manufacture, mild steel and aluminum handrails and balusters shall be hot dip galvanized or anodized, as appropriate, in accordance with ASTM A513.
2.72
Safety/Gate Chains 1. Mild steel chain shall be 8mm nominal size non-calibrated chain. After manufacture, mild steel shall be hot dip galvanized in accordance with ASTM A513. When tested each chain shall withstand a breaking force of 30 KN and a proof force of 15 KN. Chain links shall be welded and have an internal length not exceeding 45mm and an internal width of between 12mm and 18mm. The fins caused by welding shall be removed and the weld shall be smoothly finished all round.
2.73
Liquid Chlorine 1. Liquid chlorine shall conform to ANSI/AWWA B301.
2.74
Sodium Hypochlorite
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1. Sodium Hypochlorite shall conform to AWWA B300. 2.75 Calcium Hypochlorite 1. Calcium Hypochlorite shall conform to AWWA B300. 2.76 Aggregate Subbase Course 1. Conform to Item 200 of DPWH Standard Specifications, Highways, Bridges and Airport. 2.77 Aggregate Base Course 1. Conform to Item 201 of DPWH Standard Specifications, Highways, Bridges and Airport. 2.78 Crushed Aggregate Base Course 1. Conform to Item 202 of DPWH Standard Specifications, Highways, Bridges and Airport. 2.79 Lime Stabilized Road Mix Base Course 1. Conform to Item 203 of DPWH Standard Specifications, Highways, Bridges and Airport. 2.80 Portland Cement Stabilized Road Mix Base Course 1. Conform to Item 204 of DPWH Standard Specifications, Highways, Bridges and Airport. 2.81 Asphalt Stabilized Road Mix Base Course 1. Conform to Item 205 of DPWH Standard Specifications, Highways, Bridges and Airport. 2.82 Portland Cement Treated Plant Mix Base Course 1. Conform to Item 206 of DPWH Standard Specifications, Highways, Bridges and Airport. 2.83 Aggregate Stockpile 1. Conform to Item 207 of DPWH Standard Specifications, Highways, Bridges and Airport. 2.84 Aggregate Surface Course 1. Conform to Item 300 of DPWH Standard Specifications, Highways, Bridges and Airport. 2.85 Bituminous Prime Coat 1. Conform to Item 301 of DPWH Standard Specifications, Highways, Bridges and Airport. 2.86 Bituminous Tack Coat 1. Conform to Item 302 of DPWH Standard Specifications, Highways, Bridges and Airport. 2.87 Bituminous Seal Coat 1. Conform to Item 303 of DPWH Standard Specifications, Highways, Bridges and Airport. 2.88 Bituminous Surface Treatment 1. Conform to Item 304 of DPWH Standard Specifications, Highways, Bridges and Airport.
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2.89
Bituminous Penetration Macadam Pavement 1. Conform to Item 305 of DPWH Standard Specifications, Highways, Bridges and Airport.
2.90
Bituminous Road Mix Surface Course 1. Conform to Item 306 of DPWH Standard Specifications, Highways, Bridges and Airport.
2.91
Bituminous Plant-Mix- Surface Course-General 1. Conform to Item 307 of DPWH Standard Specifications, Highways, Bridges and Airport.
2.92
Bituminous Plant-Mix-Surface Course, Cold laid 1. Conform to Item 308 of DPWH Standard Specifications, Highways, Bridges and Airport.
2.93
Bituminous Plant-Mix (Stockpile Maintenance Mixture) 1. Conform to Item 309 of DPWH Standard Specifications, Highways, Bridges and Airport.
2.94
Bituminous Concrete Surface Course, Hot-Laid 1. Conform to Item 310 of DPWH Standard Specifications, Highways, Bridges and Airport.
2.95
Portland Cement Concrete Pavement 1. Conform to Item 311 of DPWH Standard Specifications, Highways, Bridges and Airport.
2.96
Curb and/or Gutter 1. Conform to Item 600 of DPWH Standard Specifications, Highways, Bridges and Airport.
2.97
Sidewalk Conform to Item 601 of DPWH Standard Specifications, Highways, Bridges and Airport.
2.98
Thrust Blocks 1. Vertical and horizontal thrust blocks shall be made of concrete having a compressive strength of not less than 17.0 MPa after 28 days curing period.
Thrust blocks shall be placed against solid undisturbed ground. 2.99 MISCELLANEOUS STAINLESS STEEL METAL WORKS 1. All submerged metal works shall be fabricated of Type 304, ASTM A276 stainless steel.
All stainless steel metal work shall be supported with Type 304 stainless steel anchor bolts. 2.100 ALTERNATIVE PIPE MATERIAL FOR SEWER PIPES 1. Unless otherwise specified or shown on the Drawings, only the following alternative type of pipe materials shall be permitted for sewer mains:
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Polyethylene
Ductile Iron Pipe Cast Iron Soil Pipe

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The maximum size allowed for flexible pipes (UPVC, polyethylene, fiberglass, and ductile iron) to be used in gravity lines shall be limited by its capacity to support the design loading without exceeding the limiting deflections. Rigid pipes to be used as gravity lines on the other hand shall be designed such that its computed three-edge bearing strength shall not be less than the design three-edge bearing load. 2.101 AIR- VACUUM AND AIR-RELEASE VALVES 1. Air and Vacuum Valves: Valves shall conform to ANSI/AWWA C512 Air-Release/ Air Vacuum, and Combination Air Valves for Waterworks Service and the following: 2. Air and Vacuum Valves: Air and vacuum valves shall be capable of venting large quantities of air while pipelines are being filled, and allowing air to re-enter while pipeline are being drained. They shall be of the size indicated, with flanged or screwed ends to match piping. Bodies shall be of high-strength cast iron. The float, seat, and all moving parts shall be constructed of Type 316 stainless steel. Seat washers and gaskets shall be of a material insuring water tightness with a minimum of maintenance. Valves shall be designed for minimum 150 psi water-working pressure, unless otherwise indicated.
Air-Release Valves: Air-release valves shall vent accumulating air while system is in service and under pressure and be of the size indicated and shall meet the same general requirements as indicated for air and vacuum valves except that the vacuum feature will not be required. Valves shall be designed for a minimum water-working pressure of 150 psi, unless otherwise indicated. Combination Air Valves: Combination air valves shall combine the characteristics of air and vacuum valves and air release valves by exhausting accumulated air in systems under pressure and releasing or re-admitting large quantities of air while a system is being filed or drained, respectively. Valves shall have the same general 2.102 EPOXY PAINTS FOR CONCRETE TANKS 1. Primer Epoxy Coating for Concrete Tanks: Material must have a high viscosity self-priming paint that is highly resistant to rust, corrosion, fumes, chemical attacks and has excellent resistance to oils, solvents, alkalis and most dilute acids. It must be water impermeable that penetrates on concrete substrates when applied while leaving a tough film on the surface. Concrete must be cured 28 days at 24 C and 50% relative humidity or equivalent. Prepare surfaces in accordance with ASTM D4258 Surface Cleaning of Concrete and ASTM Dry film thickness shall be 4-5 mils per coat. Material shall have a pot life of 1-2 hours @ o 25 C. 2. Top Coat Epoxy Coating for Concrete Tanks: Paint material must be highly resistant to rust, corrosion, UV exposure, fumes and chemical attacks. Epoxy coating material shall be flexible, with minimum impact resistance of 16 kgs. It shall o have a minimum dry to coat of 3 hours at 29 C at a spreading rate of 24 sq.m. per gallon at dry film thickness of 3 mils.
o
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SECTION 3 EXCAVATION, BACKFILLING AND RESTORATION 3.1 EXCAVATION 1. The Contractor shall carry out its operation in such a manner as to avoid damage to existing adjacent or underground structures, or deterioration of the Final Surfaces of excavation. 2. If the Contractor encounters ground in the Final Surface which he considers unsuitable, or if the Final Surface is damaged or allowed to deteriorate, MWC shall be promptly informed. The unsuitable ground or damaged surfaces shall be excavated and then filled to formation level with the material as indicated in the Contract Specific Specification or as approved by MWC. Any voids which result from over excavation shall be refilled with the material as indicated in the Contract Specific Specification or as approved by MWC. 3. The Contractor shall carry out its excavation work with all necessary precautions and put in place adequate support at the side faces of excavation, or employ any appropriate measures to ensure the safety and stability, and avoid the weakening or damage to the foundations of existing adjacent structures. 4. The sides of the excavation shall be vertical and shall be adequately supported at all times, except when described elsewhere in the Bid Documents where battered sides will be permitted. A detail of the cross-section for battered side excavation shall be submitted to MWC for acceptance prior to its implementation. Any slippage of faces of excavation which causes the weakening of foundation or support for existing or proposed pipelines, structures or roadways shall be stabilized and made good. 5. The Contractor shall be responsible for the disposal of all unsuitable and surplus excavated material off the Site but no excavated material suitable for re-use in the Work shall be removed from the Site except on the direction, or with the permission, of MWC. The Contractor shall remove from the site and dispose of all excess excavated material at its own expense. The location of the spoil disposal area shall meet all legal requirements for such sites. MWC may, at its discretion, identify an area within the project site which may be used for spoil disposal. The Contractor may then use the on-site area for disposal, but it shall trim and grade the on-site spoil area to meet the requirements of MWC at no extra cost. 6. Excavation for structures shall progress in uniform horizontal layers, with extreme caution exercised as the face of the excavation approaches the line and grade of the foundation base shown on the Drawings. MWC shall be notified promptly if rock is encountered or when the excavation is within 500mm of the final cut surface or foundation elevation. Excavation equipment shall be of a size and type suitable for carrying out the work as specified. During final excavation to subgrade level, the Contractor shall take whatever precautions are necessary to prevent disturbance and remolding of the subgrade. In load bearing soil (i.e. soil under structures, pipelines and roadways), final excavation to subgrade shall be by hand or by using lightweight machines with smooth edge buckets. 7. Adverse Weather Condition. MWC reserves the right to suspend or limit earthwork operations during periods of extended adverse weather conditions, and the Contractor shall have no basis for claiming such, as a reason for delays or extra payments. It is expressly understood that the job site is located in an area subject to yearly periods of heavy tropical rainfall. The Contractor shall schedule its earthwork taking account of this wet season period of the year.
3.2
CLEARING AND GRUBBING
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1. Clearing and grubbing shall be carried out in accordance with the relevant provisions of the DPWH Standard Specification, Item 100. 3.3 TEST PITS 1. The Contractor shall excavate test pits, which shall be limited in size sufficient enough to fulfill their purpose, for investigating soil conditions. In addition the Contractor shall excavate in advance sufficient test pits to determine exact location of, and to avoid damage to, existing underground structures and utilities so that progress of excavation work will not be delayed. Test pits shall be conducted when needed or, when ordered by MWC. 3.4 TRENCH EXCAVATION 1. Trenches in rock for pipes up to 100 mm nominal bore shall be excavated to provide a minimum clearance of 100 mm around the outside of pipe barrels and joints. For pipes with nominal bores exceeding 100 mm, the minimum clearance shall be increased to 150 mm for flexible pipeline and to 200 mm for rigid pipeline. 2. Trenches for pipes carrying water under pressure shall, except where otherwise described in the Contract, be excavated to a sufficient depth to ensure a minimum cover of 750 mm to the top of the pipes. 3. For trench excavation, maximum trench widths for pipes shall not exceed the maximum allowable clearance all around the outside diameter of pipes and joints. Excavation shall not exceed the maximum width herewith specified without the approval of MWC. 4. The width and length of area to be excavated for the installation of valve chambers, special or any other structures shall not exceed the maximum linear dimensions of such structures by more than 300 mm on each side. The limit for depths of excavation for structures shall not be greater than 200mm underneath the bottom of structures for gravel or sand bedding. Payment lines shall rise vertically from the extremity of installed structures and horizontally shall be the underside of installed structure. 5. Trenches on major roads shall be fully backfilled at the end of each working day or shall be covered by steel plate adequately secured and capable of supporting vehicular traffic. 3.5 HEADINGS, TUNNELS AND SHAFTS 1. When excavating headings, tunnels and shafts, the Contractor shall provide sufficient spoil storage capacity, as much as possible within or near the area, to avoid the need to remove the excavated material from the compound at peak traffic periods, or where local enactment prohibits the carting away of spoil during defined time periods. 2. It shall be the responsibility of the Contractor, to decide the need for, and to undertake with the approval by MWC, any ground investigation ahead of the face of any tunnel, heading or shaft, additional to that described in the Contract. 3. Excavation for headings and tunnels shall be adequately supported at all times. The faces of all headings and tunnels, other than in solid rock, shall be fully boxed whenever excavation has been, or will be, stopped for a period exceeding 12 hours. 4. All working shafts shall, unless otherwise permitted, be supplied with speaking tubes or telephones in communication with the Work below ground. Such tubes or telephones shall be provided with colored light signaling system. 5. The Contractor shall comply with the requirements described in the Contract for Safety in Tunneling and Standard Practice in Atmospheric Monitoring in the Construction Industry.
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6. Where a shield, boring machine or other specialized equipment is used the Contractor shall follow the procedures recommended by the lining manufacture so as to prevent excessive loading being transmitted to the lining. 3.6 EXCAVATION IN CARRIAGEWAY/ROADWAYS 1. Before commencing excavation for trenches and manholes in the carriageway, a vertical saw cut shall be made through the carriageway construction at each side of the excavation, using a disc saw or similar approved equipment. The use of trench boxes will not be permitted for excavation in the carriageway. The maximum length of trench open at any one time shall not exceed 100 meters, and shall be subject to the requirements of the Police and the relevant local government undertaking, and traffic conditions. 2. Excavation of carriageways shall be whenever possible be located such that the the opening is at least 1 meter from the edge of the carriageway. 3.7 MISCELLANEOUS 1. The Contractor shall take all practicable measures to reduce the vibration inducing settlement resulting from any sheet piling operation. 2. Natural material surplus to requirements for backfilling shall only be deposited on site as approved by MWC. 3. Excavated artificial material shall be disposed of by the Contractor. 4. When stockpiled, excavated material shall be stored in areas remote from watercourses. 3.8 TURF FOR RELAYING 1. Turves to be relaid shall measure approximately 1 m by 300 mm, when cut and shall be of uniform thickness not less than 40 mm. 2. Turves shall be green when cut; they shall be kept moist and shall be laid within one week after cutting. 3. The level of topsoil beneath turves shall be such that the final grass surface after compaction shall be flush with adjoining grass surface. 3.9 TOPSOIL FOR RE-USE 1. Topsoil shall mean the top layer of soil that can support vegetation. It shall include all turf not required for relaying or not acceptable for turfing. 2. Topsoil shall be removed from the areas prescribed in the Contract and, when required for reuse, shall be stockpiled separately and kept free from weeds. 3.10 DEALING WITH SURFACE AND GROUND WATER 1. The Contractor shall not allow water to lie in any part of the Work unless required to do so under the Contract; water arising from or draining into the work shall be drained or pumped to an approved disposal point. Any drainage sumps required shall, where practicable, be sited outside the area excavated for the Permanent Work, and shall be re-filled with concrete Class B to the level of the underside of the adjacent permanent Work. 2. The Contractor may install water ingress retaining structure, or may use sand bagging or any appropriate measures acceptable and with the approval of MWC to prevent or minimize the seepage inflows of water into permanent structure working areas.
edge of
3. The Contractor shall take all necessary precautions in any de-watering process to prevent any adjacent ground from being adversely affected by loss of fines, which may cause settlements and damage to adjacent structures, utilities, roadways and other properties. 4. Any groundwater control system required shall be installed and maintained continuously until such time backfilling has been completed. 5. The Contractor shall obtain any necessary consent to discharge. 6. The Contractor shall prepare and submit a plan documenting the measures it will take to control sediment runoff at the site at least forty-two (42) calendar days before commencing any earthwork at the site. No earthwork will be allowed until Engineer approves the Contractors sedimentation/erosion control program. 3.11 TEMPORARY DRAINS 1. Where temporary drains are required, they shall be laid in a narrow trench or grip formed below the bottom of the excavation in an approved position. The pipes shall be open-jointed and shall be surrounded with free-draining granular material. 2. Grouting pipes shall be inserted in the line of the temporary drains at intervals not exceeding 25 m and the drains shall be solidly filled with grout Class G3 or G4 and the grout pipes will be cut off on completion. 3.12 BACKFILLING 1. Backfilling shall, whenever practicable, be undertaken immediately the specified operations preceding it have been completed. Backfilling shall not, however, be commenced until the work to be covered have achieved strength sufficient to withstand all loading imposed thereon. 2. Backfilling around Permanent Work shall be undertaken in such manner as to avoid uneven loading or damage. 3. Filling material to excavations not situated in highways or prospective highways shall be of the same excavated material available on site suitable for backfilling and shall be deposited in layers not exceeding 250 mm unconsolidated thickness and compacted to form a stable backfill. 4. Where the excavations have been supported and the supports are to be removed, these, where practicable, shall be withdrawn progressively as backfilling proceeds in such a manner as to minimize the danger of collapse, and voids formed behind the support shall be carefully filled and compacted. 5. All backfilling material shall be inert and non-toxic. 6. The Contractor shall, in accordance with the requirements of appropriate affected bodies, carry out reinstatement around all structures or apparatus encountered and affected during the Work. Existing surrounds shall be reinstated over the full width of the excavation. Particular attention shall be given to the replacement or provision of any protective slabs or identification tapes. 7. Trenches shall be fully backfilled before the end of each working day. No trench greater than 5 m in length shall remain open at the end of the working day. The remaining open trench shall be securely fenced/barricaded.
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8. Backfilling of water retaining structures shall not commence until they have passed their water tightness test. 9. Over excavation shall be backfilled with material specified in the Contract or approved by MWC. 3.13 BACKFILLING ABOVE GROUND 1. Embankment and other areas of fill shall be formed of suitable materials capable of normal compaction to form a stable fill, deposited and compacted as soon as practicable after excavation, in layers of thickness appropriate to the compaction plant used. Prior to placing embankment, topsoil shall be stripped and the base surface scarified to 300mm depth. All grass and roots shall be removed. After scarification, the base shall be compacted by rolling and fill placed with maximum lifts of 300mm. Compaction of the base and embankment fill shall not be less than 90% of the maximum density as determined in accordance with ASTM D698, Method D. Moisture content shall be as uniform as possible and suitable for the compaction required. 2. The filling shall, where practicable, be built up and compacted evenly, and shall be maintained at all times with a sufficient camber or cross fall and a surface sufficiently even to enable surface water to drain readily from it. 3.14 REINSTATEMENT OF MAINTAINABLE HIGHWAYS Reinstatement of Carriageways, Footways, Footpaths, Cycle Tracks and Verges 1. Reinstatement of streets which are maintainable highways shall be undertaken in accordance with the relevant provisions of the DPWH Standard Specifications, Part E and Part H. 2. Pavement shall be restored to its original design strength and thickness or better, including the damage caused by the Contractor outside of the trench width, at his expense. 3. Concrete pavement shall be restored using a five days curing concrete period for major roads and seven days concrete curing period for other national roads, in both cases attaining the flexural strength of 3.80 MPa and compressive strength of 24Mpa. 4. Epoxy shall be used in concrete pavement less than five years old as well as on roads subjected to constant heavy loading to bond the existing and the restored pavement. The epoxy shall have a specified tensile strength 55 to 62 MPa and compressive strength of 90 to 103 MPa. Reinstatement of Curbs, Channels, Edging and Quadrants 5. Curbs, channels, edging and quadrants disturbed by the work shall be relaid with existing units, providing they are not damaged. Where existing units are not suitable for re-use, the Contractor shall provide replacement units of similar texture, color and type, consistent with those adjacent and complying with the relevant provisions of the DPWH Standard Specifications, Part H, as appropriate. 6. The relaying of curbs, channels, edging quadrants etc. shall be in accordance with Part H of the DPWH Specifications. In-situ curbs and channels shall be reinstated to conform to adjoining curbs and channels. Reinstatement of Manholes and Surface Boxes 7. The frames of all manholes and surface boxes shall be reinstated by bedding and haunching in Class A mortar unless, in the case of surface boxes, they are to seat in the recess of an
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appropriate precast concrete section. Frame tops shall be flush with the adjoining surface on all sides. 8. Specified requirements for reinstatement are included in the Contract Specific Specification, which shall be read in conjunction with the DPWH Specifications. Reinstatement shall be appropriate to the actual existing highway construction. To this end the Contractor shall in conjunction with MWC record the highway construction encountered during excavation. 9. The Contractor shall carry out the final reinstatement of all public highways affected by the Contract within six months of completion of any interim reinstatement. 10. The Contractor shall allow the Highway Authority to carry out inspections of trenches, backfilling operations, interim and final reinstatement. 11. Trench reinstatement shall be carried in stages so that the length of trench not having full interim reinstatement at any one time shall not exceed 50 meters. Traffic shall not be permitted to run on trenches not having full reinstatement. 12. Damage to carriageway surface or curb lines caused by the activities of the Contractor or by subsequent ground movement shall be reinstated to the full depth of the carriageway construction. Where MWC agrees that the damage is superficial, or where the stated trench width is within 500mm of the curb face, only the wearing course need to be removed and replaced. 3.15 REINSTATEMENT OF NON-MAINTAINABLE HIGHWAYS 1. Non-maintainable highways shall, except where otherwise described in the Contract, be reinstated in accordance with the relevant provisions of the DPWH Specifications, Parts D and Part E. 3.16 REINSTATEMENT OF UNPAVED LAND 1. On completion of work in unpaved land the Contractor shall break up the surface of all land affected, to a depth of at least 300 mm before replacing top soil, and shall cultivate and restore the land as closely as possible to its original condition. 2. Surfaces to be shown with grass seed shall be reduced to a fine tilt and cleared of stones and extraneous material greater than 50 mm in size. The seed shall be sown at the proper seasons, evenly distributed and applied at a rate of not less than the quantities given in the following table:
Nature of area to be seeded
Level Surfaces (Slope < 1:6) g/sq. m. 40 25
Sloping Surfaces (Slope >= 1:6) to cuttings and embankment g/sq.m. 40 35
Lawns Surround to tanks and Process plants Playing Gardens Fields and
20
20
Agricultural Land Roadside Verges

15 6
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15 10
3. Surfaces to be turfed shall be prepared as for seeding. The approved turves shall be placed, butted, interlocked and tamped and the joints filled with fine sandy oil. On sloping ground where they may be likely slip, turve shall be laid diagonally. Any subsidence taking place shall be made good by taking up the turf, filling with good finely sieved topsoil and replacing the turf in the manner specified above. Any turf that dies shall be replaced with new turf. 4. The Contractor shall re-seed or re-turf reinstated areas as necessary until a good sward is obtained. The Contractor shall keep reinstated grass areas weed-free and maintained them at 25-40 mm growth for the duration of the Contract. 3.17 TREES 1. The handling, planting, staking etc. shall be in accordance with the relevant provisions of the DPWH Standards Specifications, Item 611, and with the governing Laws of the Department of Environment and Natural Resources (DENR). 3.18 LAND DRAINS 1. The position of all land drains intercepted or disturbed shall be prominently marked at every point of intersection with the work. The Contractor shall record these positions, depths, pipe diameters and the types of construction, and a copy of these records shall be given to MWC. Care shall be taken during the progress of the Work to prevent the disturbance of markers. 2. Prior to the permanent reinstatement of land drainage the Contractor shall clear the ends of existing drains, where intercepted by excavations, and shall afford facilities to MWC and the landowner or occupier to inspect them and determine the extent of replacement that may be necessary. 3. The backfill of intercepting excavations shall be compacted in 200 mm layers, to give a firm bearing immediately before replacement pipes are laid and shall be brought up to the level of the underside of the land drains or of any support to be provided. 4. The affected land drains shall be cut back into firm ground until, in each case, a section is exposed which is unaffected by the Work. 5. Replacement pipes or support beams shall bear on undisturbed ground for at least 500 mm at each end. The replacement pipes shall be of the same internal diameter as the section of drain which they replace and shall be properly connected at each end. 6. Records shall be kept of all drainage system reinstatement work carried out, and a copy shall be given to MWC. Treatment of Existing land Drains. 7. Where existing land drains are crossed by a pipeline they shall be reinstated as follows: 8. A timber batten, having a cross-section not less than 150 mm x 80 mm, impregnated with approved timber preservative, shall be fixed across the trench in the line of the field drain. This should be at least 1 meter longer than the drain to be supported and shall be set so that the field drain can be laid upon it to the correct line and level. Clayware tiles, or pipes similar to those in the existing drains, shall be laid upon the batten and held in place with timber fillets on either side of the field drain. 9. Where interceptor land drains are required they shall be connected into existing land drains or discharged into a watercourse at such a point as agreed by MWC, the owner, tenant or occupier of the hand. 10. Trenchless methods of laying shall not be used.
11. The drains shall be installed using 10 mm single sized granular fill material to the underside of the topsoil. 12. Existing drains shall be connected to interceptor drains by purpose-made junctions. The Contractor shall ensure that the intercepted drains are clear at the point of connection. 3.19 BLASTING 1. Explosives shall be transported, stored and handled in accordance with Philippine Bureau of Mines, Mines Safety Rules and Regulations and in accordance with security measures established by the Philippine National Police. 2. The names and designations of all personnel who will handle explosives or work in areas explosives are used shall be provided to the Philippine National Police and these personnel shall be instructed to abide by security measures imposed by the Philippine National Police. 3. For each blast, the Contractor shall report to MWC the amounts of explosives used for each day and the time of blast. 4. The Contractor shall keep explosives on the site only in such quantity as may be needed for the work under way for that day and only during such times as they are being used. Storage of explosives on site during non-working hours is not permitted. The Contractor shall notify MWC in advance of its intention to temporarily store and use explosives. Explosives shall be temporarily stored in a secure manner and separate from all tools. No explosives shall be stored within five hundred (500) meters of the Site. Caps or detonators shall be safely stored at a point over 30 meters distance from the explosives. When the need for the explosives has ended and definitely at the end of each normal workday, all such material remaining on the work shall be promptly removed from the premises. 5. In addition to observing all Municipal ordinances and Provincial and National laws relating to the transportation, storage, handling, and use of explosives, the Contractor shall employ an experienced blaster licensed by the Philippine National Police. 6. Operations involving explosives shall be conducted to avoid injury to persons and property. Blasting shall be done only with such quantities and strengths of explosives and in such a manner that will break the rock approximately at the intended lines and grades with the unexcavated rock left in an unshattered condition. 7. Care shall be taken to avoid excessive cracking of the rock upon or against which any pipe or structure is to be built, and to prevent damage to existing pipes, or other structures and property above or below ground. To prevent damage due to flying rock, it shall be well covered with logs or mats, and sufficient warning given to all persons in the vicinity of the work, before a charge is exploded. The mats shall be of woven wire or rubber ties, sandbagged, and designed to contain all rock fragments. 8. Before any portion of a structure is placed or any pipe is laid in rock excavation, all blasting shall be completed within a minimum distance of 15 meters. 9. All loose rock from blasting operations shall be removed, and projections leveled off by methods other than blasting. 10. The Contractor is expected to declare its intent to blast at the time of its bid. If this has not been done, then MWC may refuse to allow the Contractor to blast. 3.20 REINSTATEMENT OF WALLS, FENCES AND HEDGES
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1. Any section of wall, fence or hedge damaged or removed during construction of the work shall be replaced by a similar type unless expressly stated in the Contract Specific Document. 3.21 PILING 1. Piling shall be in accordance with the DPWH Standard Specifications, Item 400. 3.22 CLOSURE AND DEMOLITION OF REDUNDANT ASSETS 1. Demolition of tanks and structures shall be as described in the Bid Documents and all demolished structures shall be reduced to 0.50 m (1.50 m in highways) below finished ground level, unless otherwise stated in the Contract Specific Specification or Drawings. 2. Tanks, manholes, basements and other chambers shall have all organic material removed 2 2 and drain holes made in the base equivalent to 1 m for each 10 m of area. They shall then be filled using non-selected filling materials. 3. Where redundant pipework is to be abandoned or decommissioned, the pipe open ends shall be plugged with Class A concrete to a depth twice the pipe diameter. 4. Redundant items which are to be left on site are listed in the Contract Specific Specification or Drawings. All other surplus materials shall be removed from site by the Contractor. 3.23 FILLING OPERATIONS 1. Filling operations shall be detailed, and importing of materials onto site shall be carried out in accordance with the Contract. 3.24 DISPOSAL OPERATIONS 1. The disposal of any materials arising from construction activities, including process waste from commissioning, shall be the responsibility of the Contractor. 3.25 FIELD DENSITY TEST 1. Backfill on roads subject to traffic load shall be tested by MWC for the required compaction using the test procedures specified in ASTM D 1556 and with transportation and other facilities to be provided by the Contractor. The reference maximum soil density shall be as determined by using the Standard Proctor Compaction Test, ASTM D 698. Tests for backfill shall be mandatory while test for pipe zone backfill may be waived for sand or gravel fill. 2. Test frequency shall be for every 150 linear meters of backfill and for all layers. 3. The above test requirement shall not be required for alleys and interior roads not subject to traffic loads but this will not relieve the Contractor for its responsibility in compacting the backfill satisfactorily. 3.26 SHEETING AND BRACING 1. Prior to installation, the Contractor shall submit Shop Drawings showing the type of sheeting and bracing to be used and its intended method of placing and maintaining it as required to support and protect the sides of excavations. Care shall be taken to prevent voids outside the sheeting, but if voids are formed, they shall be immediately filled and rammed. 2. All sheeting and bracing not left in place shall be carefully removed without endangering the new installations, the existing utilities, or adjoining property. All voids caused by withdrawal
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of sheeting shall be immediately refilled with sand and compacted by ramming with suitable tools, by watering, or any other method acceptable to MWC. 3. The right of MWC to order sheeting and bracing left in place shall not be construed as creating any obligation on its part to issue such order, and its failure to exercise its right to do so shall not relieve the Contractor from liability for damages to persons or otherwise, growing out of a failure on the part of the Contractor to leave in place sufficient sheeting and bracing to prevent any caving-in or moving off the ground. 3.27 STRUCTURAL FILL 1. The placement of selected, approved fill material in compacted lifts to support structural foundations by transmitting the applied load to undisturbed natural soil of suitable bearing capacity. The zone of influence of a structure is defined as starting at a distance of one (1) meter outside a footing end, and sloping outward and downward at a 1:1 slope to undisturbed material. 2. Structural fill shall be furnished where existing materials encountered at bearing elevations are found to be unsuitable as determined by MWC and the Contractor is directed to replace them. 3. Structural fill shall be well-graded and non-plastic material. Before any structural fill is placed over the existing ground surface, the ground shall be cleared and grubbed and the topsoil shall be stripped. Structural fill particles shall be sound and not more than five percent (5%) shall pass the No. 200 sieve, nor more than fifty percent (50%) the No. 40 sieve. The material shall be free from organic matter, clay lumps, or other deleterious materials. The maximum particle size shall not exceed seventy-five percent (75%) of the lift thickness. 4. A sieve analysis of the proposed structural fill material shall be submitted for review and approval by MWC at least 28 days before the first use of the material. In addition, samples of 3 structural fill shall be submitted to MWC for sieve analysis for each 2500 m of structural fill placed, or whenever the source or quality of fill material is varied. MWC may reject structural fill material at any time. The Contractor will not be responsible for the cost of routine materials testing, except for the initial tests required above and any retesting requested on rejected material which shall be paid for by the Contractor. 5. Structural fill layers shall be placed in lifts of 200mm in depth after compaction. Fill material shall be approved by MWC, and hauled to the fill and tipped directly on the fill lift being placed. Material shall be spread on each layer by graders or dozers. The Engineer may select the locations where individual loads are to be dumped. 6. Each lift shall be brought to near optimum moisture content prior to compaction. No compaction of completely dry materials shall be permitted. Each lift shall be compacted to ninety-five percent (95%) of Modified Proctor optimum density using pneumatic tire rollers or smooth drum vibratory rollers of capacities approved in advance by MWC. Should any test reveal inadequate compaction of a structural fill layer, then the entire layer shall receive at least one additional complete pass of the roller. A complete pass shall include a single coverage of the entire layer including twenty percent (20%) overlap of drum width. If after a reasonable amount of recompaction is completed as determined by MWC, and satisfactory results have not been obtained, then the Contractor shall remove the lift and replace it with satisfactory material. Care shall be taken to avoid contamination of structural fill with other materials. The Contractor shall be required to replace any such contaminated structural fill layers at its own expense. 7. The minimum number of passes per lift is two (2), after which MWC may conduct whatever test work it deems necessary to determine the degree of compaction obtained. Additional passes of the roller shall be required until adequate results are obtained. Retesting of compaction shall be at the Contractors own expense.
8. In areas inaccessible to large rollers, hand-held vibratory tampers may be used to obtain adequate compaction as defined above, but use of hand-held equipment must be approved in advance by MWC. 9. Structural fill shall be brought up to the required grade in lifts of equal compacted depth. Each lift shall meet the requirements of this Section of the Standard Engineering Specification. 3.28 LINES AND GRADES Requirements All excavation and engineered fills shall be constructed to the lines, grades and dimensions shown on the Drawings or as directed by MWC. Modifications MWC may modify lines, grades or dimensions at any time prior to or during construction and the Contractor shall not be entitled to any adjustment in its Unit Prices or to any extra cost as a result of such changes other than those cost changes derived from modified quantities. Construction Surveys The Contractor shall be responsible for properly setting out all the structures and slopes. All extra work and over-excavation caused by the Contractors negligence in setting out shall be at its expense, and shall be corrected immediately upon the request of MWC. Over Excavation The Contractor shall use care, and the most appropriate methods of excavation, to avoid carrying excavation beyond the lines and grades shown on the Drawings, or loosening of material or the breaking of rock outside of the excavation limits. If for any reason, excavation or disturbance is carried beyond the lines and grades shown on the Drawings, the Contractor shall, at its own expense, remove the excess material and take the necessary measure to restore the required lines and grades with either approved fill material or concrete, as directed by MWC. Should the Contractor wish to excavate beyond the limits given in the Drawings, it may only do so after obtaining prior permission from MWC. Such excavation and any backfilling with approved materials shall be at the Contractors own expense. This requirement excludes additional excavation specially ordered by MWC. 3.29 SLOPES, SLIDES AND GEOLOGICAL OVERBREAK Modification of Design Slopes Where Needed If geological conditions during the performance of the work do not permit excavation of slopes as shown on the Drawings, MWC will modify the Design slopes. Additional work resulting from such changes shall be measured and paid for according to the corresponding Unit Prices. No later claims for additional payment will be considered if the Contractor has changed the slopes without the approval of MWC. Slides, Rock Falls or Overbreak Due to Improper Methods If slides, rock falls or overbreak occur resulting ineffective excavated surfaces beyond the excavation lines shown on the Drawings which, in the opinion of MWC, are due to improper working method or negligence by the Contractor, the Contractor shall remove the resulting material and place approved backfill material in the over excavated voids at its own expense.
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Slides, Rock Falls or Overbreak Due to Adverse Geological Conditions If slides, rock falls or overbreak occur as a result of geologically adverse conditions not reasonably foreseeable by the Contractor despite the use of proper and careful excavation methods, the cost of removing the material and placing approved backfill material shall be paid for under the Contract at applicable Unit Prices. 3.30 RE-USE OF EXCAVATED MATERIALS 1. Materials excavated from the site may, under certain circumstances, be re-used for backfill on the project. All materials proposed by the Contractor for re-use shall be approved by MWC based upon test performed by MWC or independent testing agencies and as specified herein and as dictated by accepted practice. Initial tests performed for the purpose of determining the acceptabilities of on-site materials for re-use shall be paid for under the Contract. Any re-testing required of or requested by the Contractor for any reason whatsoever shall be paid by the Contractor. 3.31 STOCKPILING OF MATERIALS 1. The Contractor shall prepare and submit a program for stockpiling of both on-site and imported materials on the site or at other locations. The program shall identify those on-site areas required for stockpiling materials and MWC will endeavor to make such locations available to the Contractor at no additional cost, except that the Contractor shall bear the cost of constructing all necessary temporary facilities such as access roads, drainage ditches, etc. MWC assumes no liability whatsoever if adequate on-site locations are not available and it must review and accept the Contractors stockpiling program. 3.32 MATERIAL FOR PIPE BEDDING AND TRENCH FILLING Material to be used for pipe bedding and trench backfill (divided into Classes I, II and III) shall be free from vegetable and perishable matter and shall be obtained from sources approved by the Engineer. They shall comply with the following particular requirements: Class I Trench Fill shall be free-draining, rounded, granular material consisting of natural gravel or similar material. For pipes up to and including 300mm, the nominal size shall be 10mm; for pipes exceeding 300mm but not exceeding 900mm diameter, the nominal size shall be 14mm; above 900mm diameter, the nominal size shall be 20mm. The overall grading shall be such that the material shall have a Compaction Fraction of 0.10 or less. Class II Trench Fill shall consist of approved granular material obtained from excavations or borrow pits and shall exclude stones larger than 25mm in size. The material shall be capable of being compacted to a stable mass and shall achieve a laboratory CBR of 20% after 96 hours soaking, when compacted to 95% of the laboratory maximum dry density tested in accordance with BS 1377. Class III Trench Fill shall consist of approved granular material obtained from excavations or borrow pits, shall be capable of being compacted to a stable mass and shall achieve a laboratory CBR of 20% after 96 hours soaking when compacted to 95% of the laboratory maximum dry density. Where separate bedding material is required for pressure pipes up to and including 300mm diameter, it shall consist of Class I Trench Fill. 3.33 BEDDING FOR PIPES Unless directed otherwise by the Engineer, should any trench invert be over-dug, it shall be made good with the class of material specified for the layer immediately overlaying it.
If any bedding material is damaged by water, sewage, collapse of trench sides or in an other way, it shall be removed from the trench and replaced with new material before any pipes are laid or re-laid. The required bedding and surround for rigid pipes shall conform to one of the following three categories: Class B bedding shall comprise a Class I Trench Fill bed at the base of the pipe with a Class II Trench Fill surround to the sides and the crown. Class G bedding shall comprise a full Class I Trench Fill surround to the pipe. The minimum thickness of fill material shall be 150mm. Class Z bedding shall comprise a full mass concrete bed and surround.
The category of bedding used in the Works shall be as noted on the Drawings or instructed by the Engineer. Where Class Z bedding is required, the backfill shall not be commenced until at least twentyfour hours after the placing of the concrete has been completed. Heavy rammers shall not be used nor shall traffic loads be imposed until at least seventy-two hours after concreting, or as directed by the Engineer. Where Class B or Class G bedding is required, the bedding material shall be hollowed out to receive the sockets and allow proper jointing and wrapping. The bedding shall be completed to the required level and compacted such that the pipes are evenly supported over their entire lengths. Bedding for pipes shall be constructed by spreading and compacting material over the full width of the trench. 3.34 BACKFILLING TO PIPES During placing or compaction of backfill, the Contractor shall take all precautions necessary to prevent movement or flotation of pipes. The side fill shall be placed and compacted as soon as possible after pipe-laying and testing, or as soon as it is safe to do so without damaging concrete beddings or surrounds. Timbering or sheeting shall be withdrawn progressively as filling proceeds where practicable to ensure that no voids are left in the filling. Initial backfill shall be placed over the pipe as soon as possible to provide a protective layer of material, hand-compacted to a level 300mm above the crown of the pipe. Remaining backfill shall then be placed and thoroughly compacted in layers not exceeding 200mm thick. Material shall not be dropped from an excessive height. When required water may be added to assist compaction. Power operated rammers or other mechanical compaction equipment shall not be used within 300mm of the top of the pipe. Heavy mechanical equipment shall not be allowed to cross any pipeline until the trench has been completely backfilled and compacted. 3.35 STANDARDS OF COMPACTION The standards of compaction of trench fill materials shall be as follows:
Well-compacted: The material shall be compacted by mechanical means in layers not exceeding 200mm compacted thickness. The density obtained in each layer shall not be less than 95% of the maximum dry density determined using Tests 13 and 15 of BS 1377 or as directed by the Engineer. Tests shall be carried out as instructed by the Engineer, up to a maximum of two tests per layer per 100 metres of trench. Hand-compacted: The material shall be thoroughly compacted by hand in layers not exceeding 100mm compacted thickness, using an iron rammer weighing not less than 4.5kg. The density obtained in each layer shall not be less than 95% of the maximum dry density determined using Tests 13 and 15 of BS 1377 or as directed by the Engineer. Tests shall be carried out as instructed by the Engineer, up to a maximum of two tests per layer per 100 metres of trench. Concrete Surround: Concrete provided as a protective surround to pipes shall comply with the requirements for mass concrete as detailed elsewhere in the Specification. Where pipes with flexible joints are used, concrete protection shall be interrupted over its full cross section at each joint by shaped compressible filler consisting of 20mm thick bitumen impregnated filler unless specified otherwise in the Contract. Such joint filler shall be provided at each pipe joint as indicated on the drawings unless directed otherwise by the Engineer.
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SECTION 4 CONCRETE AND FORMWORK 4.1 CONCRETE QUALITY Minimum Compression Strength @ 28 days (MPa) 28 28
Concrete Usage
Mix Designation
Water Retaining Concrete High Strength Structural General Structural Main Structure Sub Structure Mass Concrete Porous No-Fines Concrete See Clause 4.6 4.2 SMALL CONSTRUCTION CONCRETE
WR HSS
A B C No-Fines
24 21 17 2.75
1. In miscellaneous work involving small quantities of concrete, and where permitted by MWC, a small mixer may be used. Any concrete placed under such conditions, however, shall be mixed for not less than 1-1/2 minutes after all the materials are in the mixer drum. 4.3 READY MIXED CONCRETE 1. Where concrete is to be obtained from a ready mix supplier, the Contractor shall obtain MWCs approval of the source and production methods and facilities, and it shall conform to ASTM C94, and the requirements herein. 2. Batch deliveries shall not exceed the rated capacity specified for the mixer by the manufacturer of that equipment. The Contractor shall submit affidavits (for the approval of MWC) from the ready-mix concrete supplier, certifying that the proposed mix to be supplied will satisfy the requirements of these specifications. 3. The Contractor shall also inform MWC what alternative suppliers are available to him if the approval of the source referred to above has to be withdrawn by MWC during the currency of the Contract or the supplier unable to deliver on time or breakdown of facility. 4. The delivery ticket required for each load of ready-mixed concrete shall, in addition to the information prescribed under ASTM C33, detail: a) b) c) d) e) f) the type and nominal maximum size of aggregate, the type or name and proportion of any admixture, the actual cementitious content, the position of the concrete in the Work. the time when water was introduced into the mixed concrete. the time when the concrete mix was deposited.
5. All delivery tickets shall be kept at the Site and shall be made available for inspection by MWC.
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6. Ready- mixed concrete shall be sampled an tested in accordance with the following methods Sampling / Test Method Compressive Test Specimens Compression Tests Yield, unit weight Air Content Slump Sampling Fresh Concrete 4.4 CONCRETE MIXES 1. Ready mixed concrete mixes shall conform to ASTM C94. The mix design shall be submitted to MWC for codifying at least fifteen (15) days prior to placing concrete or before the start of concrete production. 2. Further information specified in the procedures to be used in producing and transporting concrete shall be given to MWC at appropriate times. 3. The use of site produced concrete shall, in general, be allowable. The tenderer shall submit details of any proposals he may have, together with his tender. 4. Unless otherwise described in the Contract, the cementitious content of concrete shall not 3 exceed 300 kg/m . In any structural member, the maximum water/cementitous ratio 0.60. Concrete in members of structures that are to retain an aqueous liquid shall have a maximum free water/cementitious ratio of 0.450. 5. The maximum size of aggregate in any structural member shall not exceed 25% of the minimum thickness of the member with an upper limit of 20 mm, unless described otherwise in the supplementary document. 6. The frequency of sampling shall, except otherwise described in the Contract, be as follows: Type of Structure Sample to represent 3 A Volume of (m ) 10 50 100 Applicable ASTM Standard C31 C39 C138 C138 / C173 / C143 C143 C172
Critical Structures Intermediate Structures Heavy Concrete Construction
The type of structure shall be determined by MWC. 4.5 MORTAR MIXES 5. Mortar shall be mixed only as and when required in the relevant proportions indicated in the following table, until its color and consistency are uniform. The constituent materials shall be accurately gauged, allowance being made for bulking of sand.
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Class M1 M2 M3 M4
Cement: lime Putty: Sand 1:0 to :3 1 1 1: /2:4 to 4- /2 1:1:5 to 6 1:2:8 to 9
Nominal Mix by Volume Cement: Sand Class with Plasticizer 1 1:2- /2 to 3 M5 1:3 to 4 M6 1:5 to 6 M7 1:7 to 8 M8
Masonry Cement: Sand 1 1:2 to 2- /2 1 1 1:2- /2 to 3- /2 1:4:5 1 1 1:5- /2 to 6- /2
6. All mortar shall be conveyed fresh to the work as required for use. Mortar which has begun to set or which has been site-mixed for a period of more than one hour in the case of Classes M1, M2, M5 and M6, and two hours in the case of Classes M3, M4, M7 and M8 shall not be used. 7. Mortar for making good holes cut through existing concrete walls shall be Class M2, with the addition of an epoxy compound, mixed in accordance with the manufacturers instructions. Alternatively, a proprietary ready mixed epoxy mortar may be used. In either case, the Contractor shall provide full details of his proposal to MWC for review. 8. Non-shrink grouts and mortars shall be a ready mixed proprietary brand, mixed and used entirely in accordance with the manufacturers instructions. Full details shall be provided by the Contractor for MWCs review. 4.6 CEMENT GROUT 2. Cement grout shall be mixed in the relevant proportions indicated in the following table, using the minimum quantity of water to ensure the necessary fluidity and to render it capable of penetrating the works. Class Nominal Mix by Mass Cement Sand 1 1 1 3 10
G1 G2 G3
6. Cement grout shall be used within one hour of mixing except when containing retardant admixture. 4.7 TESTING Compressive Strength Tests 1. Where trial mixes are required, three separate batches of concrete shall be made using materials typical of the proposed source of supply and, where practicable, under full scale production conditions. The suitability of the proposed mix proportions to meet the specified strength shall be determined in accordance with ASTM C31, C39 and ACI 211.1 2. The workability of each of the trial batches shall be determined and three cylinders made from each batch for test at 28 days. 3. Additional sets of cylinders from each batch may be required for tests at an earlier age. 4. The suitability of the proposed mix proportions to meet the specified maximum free water/cementitious ratio shall be determined in accordance with ASTM C31, C39 and ACI 211.1
5. Testing shall be in accordance with ASTM C39, ASTM 31 and ASTM 172. Obtain cylinder samples at the rate of three (3) sets of five (5) samples for each days pour or for every 150 cu.m. of concrete poured or for every 500 sq.m. of area for slab or wall whichever is greater. Test two (2) cylinders at 14 days and two (2) cylinders for 28 days and hold one (1) cylinder for reserve. Slump Test 6. MWC will make a slump test from each batch of concrete at the time of its being placed in position, in accordance with ASTM C143. 7. The Contractor shall provide the required labour, materials, and equipment to assist in making slump tests. 4.8 POROUS NO-FINES CONCRETE 1. The proportions of aggregate, cement and water shall be determined by trial mixes, starting with a cement aggregate ratio of 1:8 by volume and a water/cement ratio of 0.45 weight. The trial mix shall be considered suitable when all the aggregate particles are coated with a shining film of cement grout. The water content shall be just adequate to ensure that the cement paste completely coats the aggregate. The concrete, when placed shall maintain large voids with no layers of laitance. 2. To prevent unsatisfactory mixing of the cement half the water is to be placed in the mixer first followed by the aggregate and then the cement. The remainder of the water is to be added after the aggregate and cement have been partly mixed. No-fines concrete shall not be mixed by hand. Vibration shall not be used to compact the concrete. Three test cylinders of no-fines concrete shall be made of each trial mix and a further three cylinders made of the 2 chosen mix. The minimum strength of the chosen mix shall be 2.75 N/mm at twenty eight days. 3. Following the successful testing of the trial mixes, a sample specimen, not less than 1.22 m2 in area and of the thickness of the permanent work of no-fines concrete, shall be made and subjected to a porosity test. The method of testing shall be to MWCs satisfaction and the test carried out in the presence of MWC. The test shall be considered satisfactory if the head loss through the specimen floor does not exceed 0.03 m of water at a rate of flow of 200 liters per square metre per hour. If this head loss is exceeded, the no-fines concrete mix shall be redesigned to MWCs approval and further tests performed. 4. No-fines concrete shall not be placed in the Work until the results of the trial mixes, and of the porosity test, have been approved by MWC. 5. The concrete shall be cured for fourteen days and, before further concrete is poured against the no-fines concrete, 1000 gauge polythene sheeting shall be placed over the no-fines to prevent the sealing of the voids by the cement paste of the newly poured concrete. 6. When no-fines have been cast in position, the Contractor shall ensure that all surfaces are kept clean. Any area that, in MWCs opinion, has become so contaminated that it would not perform its function as a drainage layer shall be removed and replaced. 7. When the polythene sheeting is laid, the Contract shall take all precautions to prevent damage to the sheeting by the movement of plant, equipment, labour, etc. Any damage shall be made good, to MWCs satisfaction. 8. Aggregates for no-fines shall be rounded gravel. permitted. Limestone aggregates shall not be
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4.9
AIR-ENTRAINED CONCRETE 1. Where air-entrained concrete is required, it shall have an average air content by volume of the fresh concrete at the time of placing in accordance with ASTM C260.
4.10
CHLORIDE CONTENT 1. Calcium chloride or admixtures containing calcium chloride shall not be used in the production of concrete.
4.11
WORKABILITY 1. Workability of fresh concrete shall be such that the concrete can be handled and placed without segregation and, after compaction, can completely fill the formwork and surround all reinforcement and ducts. 2. The quantity of water used shall not exceed that required to produce a concrete with appropriate workability to be placed and compacted in the required location. (See also Subclause 4 of Clause 4.4)
4.12
TRANSPORTING, PLACING AND COMPACTING 1. Concrete shall be transported from the mixer and placed in the Work as rapidly as practicable by methods which will prevent the segregation or loss of any of the ingredients and will maintain the required workability. It shall be deposited as nearly as practicable in its final position and all equipment for transporting concrete shall be kept clean. No concrete shall be placed until the depth and character of the foundation, the adequacy of the forms and falsework and the placement of the steel reinforcement of embedded items have been inspected and approved by MWC. Before depositing concrete, all debris, foreign matter, dirt and water shall be removed from the forms and the surface of any concrete previously placed, such as a manhole base or horizontal construction joint shall be cleaned and then brushed with cement paste. 2. The Contractor shall give adequate notice to MWC of its intention to commence concreting. 3. Concrete shall be thoroughly compacted in its final position within 30 minutes of discharge from the mixer, unless carried in purpose-made agitators operating continuously, when the time shall be within 2 hours of the introduction of the cement to the mix and within 30 minutes of the discharge from the agitator. 4. The plant used for compaction shall be operated continuously during the placing of each batch of concrete until the expulsion of air has virtually ceased, and in a manner which does not promote segregation of the ingredients. 5. Whenever vibration has to be applied externally, the design of formwork and disposition of vibrators shall be as such to ensure efficient compaction and to avoid blemishes. 6. Concrete shall be placed in a continuous operation and compacted in layers not exceeding 400mm thick, such that no concrete is deposited on concrete which has hardened sufficiently to cause the formation of seams or planes of weakness within the section. 7. Concrete shall be placed during daytime as far as practicable except with the consent of MWC. If permission has been obtained by the Contractor to carry-on working during nighttime, an adequate lighting system must be provided. Fast flowing water shall not be permitted to flow over the surface of fresh concrete within four days after placement. 8. When troughs and chutes are used in placing concrete, their angle of inclination with respect to the horizontal should not exceed 30 degrees. When pipe is used, it shall be kept full of concrete with its discharge end submerged.
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9. Concrete shall not be allowed to drop into place from a height exceeding one-and-one-half (1-1/2) meter inside forms for walls nor from a height exceeding two (2) meters on floor slabs. 10. The addition of water after batching to compensate for stiffening of the concrete before placing will not be permitted. 11. Outdoors concreting shall not be started during rain. If concreting is already in progress, it shall be suspended if the rain adversely affects the quality of the placed concrete. Pumped Concrete 12. Positive displacement pumping or other approved methods may be used to place concrete in locations approved by MWC. The type and arrangement of equipment shall be subject for approval by MWC, and the equipment shall be operated only by experienced persons. Pneumatic placing shall not be allowed. If in the opinion of MWC, the pumped concrete does not produce satisfactory end results, the Contractor shall discontinue the pumping operation and proceed with placing of concrete using conventional methods. 13. The equipment and its method of operation shall allow the concrete to enter the forms at a low velocity. 14. Concrete pumps and auxiliary equipment shall be in good condition and shall be maintained as such throughout. Thorough washing down of all parts that come in contact with concrete shall be performed after each concreting operation. 15. Aluminum conduits for conveying the concrete shall not be permitted. 16. The minimum conduit size shall be 100mm diameter. 4.13 CONCRETE TEMPERATURE 1. The resultant temperature of the combined materials in any batch of concrete at the point and 0 time of delivery to the Work shall not exceed 6 C above the prevailing shade temperature, 0 when the latter is over 21 C. 2. The Contractor shall not permit any cement to come into contact with water at a temperature 0 greater than 60 C. 3. Where the temperature of the fresh concrete is likely to exceed 32 C, concreting shall not be permitted unless measures are taken to keep the temperature below the level. 4.14 PROTECTION AND CURING 1. Careful attention shall be given to the proper curing and protection of all new concrete. This work shall be protected from the elements, fast flowing water and from defacement. Concrete shall be cured for a period not less than that given in the following table by methods that shall ensure that cracking, distortion and efflorescence are minimized: Type of Structure Vertical Walls and Roof Slabs 7 Thrust Blocks 3 Bedding Concrete 14 Supporting for Existing Concrete
0
Curing Time (Days) 14
7 Other Minor Structures Note: Thrust Blocks and Bedding Concrete may be backfilled after concrete has hardened sufficiently to permit removal of forms, but pipes cannot be filled with water until 7 days have passed. 2. Components which are intended to have a similar exposed surface finish shall receive the same treatment. 3. Care shall be taken not to disturb the concrete by direct or indirect loading, striking of forms or otherwise, until it has hardened sufficiently. 4. Construction loads shall not be allowed on beams, decks or slabs until the concrete has attained its designed strength, nor shall the Contractor impose loading exceeding the design loading. Water Curing 5. Concrete shall be moist cured by maintaining all surfaces wet continuously (not periodically) for the duration of the entire curing period or until covered with fresh concrete. Wooden forms shall be wetted immediately after concrete has been poured and shall be kept wet with water until removed. Water for curing shall be free from any elements which will cause staining or discoloration of the concrete. Curing With Moist Earth 6. Encasement concrete and thrust blocks may be cured by this method, in lieu of the burlap method. The surface shall be covered with moist earth minimum 0.15 meter thick, for not less than four (4) hours and not more than twenty four (24) hours after the concrete is placed. 4.15 RECORDS OF CONCRETE 1. The Contractor shall keep up to date records of the dates and times when concreting is carried and of the water and temperatures at those times. The records shall be supplied to MWC every week. 4.16 CONSTRUCTION OF FORMWORK 1. Formwork shall be sufficiently rigid and tight to prevent loss of mortar from the concrete and to maintain the correct position, shape and dimensions of the finished work. It shall be so constructed as to be removable from the cast concrete without shock or damage. 2. The forms shall be capable of producing a consistent quality of surface as described in the Contract. 3. Where holes are required in forms to accommodate projecting reinforcement, fixing devices or other built-in items, precautions shall be taken to prevent loss of mortar matrix. 4. Formwork shall give access for the preparation of joint surfaces before the concrete has hardened. 5. For the purpose of compliance with the provision of Clause 4.14, the Contractors method of constructing formwork shall allow for props to soffit forms to remain in position continuously for the period described.
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6. Unless described otherwise all exposed vertical and horizontal ariser shall be finished with a 25 mm x 25 mm champer, with the exception of :- weir tops, sheer nosings, and horizontal arriser abutting flooring, covers or stair heads. 4.17 CLEANING AND TREATMENT OF FORMS 1. The interiors of all forms shall be thoroughly cleaned before any concrete is placed. The faces of the forms in contact with the concrete shall be clean and treated with a suitable release agent, where applicable. 2. Where a concrete surface is to be permanently exposed, only one release agent shall be used throughout the entire area. Release agent shall be applied evenly and contact with reinforcement and other embedded items shall be avoided. Where the concrete surface is to receive an applied finish, care shall be taken to ensure the compatibility of the release agent with the finish. 4.18 STRIPPING OF FORMWORK 1. Formwork shall be removed without shock or disturbance of the concrete and shall be in accordance with ACI-347. 2. Formwork to vertical surfaces or sloping formwork not supporting concrete in flexure shall not be removed until, the concrete strength shall be sufficient to meet any wind loading upon the concrete likely to arise at the time when the formwork is removed; and a) the concrete strength (as confirmed by tests on cylinders cured under representative 2 conditions) has reached 5 N/mm or; b) for concrete containing Portland cement only, in the absence of cylinder test results, a minimum period shall have elapsed since the concrete was poured equivalent to 11 0 0 hours at 15 C for unsealed plywood forms, or 8 hours at 15 C for impermeable forms. 3. Formwork supporting concrete in flexure shall not be removed until concrete strength (as confirmed by tests on cylinders) has reached adequate strength to support its own weight plus any additional loads on it. 4. The Contractor shall give adequate notice to MWC of his intention to strike formwork. 4.19 SLOPING FORMWORK 1. Top formwork shall be provided to surfaces with a slope of 30 or more from the horizontal.
0
4.20
CUTTING AND BENDING OF REINFORCEMENT 1. Cutting and bending of reinforcement shall be in accordance with ASTM A615 and shall be 0 done without the application of heat and in a temperature of not less than 5 C. Bends shall have a substantially constant curvature. 2. Reinforcement shall not be straightened or re-bent without the approval of MWC. If permission is given to bend projecting reinforcement, care shall be taken not to damage the concrete and to ensure that the radius is not less than the minimum specified in ASTM A615.
4.21
FIXING OF REINFORCEMENT
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1. Reinforcement shall be firmly supported in position and secured against displacement. 2. Non-structural connections for the positioning of reinforcement shall be made with tying wire or other fixing devices. Precautions shall be taken to ensure that projecting ends or ties or clips do not encroach into the concrete cover. 3. The concrete cover shall be not less than the required cover minus 5 mm and where reinforcement is located in relation to only one face of a member, not more than the required cover plus: 5 mm for bars up to and including 12 mm size 10 mm for bars over 12 mm up to and including 25 mm size 15 mm for bars over 25 mm size 4. All reinforcing steel shall be supplied by an approved reinforcement manufacturer. Site records shall be kept of delivery documents and labels. The Contractor shall check the schedules against the drawings and be responsible for their accuracy and fit. The Contractor shall maintain a record of test results for Qualification, Performance and Retests to include the following: Yield load Yield/Proof stress Ultimate load Mode of failure and where occurring Other pertinent data
Reinforcement shall be fabricated to the shapes and dimensions shown and shall be fixed in strict accordance with the owner approved Drawings as prepared by the Contractor. However, minor adjustments may be made to keep reinforcement clear of pipes, openings, water bars, built in items etc. Reinforcement shall be fixed into cages or mats by binding the intersections and laps with tying wire or approved fixing clips. The fixings shall be of sufficient quantity to ensure that the reinforcement is held securely in place during construction and concreting. Use of additional steel for support of temporary works shall be permitted subject to the approval of the Engineer. Tack welding shall not be carried out unless authorised by the Engineer and recommended by the reinforcement manufacturer, and then only to the manufacturers recommendations. In addition to supports shown on drawings or schedules, the Contractor shall provide chairs and spacers as necessary to support reinforcement in position and maintain the specified cover. Bar reinforcement must be fixed in position before the concrete is placed. Suitable precautions shall be taken by Contractor to prevent displacement of the reinforcement during the placing and compaction of the concrete and maintain the specified cover. The placement of reinforcement with kinks or bends shall not be permitted.
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Contact between ordinary carbon steel and stainless or galvanized reinforcement shall be prevented.
4.22
SURFACE CONDITION OF REINFORCEMENT 1. Concrete shall not be placed until reinforcement is free from any substance, which might adversely affect the steel or concrete chemically or reduce the bond. 2. Reinforcement which is to remain exposed for future extension of the work shall be coated with cement grout.
4.23
LAPS AND JOINTS 1. Laps and joints in reinforcement shall be made only at the positions described in the Contract or as agreed by MWC.
4.24
WELDING OF REINFORCEMENT 1. Reinforcement shall not be welded on site except where described in or permitted under the Contract. All welding procedures shall be subject to the prior approval of MWC in writing.
4.25
BUILT-IN ITEMS 1. Where pipes, sleeves, water bars or other items are built into concrete, they shall be rigidly secured in position to prevent movement and shall be free from external coatings which might reduce the bond. The Contractor shall take precautions to prevent the formation of air pockets, voids or other defects while the concrete is being placed.
4.26
CONSTRUCTION JOINTS 1. Except where construction joints in concrete are described in the contract, the Contractor shall obtain MWCs approval to the positions and details of such joints before any work is commence. 2. Joint lines shall be arranged to coincide wherever possible with features of the finished work. 3. Concreting shall be carried out continuously up to construction joints. No concrete shall be placed against in-situ concrete that has been in position for more than 30 minutes, unless a construction joint is formed. 4. Concrete shall not be allowed to taper off to a thickness of less than 50 mm. Vertical joints shall be formed against a stop board suitably notched to accommodate the reinforcement. The top surface of each lift of concrete shall be straight and level unless described otherwise in the Contract. 5. Where kicker is used, it shall be at least 70 mm high and shall be incorporated with the previous concrete. 6. The surface of any concrete against which new concrete is to be cast shall be free from laitance and shall be roughened to the extent that the large aggregate is exposed but not disturbed. The joint surface shall be cleaned immediately before the fresh concrete is placed against it. 7. Where practicable, such preparation of joints shall be carried out when the concrete has set but not hardened if not a bonding agent shall be applied. (ASTM C 881)
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4.27
SURFACE FINISHES PRODUCED WITHOUT FORMWORK Screeded Finish 1. The concrete shall be leveled and screeded to produce a uniform plain or ridged surface as required. No further work shall be applied to the surface unless it is a first stage for a Wood Float or Steel Trowel Finish Wood Float Finish 2. The screeded finish shall be wood floated under light pressure to eliminate surface irregularities. Steel Trowel Finish 3. When the moisture film has disappeared and the concrete has hardened sufficiently to prevent laitance from being worked to the surface, the surface to the Wood Float Finish shall be steel-trowel under firm pressure to produce a dense, smooth, uniform surface free from trowel marks. 4. Where the type of finish is not given it shall be Wood Float Finish. 5. Surfaces where people may step on shall be wood floated under light pressure to eliminate surface irregularities. 6. Vertical surfaces and others not intended as walkway or stepping board shall be steeltroweled under firm pressure to produce a dense, smooth, uniform, surface free from trowel marks.
4.28
SURFACE FINISHES PRODUCED WITH FORMWORK Rough Finish 1. This finish shall be obtained by the use of moulds or properly designed forms of closely jointed sawn boards. The surface shall be free from substantial voids, honeycombing or other large blemishes. Fair Finish 2. This finish shall be obtained from forms designed to produce a hard smooth surface with true, clean arises. Only very minor surface blemishes shall be permitted and there shall be no staining or discoloration. Any projections shall be removed and the surface made good. Fair Worked Finish 3. This finish shall be obtained by first producing a Fair Finish and filing all surface blemishes with fresh, specially prepared cement and fine aggregate paste while the concrete is still green. After the concrete has been properly cured, the faces shall be rubbed down if required, to produce a smooth and even surface. If the surface is to be exposed in the final work, every effort shall be made to match the color of the concrete. 4. Exposed surfaces shall be fair finish while those to be covered by soil can be rough finish.
4.29
TIE BOLTS FOR FORMWORK
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1. Only tie bolts which avoid embedding any metal parts permanently within 50 mm of the concrete surface shall be permitted. Voids remaining after the removal of all part of each tie bolt shall be filled flush with the surrounding concrete using a freshly prepared cement and fine aggregate paste. In the case of structures designed to retain an aqueous liquid, the Contractor shall ensure that the measures adopted shall not impair the water tightness of the structure. 4.30 TOLERANCE FOR CONCRETE SURFACES 1. Concrete surfaces in the final work shall have no abrupt irregularities to an extent observable by eye. Subject to retaining the required concrete cover to reinforcement, other deviations from the surfaces described in the Contract shall be no more than the following possible amounts: Deviation from Line, Level, Vertically Cross Sectional Dimension or Length (mm) 10 5
Type of Finish
Screeded or Rough Any Other 4.31 MARKING OF PRECAST CONCRETE COMPONENTS
1. Where appropriate, indelible identification and orientation marks shall put on all precast concrete components in such a position that the marks shall not show or exposed in the finished work. 4.32 CONCRETE CAST AGAINST ROCK 1. Rock surfaces against which concrete is to be placed shall be clean and free from oil, standing or running water, mud, loose rock, objectionable coating, debris, and loose or unsound fragments. 2. Immediately before concrete is placed, all surfaces shall be cleaned thoroughly by the use of either high velocity air-water jets, brooming, wet sand blasting, bush-hammering, or other satisfactory means including combinations of the above. 3. Rock surfaces against which concrete is to be placed shall be kept wet for at least 12 hours during the 24 hour period prior to placing concrete and shall be in a damp condition at the time of placing, with all pools of water removed. 4.33 CONCRETE CAST AGAINST PREVIOUSLY PLACED CONCRETE 1. Before any concrete is cast against previously placed concrete, the surface of the old concrete shall be prepared as described in this Specification. When placing wall concrete on top of footings or other horizontal joints, a 9.5mm maximum size gravel concrete mix with the same compressive strength as the regular concrete mix shall be placed for a height of 0.15 meter from the footing or horizontal joint. Repair of Defective Concrete
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2. As soon as forms are removed, all surfaces shall be carefully examined and any irregularities shall be immediately rubbed or ground in a satisfactory manner in order to secure smooth, uniform and continuous surface. Plastering or coating of surfaces to produce a smooth surface will not be permitted. No repair shall be made until after inspection by MWC, and then only in strict accordance with his directions. Concrete containing voids, holes, honeycombing, or similar depression defects, shall be completely removed and replaced; provided that where required or approved by MWC, defects shall be repaired with gunite or with cement mortar placed by an approved compressed air mortar gun. In no case will extensive patching of honey-combed concrete be permitted. All repairs and replacements herein specified shall be promptly executed by the Contractor at his own expense. 3. Defective surfaces to be repaired shall be cut back from true line a minimum depth of 15mm over the entire area. Feathered edges shall be avoided. Where cutting and chipping is required to remove all laitance or soft materials, the surface shall be wetted sufficiently in advance before shooting with gunite or with cement mortar. While the repair material is being applied, the surface under repair will remain moist but not so wet as to overcome the suction upon which a good bond depends. The material to be used for repair purposes shall have the same sand, cement and air proportions as the mortar in the mix of the concrete to be repaired. 4. Surfaces of repaired concrete shall receive the same kind and amount of curing treatment as required for the surrounding concrete. 5. The use of a well-established brand of epoxy mortar for the repair of concrete will be allowed only with the prior consent of MWC. The method of repair shall follow the manufacturers instructions. 6. Stains and discoloration of exposed concrete surfaces shall be removed in a manner approved by MWC. Splicing 7. Steel reinforcement shall not be spliced at points other than those shown on the Drawings. Lapping length requirements shall be as shown on the Drawings. When it becomes necessary to move the position of such splices, the new position and the type of splice shall be subject to the approval of MWC. 8. Welded splices, if acceptable to MWC, shall conform to the requirements of ACI 318 and all welding shall be done in accordance with the Reinforcing Steel Welding Code (AWS D 12.1). 4.34 ACCEPTANCE CRITERIA CONCRETE: 1. Acceptance criteria is outlined in ASTM C-94 (Sections 16 and 17) and ACI Code of Practice 214. Concrete which achieves the required compressive strength will be accepted as satisfactory for payment provided placement, finish and tolerance meet the specified requirements. 2. Concrete may be accepted if the average of the test results indicate a deficiency of not more than fifteen percent (15%) provided further that no individual test is deficient by more than fifteen percent (15%) of the required strength subject to cost reduction in accordance with the following schedule:
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Percent (%) Deficiency In Average Strength Less than 3 3 to less than 5 5 to less than 10 10 to 15 more than 15
Percent (%) of Unit Price Reduction 0 15 30 40 100
3. Concrete represented by test results wherein the average strength indicated a deficiency of not more than fifteen percent (15%) but with an individual test that is deficient by more than fifteen percent (15%) will not be eligible for payment but may be accepted or ordered replaced at the discretion of MWC. 4. Concrete represented by compressive strength tests which fail to achieve the required strength as specified shall be liable to rejection and subsequent removal and replacement. 5. The Contractor may be given the opportunity by MWC to verify the strength of the concrete based on tests results of diamond drill core samples cut from the suspect concrete. 6. Such core samples shall be taken and tested in accordance with ASTM C 42 except that they shall have an L/D ratio of not less than 1.25 prior to capping for testing. All core samples so tested shall be water cured for a minimum of 24 hours prior to testing and shall be tested in a saturated state. 7. Rebound Hammer Tests (ASTM C 805) may be carried out by the Contractor prior to drilling core samples from suspect concrete and the results of such rebound tests will be used as basis for acceptance or non-acceptance of the concrete. 8. All cost associated with the cutting, preparing and testing of diamond drill core samples will be borne by the Contractor. Acceptance of the suspect concrete and subsequent payment for the concrete be based on the result of such tests. STEEL REINFORCEMENT:
9. If any test specimen fails as per PNS 49, retest shall be permitted on two random specimens for the batch. If all results of these retest specimens meet the requirements, the batch shall be accepted, if not, it shall be rejected. All cost associated with testing and retesting will be borne by the Contractor. SURFACE FINISHES:
10. After removal of formworks, any defective concrete surface beyond repair shall be rejected, demolished and replaced with new concrete. The evaluation and acceptance of concrete shall be in accordance with Chapter 17 of ACI 301. 4.35 CONCRETE DIRECTLY IN CONTACT WITH SEWAGE
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1. For all concrete directly in contact with sewage, use Type II cement plus fly ash (not more than 25% by weight) conforming to the requirements of ASTM C-150 and C618. Design concrete mix as per ACI 211.1. 2. Alternative: Cemex Marine Cement or approved equivalent. Design mix as per manufacturers instructions
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SECTION 5 CONSTRUCTION OF PIPELINES, TUNNELS AND ANCILLARY WORK 5.1 GENERAL 1. Pipelaying shall conform to the procedures given in the following AWWA Standards and Manuals and as modified in the Contract Specific Documents: a) Cast Iron and Ductile Iron Pipe b) Polyvinyl Chloride (PVC) Pipe c) Steel Pipe d) Concrete Pressure Pipe e) Fiberglass Pressure Pipe f) Polyethylene Pipe (Pe) Standard C600 Manual M23 Manual M11 Manual M9 ASTM D3839 ASTM D2774
2. Where socketed pipes are required to be laid on a granular or sand bed, or directly on a trench bottom, joint holes shall be formed in the bedding material or excavated Final Surface to ensure that each pipe is uniformly supported throughout the length of its barrel and to enable the joint to be made. 3. Pipes shall be laid on setting blocks only where a concrete bed or cradle is used. 4. Where pipes are required to be bedded directly on the trench bottom, the Final Surface shall be trimmed and leveled to provide an even bedding to the pipeline and shall be free from all extraneous matter that may damage the pipe, pipe coating, or sleeving. 5. No protective cap, disc or other appliance on the end of a pipe or fitting shall be removed permanently until the pipe or fitting which it protects is about to be jointed. Pipes and fittings, including any lining or sheathing, shall be examined for damage and the joint surface and components shall be cleaned immediately before laying. 6. Suitable measures shall be taken to prevent soil or other material from entering pipes, and to anchor each pipe to prevent flotation or other movement before the Work are completed. 7. Where pipeline marker tape is specified, it shall be laid between 150mm and 300mm above the pipe. Where a tracer system is specified it shall be continuous and adequately secured to valves and fittings. 8. Over-excavation shall be backfilled with material shown on the drawing or approved by MWC. 9. Final manufacture of special or cut pipes shall not be undertaken until actual on-site dimensions have been determined. 10. Polyethylene pipes shall be snaked horizontally in the trench and shall be allowed to come to equilibrium temperature with the trench before final backfilling and connections are made. 11. Unless otherwise detailed in the Bid Documents, the Contractor shall submit details of its proposed method of crossing rivers and esteros. Preliminary details should have been submitted with the Bid.
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5.2
PIPE BEDDING 1. Bedding for pipes shall be constructed by spreading and compacting the required bedding material over the full width of the pipe trench. After the pipes have been laid, additional material shall, if required, be placed and compacted equally on each side of the pipes, and where practicable, this shall be done in sequence with the removal of the trench supports.
5.3
CONCRETE PROTECTION TO PIPES 1. Pipes to be bedded on or cradled with concrete shall be supported on pre-cast concrete setting blocks, the top face of each block being covered with two layers of compressible packing. 2. Concrete, provided as a protection to pipes shall be Class B (17 MPa), minimum 150 mm thick, placed to the required depth in one operation. 3. Where pipes with flexible joints are used, concrete protection shall be interrupted over its full cross-section at each pipe joint by shaped compressible filler. 4. Rapid hardening cement shall not be used in concrete for the protection of plastic pipe. 5. Plastic pipes shall be wrapped with a layer of plastic sheeting before being surrounded by concrete.
5.4
COMPLETION OF PIPE SURROUND 1. After completion of the relevant operations in Clause 5.1, 5..2 and 5.3, fill material shall, where required, be placed and compacted over the full width of the trench in layers not exceeding 150 mm before compaction, to a finished thickness of 150 mm above the crown of the pipes. 2. Subsequent filling shall then be carried out as specified in Sub-clause 2 of Clause 5.6.
5.5
PIPELAYING IN HEADINGS Pipes to be laid in headings shall be supplied in lengths suitable for handling, jointing and packing within the working space available. Headings shall be driven from shaft to shaft or in such other lengths as may be described in the Contract before any pipelaying is commenced. After pipelaying, headings shall be packed solid with 17 MPa concrete so as to fill all voids. Where manual packing is employed, each pipe shall be surrounded before laying and jointing the next pipe. When grouting of headings is described in the Contract, grouting pipes shall be left in the top of the heading projecting behind each head tree and the whole grouted solid with grout. Grouting shall be carried out at the end of each shift or after three settings have been packed; whichever is the shorter interval.
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5.6
THRUST BLOCKS 1. Except where welded steel pipelines or self-anchoring joints are used, thrusts from bends and branches in pressure pipelines shall be resisted by concrete thrust blocks cast in contact with undisturbed ground. 2. Any additional excavation required to accommodate thrust blocks shall be carried out after the bend or branch is in position and the thrust face shall be trimmed back to remove all loose or weathered material immediately prior to concreting. 3. Thrust blocks shall be allowed to develop adequate strength before any internal pressure is applied to the pipeline. 4. Rapid hardening cement shall not be used in concrete for thrust blocks to plastic pipes. 5. Plastic pipes shall be wrapped with a layer of plastic sheeting before being surrounded by concrete.
5.7
PIPE JOINTING GENERALLY 1. Pipe jointing surfaces and components shall be kept clean and free from extraneous matter until the joints have been made or assembled. Care shall be taken to ensure that there is no ingress of grout or other extraneous material into the joint annulus after the joint has been made. 2. Where pipes with flexible joints are required to be laid to curves, the deflection at any joint as laid shall not exceed three quarters of the maximum deflection recommended by the manufacturer.
5.8
WELDED JOINTS IN PLASTIC PIPES 1. Fusion welded joints in high density and medium density polyethylene pipes shall be made only between pipes having the same physical characteristics. Joints between pipes from different manufacturers shall only be made with the specific approval of MWC. 2. When solvent welded u-PVC pipes are jointed outside the trench, they shall not be lowered into place until the period recommended by the manufacturer for complete setting of the joints has elapsed. 3. A pipe section containing a completed weld shall achieve the same strength characteristics as the parent pipe. 4. Butt fusion and electrofusion joints in polyethylene pipes shall be carried out entirely in accordance with manufacturers instructions.
5.9
BUTT FUSION JOINTING IN POLYETHYLENE PIPELINES 1. In the following specification and procedure terms used are defined as: a) Drag Pressure (Pd) The ram pressure necessary to just overcome the frictional drag and cause the pipe to move continuously. b) Fusion Pressure The ram pressure required to generate 0.15 Mpa interface stress. c) Heat Soak The period in seconds during which the pipe ends are left to soak against heater plate, with the ram pressure between 0 and Pd.
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d) Welding Pressure The sum of Drag Pressure and Fusion Pressure. 2. Two district butt fusion welding techniques shall be employed: a) Single Pressure procedure for MDPE pipes < 315mm diameter and HPPE pipes, 250, 280 and 315 diameter of SDR = 11. Dual pressure procedure for MDPE pipes > 315 and HPPE pipes of 250, 280 and 315mm diameter with SDR = 11.
b)
3. The welding machine shall have a frame containing clamps, which are sufficiently robust to reround the pipe to be joined; the clamps shall be accurately aligned. 4. Generally, pipes shall be put in the machine with the manufacturers markings aligned. 5. The machine shall have a minimum of two rams mounted on the pipe centerline axis. The 2 interface stress generated by the rams will be a maximum of 0.15 N/mm . 6. Using the procedure outlined, the Contractor must calculate the machine cylinder pressures to achieve the interface stress specified (after allowance for drag). The calculated pressures for each pipe size must be clearly indicated in a table either held by the welder or attached to the machine. An example of such a table is shown as Table 3. 7. The rams shall move freely under a constant pressure and control the movement of any sliding clamps. All slides must be free from rust and kept well maintained and lightly lubricated. 8. The machine must incorporate a mechanism for alignment and automatic releasing of the heater plate from the heated weld surfaces. 9. Adequate power shall be supplied to the planning tool such that continuous swarf of uniform thickness is removed during planning. The trimming blades of the planer shall be sharp and have defect-free cutting edges. They shall be kept clean at all times. 10. When in use, the planer shall be mounted securely within the frame of the welding machine such that there is no tendency for the tool to twist during machining. 11. The heater plate shall be made from aluminum or alloy and be uniformly coated `with PTFE having adequate release properties. Release agents will not be allowed. 12. The PTFE coating shall be colored to show any contaminants. The plate shall be electrically heated and be provided with a calibrated thermostatic controller. 13. The heater plate must be aligned square to the pipe ends, such that there are no gaps greater than 0.5mm when the pipe is pushed against the plate under drag pressure. 14. The heater plate generator shall have adequate power supply at 110 v to deliver sufficient 0 0 heat to maintain the plate surface temperature at between 225 C and 240 C when cold pipe is in contact with the plate. 15. The plate surface temperature shall be measured at several points at the section to be in contact with the pipe. 16. A protective holder that shields the plate against draught and dust contamination shall be provided for the plate when not in use. It must be used at all times to store the plate. The holder shall not contain any loose or fibrous material that could contaminate the plate. It must be kept clean at all times.
17. Only approved debeading tools will be permitted. Any such tool shall be demonstrated to debead without notching the pipe and shall remove the bead in a continuous strip. Welds may only be debeaded when they have cooled to ambient temperature. 18. Ram pressures must be monitored on a calibrated gauge of at least 50mm diameter or using a transducer that is calibrated over a given range to 5%. 19. The range of the gauge shall be such that the combined drag and fusion pressures are not within 20% of either gauge limit. 20. All welding shall be carried out with the equipment and operator in an approved shelter. The shelter must provide adequate protection against rain, wind and draughts (to prevent chilling of the plate and of pipe ends after heating). 21. The shelter shall be maintained in a neat and tidy condition and precautions taken against accumulation of dust. 22. No welding will be permitted in the open air without cover. 23. Prior to inserting the heater plate, the far ends of the pipes shall be covered to prevent any cooling of the plate by internal draughts. 24. For in trench welding all surface water shall be pumped from the trench and a shelter to protect from rain, wind, draughts and dust shall be assembled over the working area at all times when the welding is in progress. 25. All grease or foreign matter on the trimmer blades must be removed with isopropanol or other approved solvent prior to trimming. 26. Prior to any welding session and after cooling to ambient temperature, the cold heater plate must be thoroughly washed with copius quantities of clean water. Care must be taken not to scratch the coating on the plate. Washing shall be accomplished with new paper based tissue. 27. Grease and oil films on the heater plate surface shall be removed from the cold plate with solvent. 28. Prior to any welding session, the Contractor shall perform a dummy weld, using the equipment and welder, he proposes to use for the session. MWC shall witness the dummy weld procedure. Should the procedure and finished weld be satisfactory, MWC will permit the session to commence. Neither the equipment nor the welder shall be changed mid session without the approval of MWC. The dummy weld shall be handed to MWC for testing by others. 29. Pipe cuts shall only be made using a saw having not less than 10 teeth per inch. It is recommended that power jigsaws be used for cutting. 30. The diameter of pipes to be welded shall mate such that the maximum lip due to mismatch is within the tolerances given in Table 1. When matching ends are outside these tolerances then the pipe shall be re-aligned and re-machined. 31. The ends of pipes to be planed shall be cleaned with clean water on both outside and inside surfaces to remove mud, dirt or grease. They shall then be dried using new, clean, tissues. (Grease shall be removed with the approved solvent) 32. During planing, a continuous swarf ribbon will be obtained by the time planing ceases. Following planing, dust and loose shavings shall be removed from the surfaces by wafting with paper tissue. The machine surfaces shall not be touched by hand or clothing.
33. When the machined surfaces are matched together under fusion pressure (Pf) there should be no gap greater than 0.25mm.
Single Pressure Welding Procedure: 34. For each weld to be undertaken the Drag Pressure (Pd) shall be measured three times, the average calculated and this shall be recorded as the Drag Pressure. 35. Heating. The pipe shall be pressed against the heater plate to form the initial bead using a total pressure equal to the fusion pressure (Pf) to generate 0.15 Mpa interface stress plus drag pressure (Pd). 36. The initial bead size shall be as given in Table 4 and be formed uniformly around the circumference. 37. Heat Soak. After initial bead-up, the ram pressure shall be reduced to between 0 and drag pressure (Pd) alone, with the pipe left to soak against the plate for times as given in Table 4. 38. During the removal of the heater plate, no molten polymer shall stick to the heater plate. If this occurs the weld shall be aborted, the plate cleaned and the plate surface quality examined. 39. The maximum plate removal time, before the hot ends are brought together, shall be as given in Table 2. 40. The hot pipe ends shall be brought together in a smooth, controlled manner within 1 to 3 secs, and the ram pressure raised to the total welding pressure (Pd+Pf). 41. The weld beads should roll back in a uniform manner and there should be no sign of bubbles or contamination present. The weld bead sizes shall be as given in Table 1. 42. Cooling: a) For pipe supplied as coils on drums, the clamps may only be released and the welded section removed after the full cooling times given in Table 4. b) For pipes supplied as straight lengths, the clamps may be carefully released after the cooling times given in Table 4 and the welded pipes allowed to cool further. Care shall be taken to apply only minimal stresses before cooling is complete. Dual Pressure Welding Procedure 43. Dual Pressure Cycle. The objective of dual pressure welding is to allow the molten polymer (formed after heating of pipe ends) to cool with the minimum positive pressure. Therefore, the conventional fusion stress of (0.15 Mpa) is only applied for 10 secs after bringing the pipe ends together to allow the melt on each surface to mix and a bead to form to clear any th contaminants from the weld interface. Thereafter the stress is reduced to 1/6 of this level. The procedure is shown schematically in Figure 3. 44. The data outlined in Table 5 give typical machine conditions in detail: 45. For each weld to be undertaken the Drag Pressure (Pd) shall be measured three times, the average calculated and this shall be recorded as the Drag Pressure.
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46. Heating. The pipe shall be pressed against the heater plate to form the initial bead using a pressure equal to (Pf) to generate 0.15 Mpa interface stress plus drag (Pd). 47. The initial bead size shall be as given in Table 5 and be formed uniformly around the circumference. 48. Heat Soak. After initial bead-up, the ram pressure shall be reduced to drag pressure (Pd) alone, with the pipe left to soak against the plate for 10 seconds/mm wall thickness plus 1 minute. (Times given in Table 5). 49. During removal of the heater plate, no molten polymer shall stick to the heating plate. If this occurs the weld shall be aborted, the plate cleaned and the plate surface quality examined. 50. The maximum plate removal time, before the hot ends are brought together, shall be given in Table 2. 51. The hot pipe ends shall be brought together in a smooth, controlled manner and the ram pressure raised to the total fusion pressure Pd+Pf. 52. The weld beads should roll back in a uniform manner and there should be no sign of bubbles or contamination present. 53. After 10 seconds of application of fusion pressure, the pressure shall be reduced smoothly to the cooling pressure (Pc) = drag pressure (Pd) + 1/6 * Pf. 54. Cooling: a) The weld shall be cooled in the machine clamps under the reduced pressure of Pc 0 until the maximum weld interface temperature is below 90 C. b) The clamps may be carefully released after the cooling times given in Table 5 and the welded pipe allowed to cool further-provided that care is taken to apply only minimal stresses before cooling is complete. Note the following relates to both Single Pressure and Dual Pressure Procedures. 55. The external bead shall be removed from all welds using an approved de-beading tool, which does not damage the pipe. The bead shall only be removed when cold. 56. The bead shall be uniform on both sides of the weld face and equal in size (to within 2mm). They shall have no wrinkles or discontinuities and shall have overall dimensions as given in Table 1. 57. On examination of the internal bead surface (and the external pipe weld surface) after debeading there shall be no sign of any circumferential slit detect between weld beads. It should not be possible to separate the bead. 58. To assist in the identification of slits, the beads should be repeatedly flexed in different locations, thus opening any slits, which may be present. If a white yielded region is visible at the bead junction along the entire length of the bead, this is a sign of a weld with no contamination. 59. If any defect is seen, the weld shall be rejected and cut from the pipe. 60. All further production welding shall cease until equipment has been examined and thoroughly cleaned and further trial welds made and accepted after testing.
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61. Testing of welds will be undertaken by MWC up to a maximum of 2 welds per day plus dummy welds. 62. Records a) The Contractor will be required to keep a daily log of welding conditions used for each weld made. b) Each weld must be clearly marked with the weld number at two points (approx. 180 orientation) using a black indelible marker pen or metal stamp. (The weld numbering format must be agreed with MWC). c) The weld conditions outlined in Table 3 shall be noted for each weld. A copy of each days records shall be given to MWC. Table 1. Typical Welding Conditions for MDPE and HPPE
0
Pipe Wall Thickness (mm)
Mismatch on Diameter (mm)
Initial Beading Pressure 2 (N/mm )
Typical Final Bead Sizes (mm)
5-12 12-18 18-25 25-35 35-45 45-60 *Plate Temp = 225 C to 240 C
0 0
1.0 1.0 1.5 2.0 3.0 4/4.5
0.15 0.15 0.15 0.15 0.15 0.15
8-12 10-15 15-20 20-30 30-40 30-40
N.B. Pipe may only be removed from clamps when the interface temperature is less than 90 C. Table 2. Plate Release Times (assuming no air movement in proximity of welding equipment)
Ambient External Temperature 0 ( C)
Time to Remove heater Plate (s)
10-15 15+
12 15
N.B. These times are maximum values
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Table 3. Example of Weld Record Sheet Contract: Client: Welder(s): Pipe Supplier: Pipe Dia: ___________________ Manila Water Company Contractor: Welding Machine: Pipe Material: Wall Thickness: ___________________ ___________________ ___________________ ___________________
Date
Weld No.
Ambient Temp. 0 C
Plate Temp. 0 C
Drag Pressure (bar)
Fusion Pressure (bar)
Soak Pressure (bar)
Soak Time (s)
Plate Release Time (8)
Fusion Time (s)
Cooling Time (mins)
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Single Pressure Butt Fusion Welding Conditions for MDPE & HPPE: 90mm to 315mm Machine: Fusion Eqpt. BF4 (Mk2) Effective Cylinder Area (cm)2: 0 0 Heater Plate Surface Temperature: 225 C to 240 C 17.1
Table 4 Cooling Times (minutes) Out of Clamps 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 7.5 5.0 5.0 7.5 Bead Up Pressure (bar) Cooling Time (minutes) in Clamps 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 15.0 10.0 10.0 15.0 Cooling Pressure (bar) After 10 sec. 0.8 1.2 1.8 1.2 1.8 2.8 1.6 2.3 3.6 2.6 3.8 5.8 3.3 4.8 7.4 5.2 7.5 11.5 6.4 9.2 14.2 8.0 11.6 17.9
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Initial Bead Size (approx) (mm)
Outside Diameter (mm)
Wall Thickness (mm)
Soak Time (records)
Soak Pressure (bar)
Fusion Pressure (bar0
SDR
90 90 90 110 110 110 125 125 125 160 160 160 180 180 180 225 225 225 250 250 250 280 280 280
26 17.6 11 26 17.6 11 26 17.6 11 26 17.6 11 26 17.6 11 26 17.6 11 26 17.6 11 26 17.6 11
3.5 5.1 8.2 4.2 6.3 10.0 4.8 7.1 11.4 6.2 9.1 14.5 6.9 10.2 16.4 8.7 12.8 20.5 9.6 14.2 22.7 10.8 15.9 25.5
0.8 1.2 1.8 1.2 1.8 2.8 1.6 2.3 3.6 2.6 3.8 5.8 3.3 4.8 7.4 5.2 7.5 11.5 6.4 9.2 14.2 8.0 11.6 17.9
2 2 2 2 2 3 2 2 3 2 2 3 2 3 3 3 3 3 3 3 3 3 3 3
95 110 140 100 125 160 110 130 175 120 150 205 130 160 225 145 190 265 155 200 288 170 220 315
Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag
94
0.8 1.2 1.8 1.2 1.8 2.8 1.6 2.3 3.6 2.6 3.8 5.8 3.3 4.8 7.4 5.2 7.5 11.5 6.4 9.2 2.4 8.0 11.6 3.0
Coils, clamp until cooling Coils, clamp until cooling comple ted
Add Drag
Add Drag
Add Drag
315 315 315
26 17.6 11
12.1 17.9 28.6
10.1 14.7 22.6
3 3 3
180 140 345
Drag Drag Drag
10.1 14.7 22.6
10.1 14.7 3.8
10.0 10.0 15.0
5.0 5.0 7.5
Dual Pressure Conditions Needed for Pipes Shown as Shaded Dual Pressure Butt Fusion Welding Conditions for MDPE & HPPE: 355mm to 1000mm Machine: Fusion Eqpt. BF6 Effective Cylinder Area (cm)2: 0 0 Heater Plate Surface Temperature: 225 C to 240 C 27.86
Table 5 Bead Up Pressure (bar)
Cooling Pressure (bar) After 10 sec.
Fusion Pressure (bar)
Cooling Time (minutes) in Clamps
355 355 355 400 400 400 450 450 450 500 500 500 560 560 560 630 630 630 710 710
26 17.6 11 26 17.6 11 26 17.6 11 26 17.6 11 26 17.6 11 26 17.6 11 26 17.6
13.7 20.2 32.3 15.4 22.7 36.4 17.3 25.6 40.9 19.2 28.4 45.5 21.5 31.8 50.9 24.2 35.8 57.3 27.3 40.3
7.9 11.4 17.6 10.0 14.5 22.4 12.7 18.4 28.3 15.6 22.7 35.0 19.6 28.4 43.8 24.8 36.0 55.5 31.5 45.7
3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 4 4 3 4
195 260 385 215 285 425 235 315 470 250 345 515 275 380 570 300 420 635 335 465
95
Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag Drag
7.9 11.4 17.6 10.0 14.5 22.4 12.7 18.4 28.3 15.6 22.7 35.0 19.6 28.4 43.8 24.8 36.0 55.5 31.5 45.7
1.3 1.9 2.9 1.7 2.4 3.7 2.1 3.1 4.7 2.6 3.8 5.8 3.3 4.7 7.3 4.1 6.0 9.2 5.3 7.6
10.0 15.0 15.0 10.0 15.0 20.0 10.0 15.0 20.0 10.0 15.0 20.0 10.0 15.0 20.0 10.0 15.0 20.0 15.0 20.0
5.0 7.5 7.5 5.0 7.5 10.0 5.0 7.5 10.0 5.0 7.5 10.0 7.5 7.5 10.0 7.5 7.5 12.5 7.5 10.0
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Cooling Times (minutes) Out of Clamps
Initial Bead Size (approx) (mm)
Outside Diameter (mm)
Wall Thickness (mm)
Soak Time (records)
Soak Pressure (bar)
Add Drag
Add Drag
Add Drag
SDR
800 800 900 900 1000 1000
26 17.6 26 17.6 26 17.6
30.8 45.5 34.6 51.1 38.5 56.8
40.0 58.0 50.7 73.4 62.6 90.7
3 4 4 4 4 4
370 515 405 570 445 630 Drag Drag Drag Drag
40.0 58.0 50.7 73.4 62.6 90.7
6.7 9.7 8.4 12.2 10.4 15.1
15.0 20.0 15.0 20.0 15.0 20.0
7.5 10.0 10.0 10.0 10.0 12.5
(If (ra) in (cm)2 then multiply (ra) by 100)
FIGURE 1
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SINGLE PRESSURE WELDING PROCEDURE
Sing le Pres sure Wel ding Cycl e for PE Pres sure Pipe s
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1. Calculate Fusion Pressure (Pf): Based on Interface Pressure=0.15Mpa, see Figure 2. Measure Drag Pressure (Pd) 3. Check Plate Surface Temperature is between 225C and 240C 4. Form Initial bead using Pressure Pf 5. Reduce Pressure to between 0 and Drag Pressure 6. Soak against Plate (for the times given in Table 5) 7. Remove Plate Swiftly 8. Build-up Pressure to Pf+Pd (in controlled manner) 9. Do not remove from Clamps until Interface is below 90C 10. Cooling Times are given in Tables 4 and 5
DUAL PRESSURE WELDING PROCEDURE
Dual Pressure Welding Cycle for PE Pressure Pipes

11. Calculate Fusion Pressure (Pf): Based on Interface Pressure=0.15Mpa, see Figure 12. Measure Drag Pressure (Pd) 13. Check Plate Surface Temperature is between 225C and 240C 14. Form Initial bead using Pressure Pf 15. Reduce Pressure to between 0 and Drag Pressure 16. Soak against Plate (for the times given in Table 5) 17. Remove Plate Swiftly 18. Build-up Pressure to Pf+Pd (in controlled manner) 19. Hold Pressure Pf for 10sec. to allow Bead to Roll-Over 20. Decrease Pressure to (Pd+1/6*Pf) and maintain this pressure during cooling 21. Do not remove from Clamps until Interface is below 90C 22. Cooling Times are given in Tables 4 and 5 5.10 FLANGED JOINTS 1. Flanges shall be properly aligned before any bolts are tightened. 2. Jointing compounds shall not be used when making flanged joints, except that, to facilitate the making of vertical joints, gaskets may be secured temporarily to one flange face by a minimum quantity of clear rubber solution. Bolt threads shall be treated with graphite paste and the nuts tightened evenly in diametrically opposite pairs. 5.11 OGEE JOINTS 1. Ogee joints shall be so made that the required jointing material fills the joint cavity. Any surplus jointing material extruded inside the barrel shall be trimmed off and, where practicable, pointed on completion. 5.12 WELDED JOINTS IN STEEL PIPES 1. The process of welding steel pipelines shall be in accordance with AWWA C206. 2. The ends of pipes shall be cut and prepared and free from fins, planar defects, tears and other surface defects, prior to welding. Cleaning to base metal shall extend for at least 25mm from the end of the pipe on both internal and external faces. 3. The alignment of abutting pipe ends shall be such as to minimize the internal offset between surfaces. 4. The Contractor shall submit his proposed welding procedure to MWC for codifying. 5. After each welded pipe joint has been made, a coating and lining equivalent to the factory applied coating of the adjacent pipes shall be applied across the joints. 5.13 CEMENT MORTAR JOINTS
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1. In making yarn and mortar joints for pipes or fittings, the spigot shall be entered into the socket of the last pipe laid until it bears on the back face of the socket, and it shall be centered in the socket. Two turns of tarred yarn shall then be caulked into the back of the socket and Type M1 cement mortar shall be pressed into the joint to fill the socket and shall 0 be beveled off at 45 from the outside edge of the socket. 5.14 RUN LEAD JOINTS 1. Run lead joints shall be made by forcing home strands of white sterilized jute piping yarn, to the back of the socket cavity leaving a space of 75mm (60mm for pipes of 300mm nominal bore and below) measured from the socket face. A suitable clip shall then encircle the socket face or gasket and the joint cavity filled with molten lead poured in one running. After cooling, the lead shall be set up and neatly finished with the face of the lead 2-mm back from the socket face. In the case of pipes over 750mm diameter, the socket and spigot shall be heated before the joint is run. 5.15 PROTECTION OF FERROUS PIPES, JOINTS AND FITTINGS 1. Ferrous pipes joints and fittings shall be cleaned and all loose rust removed before protection is applied. 2. External protection to all ferrous pipelines in the ground shall be one of the following, as described in the Contract. External protection to all bolted pipe joints and flange adaptors in the ground shall be type P1. a) P1 The application of mastic paste in sufficient quantity to cover all protruding edges, bolt heads and sharp edges of flanges, to give a smooth external profile. The joint or fitting shall be wrapped with two separate applications of protective tape wound spirally with a minimum half width overlap. The taping shall extend along 150mm of the barrel of the pipe on each side of the joint or fitting. Or b) P2 The application of a self-adhesive rubber-based cold-applied tape wrap combined with thick PVC backing. Where bolt heads, flanges and other projections arise moulding putty shall be used to give a smooth external profile. The joint or fitting shall be wrapped with two separate applications of protective tape wrap wound spirally with minimum of half width overlap. The tape shall extend along 150mm of the barrel of the tape on each side of joint or fitting. Or c) P3 The application of heat shrink sleeves. The Contractor shall ensure that any sleeving is not torn or displaced during pipelaying and backfilling. External protection for ductile iron pipes where specified in the Contract Specific Document shall comprise: d) P4 The covering of the pipes with flat polythene sheeting securely held in place with adhesive tape at pipe joints and intermediate positions Or e) P5 Painting or coating the external surface as described in the Contract. 3. Completion of internal and external protection of steel shall be provided where pipes have a bituminous, epoxy or any other type of propriety protective coating in which a gap has been left for the joint to be made. The joint and any damage to the protective coating shall be made good.
4. Cathodic protection of pipes, joints and fittings shall comprise either impressed current or sacrificial anode. 5. Mild steel components and pipework and fittings exposed to air, including those manholes, chambers and surface boxes, shall be protected externally after installation by applying two coats of black bitumen paint to a total minimum dry film thickness of 80 m. 6. All pipework fittings which are to be within treated water compartments shall be stripped of their external surface protection where and repainted with protective paint coats which are in accordance with the appropriate standards. 5.16 CUTTING PIPES 1. Pipes shall be cut by a method which provides a clean square profile, without splitting or fracturing the pipe wall, and which causes minimal damage to any protective coating. Where necessary, the cut ends of pipes shall be formed to the tapers and chamfers suitable for the type of joint to be used and any protective coating shall be made good, and the ends sealed. 2. Where ductile pipes are to be cut to form non-standard lengths, the Contractor shall comply with the manufacturers recommendations in respect of ovality correction and tolerances to the cut spigot end. 3. Where ductile iron pipes of 450mm and greater are specifically required to be cut for use with fittings having fine tolerance on diameter and ovality, then only pipes purposely ordered for cutting shall be used. These pipes are identified by the manufacturer. Cutting shall be carried out entirely in accordance with the manufacturers instructions. Consequential damage to pipe lining and coatings shall be made good, with compatible materials. 4. Where cement mortar lining has been damaged, before repairing the lining, all loosely adhering materials shall be removed. 5. Cement mortar for repair shall be 1:2.5 cement: sand mortar. 6. The use of cut concrete or clay pipes shall be kept to a minimum. 7. The cut ends of reinforced concrete pipe shall be thoroughly cleaned and two coats of epoxy resin coating applied to seal the end. 5.17 PRECAST CONCRETE MANHOLES Precast concrete chamber and shaft sections shall be constructed with step irons, ladders or slabs aligned correctly. Joints shall be made so that the required jointing material fills the joint cavity. Any surplus jointing material extruded inside the chamber or shaft shall be trimmed off and joints shall be pointed on completion. The jointing material shall be Class M1 mortar. Where manholes are to have surround, the concrete shall be Class A and the height of each concrete pour shall not exceed 2 m. Each construction joint shall break joint with that of the chamber or shaft sections by at least 150mm. 5.18 PRECAST CONCRETE SEGMENTAL MANHOLES 1. Precast concrete segmental manholes shall be constructed in accordance with the relevant provisions of ASTM-C76.
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5.19
BRICK AND IN-SITU CONCRETE MANHOLES AND CHAMBERS 1. Manholes and chambers in brickwork or in-situ concrete shall comply at least with the relevant provisions of this SES. 2. Brick chambers are to be constructed using the bond indicated on the drawings. A relieving arch shall be provided over pipes exceeding 300mm diameter.
5.20
INVERTS AND BENCHING 1. Manhole inverts and benching shall be formed of the materials described in the Contract and where there is no change of diameter, the invert shall follow the same gradient as the outgoing sewer. 2. Where inverts and benching are to be formed of in-situ concrete or high strength concrete topping, the relevant sections shall apply. 3. Where a high strength concrete topping is required, the invert and benching shall be formed in Class A (24 MPa) concrete with a Screeded Finish or Rough Finish as required, and the concrete topping shall be applied as soon as practicable thereafter. 4. Where the finished surface is to be in-situ concrete, the concrete shall be Class A with a Steel trowel or Fair Worked Finish as required. 5. Where the inverts of both manhole and sewer are constructed of brickwork, there shall be no break in bond between the two.
5.21
PIPES AND JOINTS ADJACENT TO STRUCTURES Except where the construction is by tunneling, heading or pipe jacking, a flexible joints shall be provided as close as is feasible to the outside face of any structure into which the pipe is built, compatible with the satisfactory completion and subsequent movement of the joint. The length of the next pipe (rocker pipe) away from the structure shall be in the range 0.5 meter to 0.75 meter for pipes up to 450mm nominal bore and shall not exceed 1 meter for pipes up to 750mm nominal bore. A pipeline may, where practicable, be laid through a manhole and the crown cut out to the half diameter, provided flexible joints are situated on each side no farther than 600 mm from the inner face of the manhole wall, and that adjacent pipes comply with Sub-clause 2 of this clause.
5.22
WATERTIGHTNESS OF MANHOLES AND CHAMBERS 1. Manholes and chambers shall be substantially watertight, with no identifiable flow of water penetrating the permanent Work.
5.23
SETTING MANHOLE COVERS AND FRAMES 1. Manhole frames shall be set to the required level on brickwork, or on precast concrete cover frame seating rings, as described in the Contract. The frames shall be set to level, bedded and haunched over the base and sides of the frame in Class A concrete.
5.24
CONNECTIONS TO EXISTING SEWERS
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1. Pipe saddles for concrete or clay sewers shall be bedded in Class M1 mortar and a mortar fillet formed to give a cover of at least 50mm to the base of the saddle. Pipe saddles for asbestos-cement sewer pipes shall be formed from asbestos-cement and fixed with an epoxy resin adhesive. 2. Pipe saddles for uPVC pipes shall be purpose made from uPVC and shall either be of a mechanical clip-on type or shall be fixed with appropriate solvent cement. 3. Where an appropriate saddle or junction unit is unobtainable a connection to an existing sewer may be made with a pipe cut to give an oblique junction, so that the discharge is in the direction of flow in the main sewer. The connecting pipes shall be of such a length that the socket of the cut pipe rests on the outside barrel of the sewer with no projection inside the main sewer. The pipe joint shall then be pointed in Class B mortar externally and internally where practicable. Alternatively, purpose made junctions may be used by cutting out sections of pipe, fitting a junction and securing with repair coupling. 4. The ends of connections and pipes not required for immediate use shall be closed with purpose made stoppers, discs or joinders. The position of all junctions shall be recorded by the Contractor by measurement from the manhole immediately downstream and notified to MWC before backfilling is commenced. 5. Pipe connections within the Work shall be formed using standard preformed junctions where possible. Saddle connections to existing sewers shall only be allowed when the internal diameter of the major pipe is at least 150mm greater than the branch pipe internal diameter. If the major and branch pipe sizes are such that the difference in pipe size is less than 150mm, a standard preformed junction shall be fitted into the major pipe run. 6. Saddle connections shall generally be fitted at 45 to both the horizontal and longitudinal axes of the main pipe and the hole made in concrete and clayware pipes with a diamond hole cutter of the appropriate size and angle. All connection shall be surrounded with 150mm of Class B concrete. 5.25 SEWERS AND MANHOLES TO BE ABANDONED 1. Grout for filling abandoned sewers shall be Class G4 with the addition of a fast setting agent. Grouting operations shall proceed such that no length of sewer shall be filled until all upstream communicating lengths have been completed. 2. The seals at the lower end of each run of sewer shall be fitted with a flexible breather pipe, fixed at the soffit of the sewer and turned vertically upwards to a height of 600mm above the soffit level of the higher end of the relevant sewer length. 3. The head of existing sewer lengths cut-off and exposed during excavations for new work shall be suitably sealed and a 150mm flexible injection pipe, constructed through the seal at the soffit of the sewer, shall be turned vertically and extend upwards for at least 1 m. 4. On completion of grouting operations the injection pipe shall be sealed with a plug of concrete at least 150mm deep having 150mm bearing outside the injection pipe. 5. The shafts of manholes on abandoned sewers shall be broken down to a level of 1 m (1.5 meters in highways) below finished ground level and the remaining void filled with lean concrete, deposited in layers not exceeding 225mm unconsolidated thickness, fully compacted and brought up to level (in roads the underside of the sub-base). 5.26 PIPE JACKING
0
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1. Excavation for pipe jacking shall be undertaken from within a shield equipped with steering jacks for adjusting the alignment. Face boards shall be available for boarding up the exposed excavation. 2. The Contractor shall provide such continuous superintendence as is necessary to maintain the line and level during jacking of the pipe. 3. The Contractor shall limit the jacking load applied to the pipeline such that damage to the pipes is avoided and in this connection he shall be responsible for deciding whether an intermediate jacking station is needed. 4. The jacking load shall be transferred to the pipes through a thrust ring, which shall be sufficiently rigid to ensure even distribution of the load. 5. The pipe manufacturers described permitted draw or angular deflection in relation to the product standards and shall not be exceeded at any individual joint. 6. The Contractor shall monitor graphically the relationship between the jacking force and distance moved. From this information the Contractor shall anticipate measures necessary to avoid exceeding the maximum permitted jacking forces. The Contractor shall provide MWC with daily records of the jacking force required to advance each pipe length. The jacking force instrumentation shall be calibrated on site and the Contractor shall provide MWC with the calibration certificate. 7. All lifting holes and grouting holes shall be sealed with Class M1 mortar. 8. Unless otherwise required by the Contract that joint packing designed to distribute the jacking load evenly shall be inserted at and between the pipe ends and at any intermediate jacking stations. 9. Where grouting is required this shall be carried out in accordance with Clause 5.33 after the pipes have been jacked into their final position. 10. The Contractor shall provide MWC with all calculations and design details for each jacking station. Before work may start on any thrust pit the Contractor shall demonstrate to MWC that the design will withstand the maximum jacking forces of which the jacks are capable. 11. Before a particular pipe jack may commence evidence that the pipes necessary for the completion of the jack are either on site or in storage elsewhere must be available for inspection by MWC. The envisaged number of intermediate jacking stations must be agreed in advance for commencement. At least one intermediate jacking station assembly shall be available at the start of the pipe jack unless otherwise agreed by MWC. 12. On making a joint the pipe to be jacked shall be rotated to minimize the effects of pipe end squareness. 13. Pipes, including lead pipes, which have been jacked through a pipe jack, may not be used elsewhere on the Work. Cut pipes may not be jacked. 14. The jacking load applied shall not exceed the design strength of any pipe being jacked. 15. Intermediate jacking stations shall be inserted when the main thrust pit jacking force reaches 75% of the pipe design load unless MWC has authorized, in writing, that such an interjack station is not required. 16. To safeguard against the opening of installed joints the Contractor shall ensure the pipeline does not move in any direction when the jacking loads are removed. This requirement should be borne in mind on drives where it is necessary to maintain a face pressure.
17. On completion of the drive intermediate-jacking stations must be left fully closed. All jacks, props, thrust rings and packing must be removed, the ends of the pipes cleaned, a new packing ring glued to the receiving face and the joint jacked partly closed. An O ring seal shall then be inserted into the sliding joint and the joint jacked fully closed. The order of closing stations shall be from the tunneling shield working back. 18. The annular space between the sides of the excavated tunnel and the jacking pipes shall be constantly filled with bentonite grout at a pressure, which will support the adjacent excavation. The Contractor shall provide MWC with daily records of the quantity of bentonite used for each length of pipe thrust and the point at which the bentonite was injected. The bentonite shall be thoroughly mixed and given sufficient time to fully absorb water and to swell prior to pumping or placing. 19. On completion of the pipejack the annulus shall be filled by the displacement of the bentonite with grout. 5.27 SHAFTS 1. The Contractor shall provide temporary ladders to all shafts, with landings at intervals not exceeding 6 m. Protection shall be so provided that neither the ladders, landings, supporting structures nor persons using them are subject to the risk of damage or injury by the passage of skips and/or materials in the shaft. 2. Segments used in shafts shall so erected as to break vertical joint except in any rings required to be broken out. 3. Where shafts are constructed by underpinning and lined with segments, they shall be grouted up at least once per shift. 4. After any primary lining is complete and before any openings are made at or near the foot, the excavation for the base of the shaft shall be taken out and the base concrete. 5.28 OPENINGS IN SHAFTS AND TUNNELS 1. The Contractor shall supply to MWC drawings showing his proposals for forming opening in shafts and tunnels. These drawings shall include details of temporary supports to the lining and to the ground. 2. Openings in shafts and tunnels shall only be made after the segments have been grouted. 5.29 SEGMENTAL SHAFT AND TUNNEL LININGS 1. Before each ring of any segmental lining is erected, any loose material or other obstruction shall be removed from any exposed Final Surface. 2. Segments shall be erected and assembled in-situ ring by ring and joint faces shall clean on erection. The lining shall be built as soon as possible after the ground has been cut. 5.30 UNBOLTED CONCRETE TUNNEL SEGMENTS 1. The shape of unbolted concrete tunnels shall be maintained within tolerance after erection, until the segments have been established by grout or other means. 2. Where a circumferential pre-stress is applied, the force shall be such that the whole of the concrete lining is expanded tight against the surrounding ground. An approved graphite compound shall be applied to the wedge faces of segments immediately prior to expanding the ring.
3. Where wedge block segments are specified, the excavated tunnel periphery shall be lubricated to reduce skin friction. 4. Where key segments are shorter than other segments comprising the ring, the pockets formed shall be filled with Class B (17 MPa) concrete. 5.31 BOLTED CONCRETE SEGMENTAL LININGS 1. Segmental joints to bolted concrete tunnel and shaft linings shall be true and longitudinal joints bolts tightened before the final tightening of the circumferential joint bolts connecting the ring to the adjacent ring. 2. Bituminous jointing strip shall be provided to longitudinal joints. 3. Packing shall be inserted in the joints of the lining at the time of erection, as required, to maintain correct shape, line and level. 4. Two grummets shall be threaded on each bolt to be grummetted, at the time any bolted segment is erected. One grummet shall be placed under the washer at the head of the bolt and the other under the washer at the nut. 5. Connectors between segments shall be designed and installed such that if they corrode they will not cause spalling of the segments. 5.32 GROUTING OF SEGMENTS Segmental shaft and tunnel linings shall be grouted by forcing the required grout through the grouting holes in the segments, so that all interstices around the outside of the segments are filled. Adequate venting shall be provided to ensure that air is not trapped. Grouting shall closely follow the erection of rings and shall be undertaken at least once per shift. Temporary hardwood plugs shall be inserted into grout holes after grouting; these shall be replaced by permanent plugs of material similar to that of the segments being grouted when it is evident to MWC that grouting has been effective. Grout pipes shall be provided in head walls or ring walls and any void remaining after concreting shall be filled with the required grout. 5.33 CAULKING 1. Caulking of segment joints in tunnels and shafts shall be carried out as late as practicable within the construction program; the grooves shall be raked out and cleaned immediately before caulking. 2. Caulking of circumferential and longitudinal joints shall be bonded to form a homogenous and continuous mass consolidated to fill the recess up to the inner surface of the segment or to the depths described in the Contract. 5.34 POINTING OF JOINTS 1. Where joints between segments are required to be pointed, they shall be raked out, cleaned, filled with a proprietary non-shrink cement mortar and pointed flush. 5.35 SHAFTS AND TUNNEL TO BE WATERTIGHT 1. Shafts and tunnels shall be substantially watertight, with no identifiable flow of water penetrating either the primary or secondary lining.
5.36
RECORDING INFORMATION 1. The Contractor shall keep records of the line; level and the diameter measured horizontally and vertically of any tunnel lining and shall give copies of these records daily to MWC. Similar records shall be kept and supplied for shafts and for pipe jacking.
5.37
JUNCTIONS AND LATERALS ON SEWERS 1. Laterals shall be laid from the junctions to the boundary of the properties. 2. Junctions and laterals shall be effectively sealed with an end cap, the location of which shall be positively indicated.
5.38
MARKER AND INDICATOR POSTS 1. Marker posts shall be erected on the route of the pipeline and indicator posts at the location of valves and other fittings, where shown. 2. Permanent ground markers shall be constructed at locations shown. A schedule of coordinates of the ground markers shall be supplied to MWC on completion of the Contract.
5.39
TOLERANCES FOR PIPELINES, SHAFTS AND TUNNELS 1. The position of the internal face of any pipeline, shaft or tunnel shall not deviate from that described in the Contract by more than the following permissible deviations:
Work category Pipeline Pipe jacking Shafts and chambers Shafts and tunnels
Dimensions or Alignment Line and level Line Level Vertically Finished diameter
Possible Deviation 20 mm 75 mm 50 mm 1 in 300 1% but not exceeding 50 mm 75 mm 50 mm 50 mm 25 mm 20 mm 10 mm
Tunnels without Secondary lining
Line (shield drive) Line (hand drive) Level (shield drive) Level (hand drive) Line Level Maximum lipping between Edges of adjacent Segments
Tunnels with Secondary lining Shaft, tunnel and Sewer lining segments
5mm
5.40
SLEEVE TYPE COUPLING Mating dimensions shall be suitable for the pipe to be joined and shall provide permanent tightness and strength with flexibility. The coupling shall be complete with rubber gaskets, nuts and bolts.
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Installed couplings shall be coated externally with petrolatum paste wrapped with petrolatum tapes and covered with an outer wrapping of PVC tape or roofing paper. Petrolatum tape shall be overlapped to the recommendations of the manufacturer or a minimum of half the width of the tape and extended to 300mm beyond its side of the coupling. The Contractor shall submit samples of petrolatum paste and petrolatum tape proposed along with the manufacturers brochures giving engineering data, application recommendations, and other instructions necessary for a satisfactory application. Protection proposed shall have been in use for at least 5 years. 5.41 JOINTING FOR BELL AND SPIGOT RUBBER RING
1. Bell and spigot shall be cleaned and carefully examined.
2. Lubricate the rubber ring gasket thoroughly with a vegetable compound soap before placing into position and at the same time lubricate the inside face of the bell or the spigot end.
3. Ensure that the rubber ring gasket is properly seated in the spigot groove with a uniform tension is maintained around its entire circumference, or in the bell end as applicable.
4. Ensure that the spigot enters the bell in correct straight alignment, and not at an angle. After engagement, the joint may be deflected in accordance with manufacturers recommendations.
5. Pipe of sufficient size to admit a man shall have a gasket checked for correct position with a feeler gauge from the inside of the pipe, particular attention being given to the bottom half of the pipe. Temporary steel or wood inserts shall be placed between the tip of the spigot and seat of the bell to provide a space for use of the feeler gauge around the entire circumference of the joint. Upon determination that the gaskets in its proper position, all joint spacers shall be removed and the spigot pushed into the bell to its fullest extent as recommended by manufacturer. The gasket position for pipe of smaller size shall be examined around the entire circumference from the outside.
6. Joints of pipe 600mm diameter and larger shall be pointed on the inside with (one (1) part cement to three (3) parts sand) cement mortar after the backfill has been placed.
5.42
INTERCONNECTION BETWEEN PIPES
1. At points of connection to existing mains, the Contractor shall excavate and inspect the pipe or valves to determine the material type and make measurements. Following measurements, the hole shall be backfilled and the surface temporarily restored with asphalt pavement.
2. Based on the field data, the Contractor shall prepare and submit sketch for MWCs approval.
3. Where called for on the Drawings, the Contractor shall supply and install specific fittings as well as any other fittings required for interconnections. Where specific fittings are not called for, connection can be made by use of a tee, saddle tap, direct tap, direct welding or other means appropriate to the type of pipe being used.
4. Generally, the connections will be made with the pressure at the existing mains reduced to zero unless it would not be possible to do so. The Contractor shall coordinate with concerned MWC units regarding the locations of all valves required to shut down and provide the means for checking the valves to be sure that they are operable. MWC will provide assistance in developing this plan.
5. Prior to any connection work, the Contractor shall notify MWC of his intention to commence the particular work. No interconnection work shall be commenced unless an approval by MWC has been given in writing.
6. The Contractor shall inform MWC regarding the expected duration of any water service shutdown due to his interconnection work. However, shutdown of any watermain for a period exceeding twenty four (24) hours will not be permitted. For its part, MWC shall notify all consumers in the area who will be affected by any water interruption.
7. Before starting the work that may interfere with the existing water service distribution, the Contractor shall do all possible preparatory work, including the availability of tools, materials, labor and equipment that will be required to complete the work.
8. Maximum sanitary precautions shall be exercised by the Contractor during interconnection work in order to guard against any health hazard that could precipitate if without due care and precautions being undertaken.
5.43
PIPE SUPPORTS
1. The Contractor shall submit to MWC, shop drawing of pipe support he intends to adopt for construction purposes.
5.44
SERVICE CONNECTIONS
1. Service connections shall be with corporation stop or ferrule.
2. Corporation stop shall be tapped at a 45 degree angle pointing upward. Ferrules shall be tapped at the top of the watermains.
3. Service connection tubing may be installed under concrete pavement by boring horizontally beneath the paved surface at the Contractors option. The Contractor shall prove and
demonstrate that his method will not disturb the existing pavement and base course nor cause settlement that will damage the road surfaces and shall be to MWCs approval. If method involves jacking a temporary casing, the casing may not be withdrawn if such operation shows any danger of damage to the pavement or service connection. Boring by water jetting is not permitted.
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SECTION 6 BUILDING WORKS
6.1
BRICKWORK AND BLOCKWORK GENERALLY 1. Brickwork and blockwork shall comply with the relevant provisions of the ASTM A36 Standard Specifications, Part I. Stonework shall comply with relevant provisions of ASTM C 503-89 and ASTM C 568-89. 2. The moisture content of the bricks shall be adjusted so that excessive suction is not exerted on the mortar. 3. Bricks in each course shall be break joints correctly with the bricks underneath. The courses shall be laid parallel with joints of uniform thickness and shall be kept straight or regular curved as required. Vertical joints shall be in alignment as required by the bond and both vertical and horizontal joints shall have an average thickness of 10mm. Bricks forming reveals and internal and external angles shall be selected for squareness and built plumb. 4. Brickwork and blockwork shall rise uniformly; corners and other advanced work shall be raked back and not raised above the general level more than 1.00 m. No brickwork or blockwork shall be carried up higher than 1.50 m. in one day. No bats or broken bricks shall be incorporated in the work unless essential for bond. Where cut blocks are required, all cutting shall be carried out with a mechanical cutting disc. 5. Completed brickwork and blockwork shall be protected at all times from scaffold splash, mortar droppings, grout leakage from suspended slabs and the harmful effects of weather. Brickwork and blockwork shall be allowed to set thoroughly hard before cutting or chasing is carried out. 6. The required class of mortar and type of cement shall be described in the Contract or, shall comply with the relevant provisions of the DPWH Standard Specifications, Item 705. 7. The required thickness and bond for brickwork and blockwork is indicated on the drawings.
6.2
BRICKWORK AND BLOCKWORK, JOINTING AND POINTING 1. Bricks and blocks shall be laid in mortar, properly bedded and jointed and all joints filled with mortar at every course. 2. Where the surface of walling does not provided an adequate key, the joints on faces of walls to be plastered shall be raked out 12 mm. 3. The type of jointing and pointing shall be described in the Contract. 4. Provision shall be made in the Contract for sample areas of different wall types and finishes.
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6.3
DAMP PROOF COURSE 1. Construction of damp proof courses shall comply with the manufacturers instructions and requirements, and shall be described in the Contract Specific Document. 2. Damp proofing shall comply with the relevant provisions of ASTM D41, ASTM D43, ASTM D226, ASTM D227, ASTM D449 and ASTM D450.
6.4
CORBELLING 1. Over sail corbelling shall not exceed 30mm on each course.
6.5
BONDING TO CONCRETE 1. Where brickwork or blockwork is to be bonded to concrete, this shall be achieved by means of metal ties evenly spaced at 600mm to vertical and 800mm to horizontal of the wall surface, and brickwork and blockwork shall be brought up subsequent to the concrete. 2. Additional ties shall be provided near the sides of all openings such that there is one for each 300mm height of the opening.
6.6
UNDERPINNING 1. Underpinning in brickwork or blockwork shall be carried up to within one course of the underside of the existing structure and allowed to set. The remaining course shall be bedded in mortar and wedged with slate pieces tightly against the existing structure.
6.7
CENTERING AND LAGGING
1. Centering and lagging used for the construction of brickwork and blockwork shall remain in place for such time as is necessary for the brickwork and blockwork to develop sufficient strength to prevent sagging or cracking of joints.
6.8
PREPARATION FOR PLASTERING
1. The surface of in-situ concrete shall be cleaned of dust, loose particles and other matters. Surfaces shall be wetted immediately before plastering is commenced.
6.9
CEMENT PLASTERING
Cement plastering shall normally be applied in one coat and batches shall be used as soon as possible after water has been added. The total thickness of the coat shall be of the order of, but shall not exceed, 20mm.
Where the finished thickness of the plaster is to be greater than 20mm, then 2 coats shall be used and the thickness of the base coat shall not be less than 13mm.
Concrete masonry and hollow block surfaces shall be dampened by brushing or spraying with clean water, mixed 1 part bonding agent to 5 parts water.
The plastering mortar shall be a mixture of Portland cement and washed sand by volume in the proportions of 1 volume cement to 3 volumes of sand, together with 1 part of liquid bonding additive to 3 parts of water. The dry cement and sand shall be thoroughly mixed before the mixture of the liquid additive, with water of the proper proportions, is added to the dry mortar mix. The complete mixture shall then be mixed into a workable mortar paste.
Before the base coat has hardened, it shall be evenly scored to assist in bonding the finish coat. When the base coat has hardened enough to receive the finish coat, it shall be dampened and the finish coat applied. The finish coat shall be finished to give the appearance of a rubbed finish, or as otherwise required to match the surrounding surfaces.
Plastered surfaces shall be shielded from the direct rays of the sun for two (2) days and shall be kept moist.
6.10
OTHER FLOOR WALL AND CEILING FINISHES
1.
Ceramic Tiles a. General All tiles shall be installed by competent tradesmen and in accordance with the best practices of the trade. Finished surfaces shall be produced in the true plans, free of damage, scratches, or otherwise faulty tile in all places solidly backed up and firmly secured. All tiling work shall be laid out so that field or pattern is exactly centered on the area to preclude the use of tiles less than full size; do any cutting along edges of area. Joints of uniform standard width and in true alignment shall be maintained throughout; completely fill with grouting or pointing mortar and finish smooth and flush with tile. Cut and drill without marring tile, smooth cut edges with a fine stone. Fit carefully around pipes, outlets and similar items so that cover plates or trim will cover the cut edges. Remove surplus mortar and grout from tile surfaces before these have set. Samples. Duplicate samples of each color and kind of tile shall be submitted to MWC for approval. All materials installed in the work shall match the approved samples. b. Materials Ceramic tile for toilet walls shall be white glaze ceramic tile, size 300 mm x 300 mm (12 x 12). Caps, inside and outside corners, and other moldings, as required, shall be provided. Ceramic tile for toilet floors shall be vitrified unglazed, 300mm x 300mm (12 x 12). Acid resistant vitrified tile shall be used in the laboratory. Portland Cement shall be standard brand per ASTM C-150.
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Tile adhesive and grout shall be of approved brand and quality. c. Installation
All tiles shall be delivered to the site in sealed containers with labels intact. All tiles shall be set in full mortar bed with all joints plumb and to indicated heights. Mortar bed for floor tiling shall be spread until the surface is level or sloped for drainage and as large an area that can be tiled before the mortar has reached initial setting. Vertical tiles shall be plumb. The back of all tiles shall be covered with tile adhesive to make the bed full and even. All tiles shall be soaked in water for twenty-four (24) hours before laying. For wall tile, spread Portland Cement paste with a trowel on the back side of the tiles and set on the prepared walls, true to line and plumb. Set wall tile with slight twisting motion to assure suitable contact with the wall. Caulking. At completion of tile work, clean cut joints between tiles of excess adhesive and finish with cement paste. Clean-up. Excess adhesive materials shall be removed from face of tile with soft cloth dampened with water or kerosene as the case may be.
Plain Cement Finish a. General Colored cement shall be delivered in cartons, cans or kegs to the building site with the labels intact and seals unbroken, subject to inspection by MWC before being opened. Sample. Where colored cement and colored floor hardener cement finish and surface finish are required, samples shall be submitted to MWC for approval. Final choice shall be his. b. Materials Fine aggregate shall consist of sand, stone screenings or other approved inert materials with similar characteristics or a combination thereof, having clean, hard, strong, sound, durable, uncoated grains, free from injurious amount of dust, lumps, soft or flaky particles, shale, alkali, organic matter, loam or other deleterious substances. The use of beach sand is prohibited without the written consent of MWC. Gradation shall be as follows: Percent Passing Sieve No. 10 (2.00 mm) No. 16 (1.18 mm) No. 100 (150 mm) No. 200 ( 75 mm) Fineness modulus Water/cement, ratio by weight Limit 100 95 to 100 25 max. 10 max. 1.6 to 2.5 0.65 max.
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If the fineness modulus varies by more than 0.20 from the value assumed in selecting proportions for the mortar, the aggregate shall be rejected unless suitable adjustments are made in proportions to compensate for the change in grading. Portland Cement. In accordance with the requirements of SES 6.9. Floor Hardener. Non-metallic aggregate hardeners, inorganic pigments and binders, non-slip and colored by Armor top or approved equivalent at the rate of 60 lb per square foot or equivalent, to medium traffic mixture. c. Installation The concrete sub-floor shall be cleaned and then moistened but not soaked, after which dry cement shall be sprinkled over the surface and the mortar spread on the setting bed. Tamp to assure a good bond over the entire area and screed to provide a smooth and level bed at proper height. Mix mortar one (1) part Portland cement to two (2) parts sand. To finish the surface with colored, sprinkle enough quantity that will assure average. Finish with mason pallet joints. Keep free for 48 hours. Vinyl Tiles (Not Recommended) a. General Submit one piece sample of vinyl tile to be used. Deliver all materials in good condition to the job site in manufacturer's original unopened containers with label information clearly marked thereon. Install flooring after all other trades, including painting, have been completed. All surfaces to receive resilient flooring finishes shall be dry, clean and smooth. b. Materials Provide 3/32" gauge 12" x 12" tile. Tile shall be resistant to alkali, grease and oils and shall withstand static loads of 50 psi. Install tile with conventional full-spread system with S-89. c. Execution Inspection: Examine substrate and conditions under which flooring is to be installed. Do not proceed with installation until unsatisfactory conditions have been corrected. Preparation: Concrete shall be smooth with no more than 1/8" variation from the plane within any ten (10) feet. Grind down all ridges and other irregularities. Fill all cracks, holes and depressions with latex cement underlayment (patching compound) as recommended by the flooring manufacturer. Remove all paint, oils, waxes, sealers (and curing compounds not compatible with the adhesives employed). Organic solvents are to be avoided.
Moisture test: Determine the suitability of the concrete subfloor for receiving the resilient flooring with regard to moisture content (curing compounds) by a bond test as recommended by the flooring manufacturer. Subfloor cleaning: Broom or vacuum clean subfloor prior to the installation of the flooring material. Installation: Layout: Lay flooring material with a minimum number of seams consistent with prudent use of the materials. Avoid cross seams. Adhesive application: Mix and apply the adhesives following the manufacturer's instructions, observing the recommended trowel notching, spread rates and open times. Flooring installations: Install the flooring in strict accordance with the manufacturer's written instructions. Seal all seams in the flooring, using tools, materials, methods and sequence of work in conformance with the written instructions of the flooring manufacturer. Finish all seams flush to the floor and free from voids, recesses and raised area. Cleaning and protection: Remove all excessive adhesives from the surface of the flooring. Plywood Plywood shall have a thickness of 6mm. Plywood 19mm thick and thinner shall be at least three ply. Face wood shall be Tanguile. All plies shall be bonded by the hot plate method with urea (white) glue. Plywood specified to be waterproof plywood shall be bonded with water resistant thenol (red) glue. Plywood shall be formed using presses that exert a minimum of 1.0 MPa pressure. The pressure shall be maintained for 15 minutes. Plywood panels shall be prefinished on both sides. The grade of finish shall be firstgrade according to local practice, unless otherwise specified. Acoustic Ceiling Systems (a) Materials Acoustic Tiles: Acoustic Mineral Board Ceiling shall be 600 mm x 1200 mm x 16 mm lay-in regular of "Armstrong" Brand.
1.
Design a. Armstrong - Mineral Board for offices
2.
Armstrong Retention Clip
Primary Suspension Members 1. Wire Hangers Inserts: 5 millimetre diameter galvanized wire loop and 0.6 millimetre thick galvanized shell or 2 millimetre thick galvanized steel strap with 8 millimeter hole.
(b)
Installation (1) Install materials and systems in accordance with manufacturer's printed instruction. Use procedures that will minimize damage or soiling of the units during installation. Coordinate spacing of hangers, carrying channels, runners and molding with the location of electrical fixtures and other items in or on the ceiling. Seismic Bracing: Support ceiling suspension system within 2 metres of wall and at 4 metres on center in each direction with four 2.8 millimetre wires connected within 50 millimetres of an intersection of a main runner with a cross runner and sprayed 90 degrees from each other at an angle not exceeding 45 degrees from the plane of the ceiling. Center tile pattern both directions in each major space or room as indicated or directed and where possible, adjust pattern so that edge pieces will be not less than 50 millimetres in width. Provide bracing above the ceiling plans as required to stabilize the ceiling system. Do not attach runners to wall mouldings. Make exposed surfaces of acoustical units level and flush with joints straight and true. Neatly cut and fit units around light fixtures and around other items protruding through acoustical ceilings. Install exposed members with flush hairline joints. Provide color coded tacks at access tiles to designate locations of mechanical and electrical access.
(2) (3)
(4)
(5) (6)
(7)
(c)
Adjusting and Cleaning (1) Clean or replace units that have been soiled or damaged.
6.11
CARPENTRY AND JOINERY
1. Framing members shall not be spliced between bearing points, and shall be free from pronounced defects. Joints and splices shall be bolted or spiked together, and shall occur over bearings only.
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2. Holes for bolts shall be of the same nominal diameter as the bolt. Plate washers shall be installed under heads and nuts of all bolts in contact with wood. Nuts shall be drawn tight and threads burred to prevent loosening.
3. Screws shall be screwed and not driven into place. Pilot holes may be drilled for screws the same diameter as the shank.
4. The sizes shown for wood on the Drawings are the nominal sizes. All dressed lumber after planing shall not vary from the indicated dimensions by more than ten percent (10%). Thickness and width of lumber shall be uniform throughout its length. Lumber shall not be delivered to the site in lengths shorter than 2.5 meters.
5. When wood frames are to be installed against concrete or masonry, the face of wood in contact with masonry shall have two (2) coats of wood preservative compound or asphalt as approved by MWC, applied and allowed to dry before fixing.
6. Generally, cutting and shaping of all timber shall be completed before preservative treatment is carried out. When any cutting or shaping has to be carried out after treatment, the cut or worked surface shall be given 2 coats of the preservative. After treatment, timbers shall be thoroughly dried out before use.
7. Where timber is to receive decorative finishes, then, after the application of any preservatives and drying out, any knots or resinous areas shall have 2 coats of knotting applied before finishes.
6.12
STRUCTURAL STEELWORK
1. All steelwork shall comply with the relevant provisions of the ASTM A36/DPWH Standard Specification, Item 712 or, as described in the Contract.
2. All members shall be cut to length by cold sawing.
3. Where a structural member is supported on masonry or brickwork, the minimum length of bearing shall be 100mm.
4. End connections, base plates and other design requirements shall be shown on the plans or, described in the Contract.
5. Where steelwork is to be galvanized, it shall be as described in the Contract.
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6. No unplanned holes shall be cut on site in structural steelwork. Clamps shall be used for supporting equipment from structural steelwork. Enlargement of bolt holes on site shall be carried out (and their protective coating made good) to the approval of MWC.
6.13
ROOFS
1. Roof members shall be built in place or fabricated and erected and as shown in the Contract Drawings.
2. Flats and gutters shall be covered with Type WBP plywood or tongued and grooved rot boarding laid diagonally, fir to falls of not less than 1 in 120 for lead and copper and 1 in 60 for bitumen felt or, as described in the Contract.
6.14
TIMBER FLOORS
1. Floor joists shall be either built into brickwork or blockwork, or held in galvanized steel joist hangers, and shall be trimmed as described in the Contract or as directed by MWC. Bridging shall be spaced at every 1.80m apart and shall be 50mm thick to the full depth of the joists or 38mm by 50mm herringbone strutting.
2. Boarding shall be cramped up and nailed with cut flooring nails. Trimmed openings shall have mitred boarders 75mm in width.
6.15
DOOR FRAMES
1. Door frames shall be fitted into prepared openings, drilled and plugged at 3 points per jamb and shall have 100mm by 12mm diameter galvanized steel dowels to posts let into flooring and bedded in non-shrink or epoxy grout.
2. The joint between external door frames and adjacent walls shall be continuously pointed with gun-applied butyl or other approved non-setting mastic.
6.16
WINDOWS
1. Window frames shall be securely fixed to openings in accordance with manufacturers instructions or, as described in the Contract Specific Specifications and, shall be continuously pointed with gun applied butyl or other approved non-setting mastic.
6.17
GLAZING
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General (a) Work Quality All work shall conform to the recommendations of the glass manufacturers. (b) Glass Thickness Thicknesses of glass specified are minimum thicknesses. Thicker glass shall be used where required by governing codes. (c) Accessories Glass and glazing systems shall be installed complete with all stops, blocks, channels, beads, sealants and glass to form a completely installed watertight installation. (d) Leak Test After installation is complete, all exterior glazing shall be given a leak test by flooding the glazing from bottom to top using 20 mm (minimum) hose with nozzle under 3 bars water pressure. (e) Warranty The Contractor shall guarantee that all work performed under this Section will be free from defects in materials and workmanship and will remain watertight for a period of two (2) years from date of building acceptance. Upon receipt of written notice of defect or leakage within the guarantee period, the Contractor shall, at his expense, make necessary repairs or replacement of the defective work. (f) Manufacturer's Label Each piece of glass shall bear the manufacturer's label showing grade, thickness and type of glass and all labels shall remain until the glass has been set and inspected. (g) Certification of Glass Thickness and Grade When glass is not cut to size by the glass manufacturer, the Contractor shall furnish an affidavit stating the grade, thickness and type of glass and manufacturer of the glass furnished. 2. Submittals Stock samples of glass along with manufacturer's literature and installation instructions shall be submitted to MWC for review and approval. 3. (a) Materials General (1) Sealant shall be as recommended by the glass manufacturer and the window manufacturer. Sealant such as 2-part polysulfides for view windows shall be as recommended in the publications of the glass manufacturer, sealant manufacturer, gasket manufacturer and glazer for the intended use. Setting channels and/or blocks shall be neoprene, 85 +5 durometer hardness chemically compatible with sealant use and recommended by glass manufacturer.
(2)
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(3) (4)
Glazing compound shall be as recommended by the glass manufacturer for job conditions. Glazing beads and seals shall be black neoprene or vinyl chloride conforming to ASTM 2287. Glazing tape shall be polymerized butyl, rubber tape, coiled on release paper, manufacturer's standard and shall be as recommended by the glazing sealant manufacturer. Glazing compound for use with wood shall be an elastomeric type recommended for wood and glass use.
(5)
(6)
(b)
Glass Types Type A: Tinted colored tempered float glass shall be heat-treated safety glass 6 mm minimum thickness used for exterior window wall lites. The glass color shall be bronze. Type B: Clear tempered float glass shall be heat-tempered safety glass and shall not be less than 6 mm thick. This glass type shall be used for interior windows and window wall lites within 0.40 m of floor, entrance doors and door lites. Type C: Mirrors shall be 6 mm select mirror glazing quality mirrors.
4. (a)
Execution Inspection Areas to receive glass and glazing shall be inspected and defects shall be reported to MWC. All glazing shall be done in accordance with the applicable Referenced Standards.
(b)
Manufacturer's Recommendations Preparation work such as priming and cleaning shall be done with materials and procedures recommended by the manufacturer.
(c)
Surfaces Surfaces shall be dry and free from dust, dirt and film. All priming shall be completed and thoroughly dried before glazing.
(d)
Unfavorable Weather Conditions No work shall be performed in damp, foggy or rainy weather.
(e)
Concealed Edges Concealed edges of glass shall be clean, straight cut and free from chips and fissures. All glass shall be shop-cut and allowances shall be made for maximum grip on all edges. Nipping glass on the job will not be allowed. Glass shall be accurately cut to size of opening. Glass shall be set with equal bearing on entire width of pane. Large sheets of glass shall be positioned with setting blocks. Glass shall not move or rattle. Glazing Beads Glass in glazing beads or channels shall be in accordance with manufacturer's printed installation instructions. Materials shall not be stretched.
(f)
(g)
Stop Glazing
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Glass set with stop glazing shall be set on glazing tape. All voids around perimeter and between glass and stop shall be filled with glazing compound to provide a completely watertight installation. Tape and compound shall be trimmed flush to sight line. (h) Sealant Sealant shall be applied on inside glass surface below glazing bead. Void below vinyl to bottom of glazing reglet shall be filled to maintain weather tight seal. (i) Metal Glazing Beads Where metal glazing beads occur, the glass shall be set completely bedded in glazing compound. Metal glazing beads furnished by the manufacturer shall be installed in accordance with manufacturer's printed instructions. Compound shall be trimmed flush to sight line. (j) Identification for Safety Glass, glazing panels and glazing shall be protected by clear identification by indicating devices which indicate the presence of glass to other workers and materials handlers. Taping or marking on the glass which would cause a permanent stain shall not be used. (k) Workmanship Glass and glazing shall be left in perfect condition and ready for final cleaning. (l) Acceptance Prior to acceptance of the work, broken, defective or scratched glass shall be promptly replaced, and damaged glazing compound shall be repaired.
6.18
PAINTING
All painting shall be carried out by craftsmen who are qualified and skilled in the trade.
Manufacturers printed instructions shall be strictly followed in the application of proprietary coatings.
Wood surfaces to be painted shall be first cleaned of dirt, oil or other foreign substances with mineral spirits, scrapers, sandpaper or wire brush. Coatings shall be applied only on thoroughly dry surfaces and during periods of favorable weather, not in extreme heat, nor in dust or smoke-laden air, nor in damp or humid weather.
No consecutive coat of paint shall be of the same shade, with the exception of white. Each coat shall be given a minimum drying time of 72 hours and shall be inspected by MWC prior to application of the next coat. Areas found to contain runs, roughness, or other signs of improper application shall be required to be recoated in accordance with the instructions of MWC.
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Woodwork shall be sanded smooth where nail holes and minor imperfections shall be filled with putty between first and second coat; color of putty shall match stain in the case of stained work.
Drop cloths shall be placed where required to protect floors and equipment from splatter and droppings.
6.19
ROOF COVERINGS
1. Roofing Panels: Shall be rib-type having a cross sectional profile and depth as specified and indicated in drawings. Roof panels shall be capable of supporting design loads between unsupported spans with deflection not greater than 1/180 of the span width on roofs, but in no case shall the wall thickness of the sheets for the panels be less than specified herein. Where gauges are specified, they are subjected to normal manufacturing tolerances. Roofing or an approved equal, with a total coated thickness of not less than 0.60 mm utilizing a double baked-on epoxy primer and high grade polyester color finish. Accessories: Sheet metal flashing, trim, moldings, closure strips, caps, splash pans, and other similar sheet metal accessories used in conjunction with preformed metal panels shall be made of the same material and finish as used for the panels, except that such accessories which will be concealed after installation, may be provided without the finish if they are aluminum or zinc-coated steel. Thickness of the metal shall be not less than that used for the panels. Molded closure strips shall be closed-cell or solid-cell synthetic rubber, neoprene, or polyvinyl chloride pre-molded to match the configurations of the preformed metal panels. Finish color for flashing, trims, moldings, caps, and other exterior metal components shall be as selected and approved by MWC. Fasteners: Fasteners for attaching panels to structural supports and to adjoining panels shall be as approved and in accordance with the manufacturers recommendations. Unless specified otherwise, the fasteners shall be either self-tapping screws, bolts and nuts, self-locking rivets, self-locking bolts, end-welded studs, bolted or riveted studs, or step rivets held by steel straps. Design the fastenings system to withstand the design loads indicated. Fasteners, with the exception of those having integral hexagonal washer heads and those having aluminum drive caps, shall have composite metal and neoprene washers. Fasteners having integral hexagonal washer heads and fasteners having aluminum drive caps shall have polychloropene washers. Screws: Not less than No. 14 diameter self-tapping type or self-drilling and self-tapping type. Blind Rivets: Stainless steel with 5 mm (3/16 inch) nominal diameter shank or aluminum with 5 mm (3/16 inch) nominal diameter shank. Use threaded-stem-type rivets for other than the fastening of trim. Rivets with hollow stems shall be closed. Bolts: Not less than 6 mm (1/4 inch) diameter, shouldered or plain shank required, with nuts. Joint Sealing Materials: Shall be as recommended by roofing panel manufacturer. Installation: Install in accordance with the manufacturers approved erection instructions and diagrams, except as specified otherwise herein. Panels shall be in full and firm contract with supports and with each other at side and end laps. Where sheets are cut in the field or where any of the factory-applied coverings or coatings are abraded or damaged in handling or installation, they shall, after the necessary repairs have been made with materials of the same type and color as the weather coating, be approved before installation. All cut ends and edges, including those at openings through the sheets, shall be sealed completely.
Correct defects or errors in the materials in an approved manner. Remove materials which cannot be corrected in an approved manner and provide non-defective materials. Provided molded closure strips where indicated and whenever sheets terminate with open ends after installation. Roof Sheets: Apply roofing sheets with the configurations parallel to the slope of the roof and as indicated on drawings. Provide roofing sheets in the longest lengths obtainable, with end laps occurring only at structural members with no transverse joints except at the juncture of ventilators, roof hatch, and similar openings. Lay all side laps away from the prevailing wind and seal side and end laps with joint sealing materials. Flash and seal the roof at the ridge, at eaves and rakes, at projections through the roof, and elsewhere as necessary. Accomplish the placement of closure strips, flashing, and sealing material in an approved manner that will assure complete weather tightness. Flashing: all flashing and related closures and accessories in connection with the performed metal panels shall be provided as indicated and as necessary to provide a watertight installation. Details of installation which are not indicated shall be in accordance with the panel manufacturers printed instruction and details or the approved shop drawings. Installation shall allow for expansion and contraction of flashing. Fasteners: Fastener spacing shall be in accordance with the manufacturers recommendations and as necessary to withstand the design loads indicated. Install fasteners in valleys or crows as recommended by the manufacturer of the sheet being used. Install fasteners in straight lines within a tolerance of 12 mm in the length of a bay. Drive exposed penetrating type fasteners normal to the surface and to a uniform depth to seat gasketed washers properly and drive so as not to damage factory-applied coating. Exercise extreme care in drilling pilot holes for fastenings to keep drills perpendicular and centered in valleys or crowns, as applicable. After drilling, remove metal filings and burrs from holes prior to installing fasteners and washers. Torque used in applying fasteners shall not exceed that recommended by the manufacturer. Remove sheets deformed or otherwise damaged by over-torque fastenings, and provide new sheets
6.20
LIGHTWEIGHT CONCRETE ROOF SCREED
1. Lightweight concrete roof screeds shall be laid to the necessary falls and shall comply with the relevant provisions of the DPWH Standard Specifications, Item 702.
6.21
ASPHALT ROOFING
1. Mastic asphalt shall comply with relevant provisions of the DPWH Standard Specifications, Item 702, and shall be laid on an underlay of sheathing felt, laid loose and with joints lapped at least 50mm. The roof shall be set out with properly formed high points, water lines and mitered bays where required.
6.22
BITUMEN FELT ROOFING
1. Built-up bitumen felt roof covering shall comply with the relevant provisions of the DPWH Standard Specifications, Item 702.
6.23
SURFACE TREATMENT TO FLAT ROOFS
1. Mineral aggregates for flat roofs shall be applied to flat asphalt and bitumen felt roofs where so described in the Contract.
6.24
PLUMBING
1. Installation of plumbing for domestic water supply and for sewer systems shall be described in the Contract.
6.25
OPENING IN WALLS, FLOORS AND CEILINGS
1. The Contractor shall box out and/or cut openings through walls, floors and ceilings for the passage of pipes and cables and, where described in the Contract, shall provide and fix in position approved tube sleeves cut off flush with the finished surface. All openings and ducts shall be sealed on completion to prevent the passage of toxic or explosive gases.
6.26
TOLERANCES FOR BUILDING WORKS
1. Tolerances for building works, except where otherwise described in the Contract, shall not exceed the permissible deviations from levels and dimensions for the corresponding types of work given and described in the Contract. 6.27 NAILING
1. Nails shall not be driven closer together than their length unless driven in drill holes, nor closer to the edge of the member than its length. Holes drilled slightly smaller than nail diameters shall be used when necessary to prevent splitting. The nails shall penetrate the second or farther member to not less than of the length of nail. Common nails shall be used unless otherwise specified or shown.
6.28.
METAL DOORS, WINDOWS AND FRAMES
1. (a)
General Work Quality All work shall be in accordance with manufacturer's published recommendations and specifications.
(b)
Work Coordinator
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All work shall be coordinated with appropriate related work to assure proper installation. Field conditions and dimensions shall be verified prior to fabrication. (c) Quality Standards All work shall conform to American Society for Testing and Materials (ASTM), American National Standards Institute (ANSI), Underwriters' Laboratories, Inc. (UL) Standards and other standards where applicable. (d) Finish Hardware Finish hardware shall be installed as per manufacturer's published directions. All hardware shall be removed after fitting and the final installation of hardware shall be made after the finish painting. 2. Submittals Shop drawings, manufacturer's literature and structural calculations that may be required elsewhere in this Section shall be submitted to MWC for review and approval. Shop drawings shall show details of the products and systems, and connections to adjoining materials. Schedules showing sizes, types, and locations of louvers and glass shall also be submitted for approval along with manufacturer's installation instructions. 3. (a) Hollow Metal Doors, Windows and Frames General (1) All work shall be shop-fabricated and shop assembled where possible. Temporary stiffeners, spacers, etc. necessary to facilitate handling and accurate erection shall be provided. All exterior doors, windows and frames shall be fabricated entirely of galvanized materials. After fabrication, all tool marks, and other surface imperfections shall be filled and ground smooth. Doors, windows and frames shall be chemically-treated to ensure maximum paint adhesion and shall have all exposed surfaces painted with a rust-inhibitive primer after fabrication. Prime coat shall be capable of passing 120-hour salt spray test per ASTM B117 and 250-hour humidity test per ASTM Standard D1735. Doors, windows and frames shall be fabricated from prime quality commercial grade-cold-rolled steel conforming to ASTM A366, Type II or III. Doors and frames shall be reinforced and drilled or tapped for fully templated mortised hardware; and shall be reinforced with plates for surface-mounted hardware, meeting ANSI 115 requirements.
(2) (3)
(4)
(5) (6)
(b)
Products (1) Metal Frames a. Pressed metal frames for doors and other openings shall be combination buckled frame and trim of type and sizes as shown. Metal shall not be lighter than 1.6 mm steel. Frames shall be of the welded unit type. Special frames, oversized frames, and frames with transom shall be provided where shown.
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b. c.
Jamb depths, trim profile, and backbends shall be indicated on shop drawings. Frames for multiple or special openings shall have mullion and/or rail members which are closed tabular shapes having no visible seams or joints. All joint between faces of abutting members shall be securely welded and finished smooth. All finished work shall be strong and rigid, neat in appearance, square, true, and free of defects, warp or buckle. Molded members shall be clean cut, straight and of uniform profile throughout their lengths. Corner joints shall have all contact edges tightly closed, with trim faces mitered, welded and finished smooth. The use of gussets will not be permitted. Floor anchors shall be welded inside each jamb, with holes provided for floor anchorage. Minimum thickness of floor anchors shall be 1.8 mm. Frames for installation in masonry and/or concrete walls shall be provided with adjustable jamb anchors of the T-strap, stirrups, and strap, or wire type. The number of anchors provided per jamb shall be as follows: - 3 anchors - 4 anchors - 1 anchor for each 0.60 m or fraction in height.
d.
e.
f.
Frames up to 2.30 m height Frames 2.3 m to 2.45 m height Frames over 2.45 m height g.
Frames to be anchored to previously placed concrete, masonry, or structural steel shall be provided with anchors of suitable design as shown on approved shop drawings. Dust cover boxes or mortar guards of not less than 1 mm steel shall be provided at all hardware mortises on frames to be set in masonry, concrete or plaster walls.
h.
(2)
Metal Doors a. Metal doors shall be full flush design. Face sheets shall be not less than cold rolled stretcher-levelled 1.4 mm steel, hollow metal construction. All doors shall have flush seamless face sheets. The door top and bottom shall be internally reinforced by steel members welded in place. Tops of exterior doors shall be provided with flush weather tight tops. Door louvers for metal doors shall be of metal of the type which integrally frames the opening and can be securely attached. Louvers shall be of the "Z" blades type for exterior and interior use. Exterior louvered openings shall be provided with removable type insect screens. Door louvers shall be uniformly located in doors and be of sizes shown. Glazed openings in doors, (sizes as shown), shall have mitered metal stops. Doors shall be rigid, and neat in appearance, free from warpage, or buckle. Corner bends shall be true and straight and of minimum radius for the gauge of metal used. Double doors shall be provided with a "T" type steel astragals.
b.
c.
d.
e.
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(3)
Metal Louver Windows Metal louver windows shall be of the same gage and of similar construction to door louvers for metal doors.
(c)
Execution (1) (2) Frames shall be set plumb and square in a true plane. Steel shims shall be provided tight between frame anchors and structure, and rigidly attached. Doors shall be installed plumb and square and level with the frames securely anchored to the adjoining construction. Doors shall operate freely, but not loosely. The door clearances shall be 2.3 mm plus or minus 1.0 mm and shall not exceed the manufacturer's printed recommendations. Door after installation shall be free from rattling in a closed position. Finish hardware shall be installed in accordance with hardware manufacturer's templates. Operable parts shall be adjusted for correct function. Hardware, with the exception of prime coated items shall be removed, tagged, boxed and reinstalled after finish painting is completed. Frames installed into previously placed concrete, masonry or steel structures shall have fasteners and fastener frame dimples filled with auto putty or equal. The fasteners and fillers at dimple holes shall be ground smooth (non-visible) before painting. Fastener locations shall not be visible when painting is finished.
(3)
(4)
(d)
Guarantee Any door that becomes warped in excess of 5.0 mm out-of- plane during the 12-month guarantee period under the contract shall be replaced.
4. (a)
Sound Doors General (1) Sound doors and frames shall be complete factory-built and laboratory tested assemblies, complete with perimeter compression seals and automatic door bottom seals at sill. Sound door assemblies shall have a minimum STC rating of 47 db. The Contractor shall provide a certification by the door manufacturer stating that the STC rating is in accordance with ASTM E90 as conducted by a qualified acoustical products testing laboratory.
(2)
(b)
Construction (1) Doors shall be formed of 1.6 mm steel face sheets jointed by welding along the vertical edges. Door tops and bottoms shall be reinforced and completely closed with die-formed 1.6 mm steel channels welded in place. The core shall be incombustible, non-coupling filler. An astragal shall be provided at pairs of doors. Frames shall be fabricated from 1.8 mm steel with the corners mitered, welded and ground smooth. Strike, hinge and other hardware reinforcement shall be of not less than 5.0 mm thick steel. The frame shall be provided with welded floor anchors at each jamb and a minimum of three (3) wall anchors per jamb.
(2)
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(3)
Perimeter seals shall be made of sturdy vinyl with a magnetic tape insert. The hinge side shall be constructed so as to avoid pinching or other distortion of the seal from opening and closing the door. Automatic door bottoms shall close the entire gap between the door and the floor. The seal shall be 50-60 durometer neoprene and the actuating mechanism shall compress or retract the seal properly when the outer face of the door is within 0.05 m of the strike jamb. Doors, frames and seal retainers shall be thoroughly cleaned, phosphatized and factory-primed with rust-inhibitive primer.
(4)
(5)
(c)
Execution (1) (2) Frames shall be set plumb and square in a true plane. Steel shims shall be provided tight between frame anchors and structure and rigidly attached. Doors shall be shipped and stored with temporary stiffeners and spacers to prevent distortion.
5. (a)
Steel-Reinforced PVC Door And Window System General (1) Materials and installation shall be in accordance with the following reference standards: ASTM D2287; Non-Rigid Vinyl Chloride Polymers and Copolymer Molding and Extension Compound. Manufacturer's printed recommendations, specifications and installation instructions. Shop drawings and sample of materials shall be submitted to MWC for approval. The Contractor shall verify all dimensions at the site to assure proper fit of the materials. The drawings shall show the assembly and installation details including anchoring and reinforcing. Samples of the frames, sash, and glazing and accessories shall be furnished. Frame samples shall show the method of connection for the various sections and surface finish. All materials for the Work of this Section shall be delivered, stored and handled so as to prevent damage of any nature. Materials that have been damaged shall be removed from the site and shall be replaced with good ones.
(2) (3)
(4)
(b)
Materials (1) The PVC section frames shown on the Drawings shall be steel-reinforced of which the inner hollow box-shaped galvanized steel core shall be entirely encased in the PVC extrusion material. The PVC material shall meet the requirements of ASTM D2287. The PVC shall be applied by an approved method so that all exposed surfaces, including corners, rabbets and radii are coated to a uniform surface finish with a minimum thickness of 0.15 mm at the webs and 0.25 mm at the flanges and wide flat surfaces. PVC shall be cured in an oven continuously for 15 minutes at 170 C.
(2)
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(3) (4)
Vinyl weather stripping shall be furnished integrally with the coating to the contours indicated on the Drawings. All steel core sections shall be hot-dip galvanized zinc finished for protection against corrosion, in accordance with ASTM A386. Doors shall be of the top and bottom hung type, with no exposed seams. Mechanical joints shall be accurately milled to hairline watertight joints. The doors shall be fabricated to include the steel tension rods, top and bottom wool pile weathering on the sides. Glazing members for doors and windows shall be so designed that they are snapped in, eliminating the use of exposed screws. Glass shall be seated in a gun grade, synthetic-rubber type putty for weather stripping, using neoprene setting blocks. Neoprene setting blocks shall be closed cell neoprene 85 + 5 durometer hardness. Hardware reinforcement on doors and windows shall be fastened in-place without the attaching method being visible. All exposed surfaces of the steel-reinforced PVC section door and windows, including the sash and PVC framing shall be free from defects or other surface blemishes. Edges of handles and appurtenances shall be ground-off smooth to remove burrs.
(5)
(6)
(7) (8) (9)
(c)
Execution (1) (2) All concrete and masonry openings shall be prepared plumb and square. Door and window frames shall be installed plumb and in true alignment in the opening. Frames shall be firmly secure to the floors, walls, heads, ceilings and support members by means of screws with expansion shields. The Contractor shall protect all exposed surfaces against damage from staining, abrasion or other injury and shall be responsible for the final cleaning of the door and window installation.
(3)
6. (a)
Steel Windows General (1) (2) Shop drawings and sample of materials shall be submitted to MWC for approval. The Contractor shall verify all dimensions at the site to assure proper fit of the materials. The drawings shall show assembly and installation details including anchoring and reinforcing. Samples of the frames, sash, and glazing and accessories shall be furnished. Frame samples shall show the method of connection for the various sections and surface finish. Installation shall be in accordance with the manufacturer's recommendations, specifications, and installation instructions. printed
(3)
(4)
All materials for the Work of this Section shall be delivered, stored and handled so as to prevent damage of any nature. Materials that have been damaged shall be removed from the site and shall be replaced with good ones.
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(b)
Materials (1) The steel window frames shall be fabricated of 3 mm minimum thick hot-rolled steel bars which are formed into solid Z-Sections, 25 mm deep, having integrally rolled weathering baffles to provide an uninterrupted perimeter contact between the frame and the casement leaf members. Corners of the frames and windows shall be mitered and electrically butt welded with the exposed surfaces ground smooth. Head drips shall be provided where the casement leaves extend to the top of the window. All casement leaves shall be side hinged and shall be equipped with friction type hinges and washers which shall be welded to the window and frame members. Windows shall be designed for glazing from the outside and be provided with spring wire glazing clips. A polished bronze cam type locking handle shall be provided for each casement leaf. Standard mullions, stove bolts or screws with expansion shields shall be provided for each window. Frames for screens shall be of formed steel and rewireable. Screen cloth shall be of aluminum, 18 x 16 mesh, securely fastened to the frames and held taut by removable plastic splines. All windows and frames shall receive a prime and finish coat of paint.
(2)
(3) (4)
(5) (6)
(7)
(c)
Execution (1) (2) All frames shall be installed using screws and expansion shields. After the setting and just before glazing, all windows shall be carefully adjusted to assure proper alignment and a continuous weather tight seal between the window and the frame. Screens shall fit closely and neatly all around and shall be easily removable. After erection of the windows, precautionary methods shall be employed to adequately protect the exposed surfaces of installed windows from damage due to installation of other work or from acid, cement or other harmful compounds.
(3) (4)
7. (a)
Aluminum Sliding Windows Scope (1) The work covered by this section consists of furnishing all equipment, materials, and labor in t he fabrication and installation of aluminum sliding windows complete in accordance with the applicable drawings and specifications.
(b)
Materials (1) Frames and sash members shall be extruded from Alloy 6063-T5. Corners of frame members shall be fitted to hairline joints secured by tapping screws applied through integral screwpockets. The sill frame shall be of step down design for easy water drain-off, achieved through adequately spaced baffled weep holes. It shall have dual tracks having an arc line contact of 198" with the rollers. Sash members shall
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be self-aligning with the horizontals sleeving onto the verticals held by tapping screws at each corner. The stiles shall be provided with integral pulls notched neatly at the ends to clear the frames during installation. Panel to panel engagement shall be achieved by a can action operation for tighter seal. (2) Weather-stripping: Weather-stripping shall be vinyl and wool pile and shall form a continuous weather seal. They shall be installed snugly in integrally extruded keyways and shall not be loosened nor removed by operating the windows. Weather-stripping for the panels will be one-piece channel shaped gaskets. Hardware: Roller sheaves shall be of nylon having a groove of 1/16" radius. They shall be adjustable and incorporate "Kilian" factory-greased labyrinth sealed radial ball bearings. The locking device shall be a spring-loaded extruded latch that automatically engages special frame lips. The screen sash shall slide on plastic shoes for easy operation. They shall be provided with manually operated locking device. Screens: Frames for the screen shall be independent, but designed to mate to the sliding window frames. The screen mesh shall be of aluminum installed in extruded aluminum tubular frames. They shall be set tautly in integral keyways held in place by vinyl splines. Finish: Exposed aluminum surfaces shall be powder coated, white. Surfaces shall be completely sealed requiring no further application additional coating or preservatives.
(3)
(4)
(5)
(c)
Execution (1) The frames are to be set plumb, level and square without forcing or distorting so that sash panels shall slide easily and quietly. Sliding panels shall retain proper weathering contact with each other and the frames are adjusted to ensure their efficient and smooth operation. Plastic buttons and rubber bumpers shall be installed on the jambs or stiles to secure proper centering of panels and the elimination of metallic rings due to metal contact during sliding operations.
6.29
ILLUMINATION
1. Adequate illumination shall be provided while work is in progress. Whenever required by MWC, the Contractor shall provide additional illumination to cover all areas to be inspected.
6.30
CLEAN-UP
1. The Contractor shall, at all times, keep the premises free from accumulation of waste material and rubbish caused by his employees or subcontractors personnel. At the completion of the painting, all tools, scaffolding, surplus materials shall be removed from and around the building, and the paint work area shall be left broom clean, unless more exactly specified.
2. Upon completion of the work, all staging, scaffolding and containers shall be removed from the site or destroyed in a manner approved by MWC. Coating spots and oil or stain upon adjacent surfaces shall be removed and the job site cleaned. All damage to adjacent
surfaces resulting from the work performed under the Contract shall be cleaned, repaired or refinished to the satisfaction of MWC at no additional cost to the Contract. 6.31 WARRANTY INSPECTION ON 11
TH
MONTH
1. A warranty inspection shall be conducted during the eleventh month following completion of all coating and painting work. The Contractor or his authorized representative shall attend this inspection. All defective work shall be repaired in accordance with the specification and to the satisfaction of MWC. MWC may, by written notice to the Contractor, re-schedule the warranty inspection within the Contract guarantee period, or may cancel the warranty inspection altogether.
6.32
WELDING
1. All welding shall be done by experienced welders using the metal-arc method or gas shielded arc method as described in the American Welding Societys (AWS) Welding Handbook as supplemented by other pertinent standards of AWS. Welding of parts shall be done only where shown, specified or permitted by MWC.
2. In assembly or during welding, the component parts shall be adequately clamped, supported and restrained to minimize distortion and for control of dimensions. Weld reinforcement shall be as specified by the AWS Code. Upon completion of welding, all weld splatter, flux, slag, and burrs left by attachment shall be removed. Welds shall be repaired to produce a workmanlike appearance, with uniform weld contours and dimensions. 6.33 ACCESS AND SUPPORT FACILITIES 1. Walkways and platforms with connecting bridges where necessary shall be provided for access to all plant components where regular inspection and maintenance is necessary. Walkways and platforms shall be skidproof and provided with stainless steel double railings not less than 1 meter in height on both sides and around the outside of the operating platform. Walkways shall not be less than 0.75 m wide. Shall also provide kick plates/toe board 75 mm height all around. 2. Access stairway or ladder shall be provided wherever the difference in elevation between adjacent structures or surroundings ground level is more than 0.60 m. Steps shall be raisedpattern floor plate grating. Access ladders shall be 0.30 m wide minimum with steps spaced at about 0.40 m center. Ladders shall be adequately anchored at bottom, top and at intermediate points. Requirements of stairway shall be in accordance with prevailing local codes. i. Stainless steel handrails shall be provided on stairways, platforms, bridges and other points of personnel access for operation and inspection. A handrail shall be provided around the perimeter of the tank if the top of exposed sidewall is more than 1 meter above grade. Handrails shall be 40 mm diameter and 25mm diameter stainless steel A304 Pipe Schedule 60. STP shall be provided with proper access lighting, ventilation and hoisting equipment for maintenance purposes.
ii.
3. All submerged metalwork shall be stainless steel A316. 6.34 SITE DEVELOPMENT OR RESTORATION WORKS
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1. Site development or restoration works where required or shown on the Drawings shall be as described below: (1) Access pavement/pathwalks shall be of at least 100 mm thick x 750 mm wide slab of 21 MPa concrete; (2) Perimeter and plant lighting shall be in accordance with SES 14; (3) Drainage shall be in accordance with SES 2.49 and SES 11.7; (4) Electric plant lighting shall consist of HPS. It shall be submitted to the Engineer for approval; (5) Fence shall be of CHB & cyclone wires with barb wires; (6) Landscaping shall be in accordance with SES 11.22; 6.35 WOOD DOORS 1. General Doors shall be of the size and type indicated in the schedule and as specified herein. Doors shall be of the quality and workmanship acceptable to the Engineer. The Contractor shall guarantee finished doors against twisting, warping, crack and such other defects due to construction and installation for a period of one year after the final acceptance of the building. 2. Solid Core, Hollow Core, Plywood Flush Type Materials Framings, lock blocks, cores, edging, plywood veneers, shall be of select-grade tanguile or as indicated on the plans, and free from loose or unsound knots or other imperfections that may impair its strength and appearance. Lumber shall be kilndried with moisture content not to exceed 12%. Doors shall be 44 mm (1-3/4") thick and in accordance with the details shown in the applicable drawings. Framing joints shall be mortised and tenoned. Entire core for solid core shall be set close together and bonded to horizontal frames (rails). Plywood shall be 6mm (1/4") thick of selected grade and color. Face veneers of doors intended for exterior use shall be of waterproof plywood. Provide edge strips around sash. Doors frames, cores and plywood veneers shall be glued together and hot-pressed into a one piece panel with molazine waterproof glue. Edge strips shall be glued around edges of doors. Doors shall be held in retainers until glue has set, then redried to remove moisture contained in glue. Assembled door shall be drumsanded, then belt-sanded into a smooth finish ready for vanish or paint. Where indicated, plywood flush doors shall be provided with louvers of sides shown. Louver blades shall be kiln-dried wood as indicated in the schedules. Louver blades shall be uniformly cut finished and fastened to frame in an approved manner. Sufficient reinforcement shall be provided for installation of door closers. 3. Installation
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Hinged doors shall be hung plumbed and fitted accurately allowing 1.5 mm (1/16") clearance at the jambs and heads and 3 mm (1/8") over thresholds. Clearance at the bottom of doors having no thresholds shall be 10 mm (3/8"). Lock stiles of doors 35 mm (1-3/8") thick and thicker shall be leveled 8 mm (1/3"). Knob locks and latches shall be installed 965 mm (38") from the finished floors to the center. 6.36 Fire protection All facilities shall be provided with fire protection facilities as per the latest National Building Code and NFPA. Architectural finishes
6.37
Schedule of architectural finishes shall be as per table below. Architectural Finishes ROOM DESIGNATION INTERIOR FINISHES FLOOR Administration Office Security Bldg. Ceramic Tiles Ceramic Tiles WALL Plain cement plaster painted finish Plain cement plaster painted finish Plain cement plaster painted finish CEILING Acoustic Bd. on Alum. Tee runners Painted finish FICEM BD with steel frame Painted finish No ceiling, provide roof insulation (if applicable) Painted finish No ceiling, provide roof insulation Acoustic Bd. on Alum. Tee runners Acoustic Bd. on Alum. Tee runners
GenSet Room
Colored Hardened
Pump/Blower Room
Colored Hardened
Plain cement plaster painted finish
Laboratory
Ceramic Tiles (acid resistant)
Plain cement plaster painted finish 300mm x 300mm glazed tiles (ht:1.5m)
T&B
300mm x 300mm unglazed tiles
DESCRIPTION CHB Wall Exterior Wall: use 150mm thk. Interior Wall: use 100mm thk. Conc. Columns and Beams (Exposed) Conc. Columns and Beams (Unexposed) PVC Door Steel Doors Ceiling (Exterior)
EXTERIOR FINISHES Plain cement plaster painted finish with groove
Plain cement plaster painted finish with groove Plain cement plaster with groove Enamel paint Painted with epoxy primer base Painted Finish (hardiflex bd. with alum. frame)
NOTE: Paint truss members for room with no ceiling. 6.38 Schedule of doors and windows Schedule of doors and windows shall be as per table below.
Schedule of Doors and Windows

ROOM DESIGNATION Office
DOORS Main:Double swing arm type alum. frame tempered glass (HD) Inside: Solid wooden with vision glass
WINDOWS Alum. Frame Sliding Window
Security Bldg. GenSet Room Pump/Blower Room Laboratory T&B
Solid Wooden Steel Door with louver Steel Door with louver Solid Wooden PVC Door
Alum. Frame Sliding Window Louver Blocks Louver Blocks Alum. Frame Sliding Window Alum. Frame Sliding Window
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SECTION 7 TESTING AND DISINFECTION 7.1 CLEANSING OF PIPELINES 1. On completion of construction and before any testing or disinfection, internal surfaces of pipelines shall be cleared thoroughly in such a way to remove all oil, grit and other deleterious matter. 7.2 PRECAUTIONS PRIOR TO TESTING PIPELINES 1. Before testing any pipeline, the contractor shall ensure that it is anchored adequately and that thrusts from bends, branch outlets or from the pipeline ends are transmitted to solid ground or to a suitable temporary anchorage. 2. No pipeline with the following features shall be tested until the curing periods have elapsed: Feature of Pipeline Cement Mortar lining and coating Cement Mortar at joint Thrust Block Curing Period 7 days 8 days 7 days
3. Open ends and open outlets from appurtenances shall be plugged properly. 7.3 NOTIFICATION OF TEST 1. The Contractor shall notify MWC at least one clear working day beforehand of his intention to test a section pipe. 2. Contractor shall submit a sketch of section of pipeline to be tested. The sketch shall include the section schematically in profile; and show points of air release or water injection and the point of observation. 7.4 TESTING OF NON-PRESSURE PIPELINES 1. Non-pressure pipelines laid in open excavation shall be tested after they are jointed and before any concreting or backfilling is commenced, other than such as maybe necessary for structural stability while under test. 2. The pipelines shall generally be tested by means of an air or water test or in certain circumstances by a visual or closed circuit television (CCTV) examination, in lengths determined by the course of construction, in accordance with a schedule approved by MWC. 3. A further test shall be carried out after the backfilling is complete. 7.5 WATER TEST FOR NON-PRESSURE PIPELINES (EXFILTRATION) 1. The test pressure for non-pressure pipelines up to and including 750 mm shall not be less than 1.2 m head of water above the pipe soffit or ground water level, whichever is the higher at the highest point, and not greater than 6 m head at the lowest point of the section. Steeply graded pipelines shall be tested in stages in cases where the maximum head as stated above, would be exceeded if the whole section were tested in one length.
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2. The pipeline shall be filled with water and a minimum period of two hours shall be allowed for absorption, after which water shall be added from a measuring vessel at intervals of 5 minutes and the quantity required to maintain the original water level noted. Unless otherwise specified, the length of pipeline shall be accepted if the quantity of water added over a 30 minute period is less than 0.50 liter per linear metre per metre of nominal diameter. 7.6 AIR TEST FOR NON-PRESSURE PIPELINES 1. Non-pressure pipelines to be air tested shall be air pumped in by suitable means until a pressure of 100 mm head of water is indicated in a U-tube connected to the system. The pressure is maintained for two minutes to allow temperature of the air to come to equilibrium with the pipe walls. 2. The pipeline shall be accepted if the air pressure remains above 75 mm head of water after a period of 5 minutes without further pumping, following a period for stabilization. Failure to pass the test shall not preclude acceptance of the pipeline if a successful water test, can subsequently be carried out in accordance with Clause 7.5. 7.7 CCTV INSPECTION OF NON-PRESSURE PIPELINES 1. Where internal inspection of pipelines by CCTV is required, the Contractor shall provide all necessary equipment, including suitable covered accommodation for viewing the monitor screen, together with personnel experienced in the operation of the equipment and interpretation of results. 2. The intensity of illumination within the pipe and the rate of draw of the camera shall be such as to allow a proper examination of the inside of the pipe. Provision shall be made for the movement of the camera to be stopped and its position recorded and for permanent photographs to be taken at any point requested by MWC. 7.8 INFILTRATION 1. Non-pressure pipelines (including tunnels) and manholes shall be tested for infiltration after backfilling. All inlets to the system shall be effectively closed, and any residual flow shall be deemed to be infiltration. 2. The pipeline, including manholes shall be accepted as satisfactory if the infiltration, including infiltration to manholes, in 30 minutes does not exceed 0.50 litre per lineal metre per metre nominal diameter. 3. Notwithstanding the satisfactory completion of the above test, if there is any discernible flow of water entering the pipeline at any point, which can be, located either by visual at CCTV inspection, the Contractor shall take such measure as are necessary to stop such infiltration. 7.9 TESTING OF PRESSURE PIPELINES 1. Hydrotesting of pressure pipe lines shall be in accordance with Section 4, AWWA C-600. 2. For pipe sizes smaller than 300mm diameter, the hydrostatic test pressure shall be 100 meters of water column based on the elevation of the lowest point in the pipeline under test and corrected to the elevation of the test gauge. The duration of the pressure test and leakage test shall be for a period of two (2) hours for each test. Any defective pipe, fitting, joint, valve, service connection or hydrant shall be removed and replaced and the test shall be repeated until satisfactory to MWC.
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7.10
SWABBING OF WATERMAINS 1. On completion of the hydraulic test of watermains, a foam swab shall be passed through the main for cleansing, sufficient times to achieve clear wash water.
7.11
DISINFECTION OF WATERMAINS 1. Disinfection of watermains shall be in accordance with AWWA C-651.
7.12
CLEANSING OF STRUCTURES 1. On completion of construction, and before any disinfection, internal surfaces of structures designed to retain an aqueous liquid shall be cleaned thoroughly in such a way as to remove all oil, grit and other deleterious matter.
7.13
TESTING OF CONCRETE STRUCTURES DESIGNED TO RETAIN AN AQUEOUS LIQUID 1. After cleaning, and as far as practicable before any earth or other filling is placed against the outside wall faces, concrete structures designed to retain an aqueous liquid shall be filled with water at a uniform rate of no greater than 2 m in 24 hours. A period of 21 days shall be allowed by the Contractor for stabilization, after which the water level shall be recorded by approved means at 24 hour intervals for a test period of 7 days. During the test period the total permissible drop, after allowing for evaporation and rainfall, shall not exceed 1/500 of the average water depth of the full tank or 10mm, whichever is less. 2. Notwithstanding the satisfactory completion of the above test, any leakage visible on the outside faces of the structure shall be stopped. Any rectification of cracks in the wall section shall, where practicable, be carried out from the inside face.
7.14
TESTING OF ROOFS 1. Roof of service reservoirs shall be watertight and shall, where practicable, be tested on completion by lagooning with water to a minimum depth of 25mm for a period of 24 hours. 2. Where it is practicable, because of roof falls or otherwise, to contain 25 mm depth of water, the roof shall be thoroughly wetted by continuous hosing for a period of not less than 6 hours. 3. In either case, the roof shall be regarded as satisfactory if no leaks or damp patches shown in the soffit. 4. The roof covering shall be completed as soon as possible after satisfactory testing.
7.15
DISINFECTION OF STRUCTURES FOR POTABLE WATER 1. Immediately before acceptance of any structure for potable water, the interior shall be disinfected using chlorinated water to give a residual of not less than 20 mg/litre of free chlorine. The structure shall be emptied, flushed with clean water and then filled with water having chlorine residual of not more than 0.50 mg/free chlorine to normal top water level. 2. After 24 hours MWC shall arrange for a sample to be taken for bacteriological analysis. The structure shall be deemed to be disinfected if there are no coliforms in that sample.
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7.16
PRESSURE TESTING POLYETHYLENE PIPELINES 1. The pressure in the main shall be raised to test pressure at a uniform rate. The time taken between commencement of pumping and achieving test pressure (tL) shall be recorded. This is the Pressure loading time. 2. The pressure will be expected to delay with time due to the characteristic stress relaxation in polyethylene. Readings of pressure delay versus time shall be taken from valve closure, with time being recorded in minutes. A typical sequence of readings is illustrated in Fig. A. 3. As the pressure delay is of exponential form the use of natural logarithmns is necessary when comparing readings. 4. Take a first reading of Pressure P1 at t1 where t1 is equal to the pressure loading time tL. Note tlc = t1 + 0.4 tL 5. Take a second reading of pressure P2 at a delay time of approximately 7tL; this time=t2. Note t2c = t2 corrected = t2 + 0.4tL loge P1 loge P2 Calculate N1 = -------------------------loge t2c loge tlc 6. For a sound main this ratio N1 will be between 0.045 and 0.13. If the value is less than 0.045 then there is too great a volume of air in the main. This air will have to be removed before a satisfactory test can be performed. 7. Take a further reading of pressure P3 at a delay time not less than 15tL. Let this time be t3. Note t3c = t3 corrected = t3 + 0.4tL Loge P2 logeP3 Calculate N2 = -------------------------loge t3c loge t2c If N2 is greater than 0.13 an unacceptable leak is indicated. 8. The sensitivity of the test may be increased by extending the value of t3. 9. On completion of any test sequence, the remaining pressure shall be released slowly and at as near a constant rate as possible. 10. When further pressure testing is required, such test must not be attempted until a period equal at least 5 times the previous test period has elapsed.
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Figure A: Pressure Test Sequence of Pressure Readings
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SECTION 8 ROADWORKS 8.1 GENERAL 1. Except as otherwise specified herein, construction shall be in accordance with the Republic of the Philippines Department of Public Works and Highways, Standard Specifications for Highways Bridges and Airports, Vol. II, 1988 Edition. and ASTM D1559 Resistance to Plastic Flow of Bituminous Mixtures Using Marshall Apparatus, except that all references to payment, methods measurements, basis of payment shall not form part of this Specification. 8.2 CLEARING AND GRUBBING 1. The whole of the area affected by the construction shall be cleaned, all vegetation, roots, stumps, rubbish etc. shall be grubbed up and disposed of off site. 8.3 REMOVAL OF STRUCTURES AND OBSTRUCTIONS 1. The Contractor shall perform the removal, wholly or in part, and satisfactory disposal of all buildings, fences structures, old pavements, abandoned pipelines, and any other obstructions which are not designated to remain, except where such obstructions are to be removed and disposed of under other Items in the Contract. 8.4 EXCAVATION 1. The roadway excavation will include excavation and grading for roadways, parking areas, intersections, approaches, slope rounding, benching, waterways and ditches; removal of unsuitable materials from the roadbed and beneath embankment areas; and excavating selected materials found in the roadways as ordered by MWC for specific use in the construction. 8.5 ROAD FORMATIONS AND SUBGRADE PREPARATION 1. The road formation shall be the surface obtained after completion of any earthworks. 2. Formations, immediately before being covered with sub-base or road base material, shall be clean, free from mud and slurry and properly shaped and compacted to an even and uniform surface. 3. The preparation and surface treatment of formations shall be carried out after the reinstatement of any excavations for services. 4. Following clearing, grubbing and stripping of topsoil, the subgrade shall be prepared by sprinkling with water and rolling with a steel roller until it is compacted to 90 percent of optimum. Subgrade in cut areas shall be scarified to a depth of 0.15 m and recompacted at a moisture content slightly above the optimum 8.6 SUB-BASE AND BASE CONSTRUCTION 1. Within 48 hours of completion of a road formation, granular sub-base material shall be compacted to the required thickness. Base course materials, spread and compacted to the required thickness shall overlie the sub base. The whole shall be protected from deterioration due to the ingress of water, adverse effects of weather and use of Contractors equipment.
2. The finished base course shall not vary more than 1.5 centimeters above or below the set grade at any point. Any area that does not conform to the grading requirements shall be reworked and compacted. 3. Base course shall conform to the requirements of Items 201, 202, 204, 205 and 206 of Department of Public Works and Highways Standard Specification for Highways, Bridges and Airports, 1988 Edition, as detailed on the drawings. 8.7 SURFACING 1. Surfacing shall be as shown on the drawings. It shall be constructed in accordance in accordance with DPWH Standard Specification for Highway Bridges and Airports, 1988 Edition, Items 300 to 311 inclusive. 8.8 CURBS AND GUTTERS 1. Curbs and gutters shall be constructed, and shall be constructed entirely in accordance with DPWH Standard Specification for Highways, Bridges and Airports 1988 Edition, Vol. II, Item 600. 8.9 SIDEWALKS 1. Sidewalks shall be constructed as shown on the drawings, all in accordance with DPWH Standard Specification for Highways, Bridges and Airports 1988 Edition Vol. II, Item 601. 2. Pre-cast concrete flags shall be laid to the required falls on sub-base material as described in the Contract, bonded with joints at right angles to the curb, and spot bedded with Class B mortar with no lipping of top surfaces. 3. Flags shall be cut to fit around surface boxes and other furniture and, on circular work where the radius is 12 m or less, shall be radially cut on both edges to the required lines. 8.10 TOLERANCES FOR FINISHED ROAD WAY SURFACES 1. Finished surfaces at each stage of road construction shall not vary from the levels described in the Contract by more than the following permissible deviations: Surface Formation and sub base Base Wearing surface or slab surface permissible deviation (mm) + 10, - 30 +/- 15 +/- 6
2. The Combination of permitted tolerances in the levels of different pavement courses shall not result in a reduction in thickness of the pavement, excluding the sub-base, by more than 15 mm from the specified thickness, nor a reduction in the thickness of the bituminous wearing course by more than 5 mm from that specified, and the maximum allowable irregularity of the wearing surface below a 3 m straight edge shall be 3 mm.
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SECTION 9 SEWER AND WATER MAIN RENOVATION
9.1
ISOLATION OF FLOWS 1. Flows shall be positively dealt with or isolated from the section under renovation.
9.2
PREPARATORY SURVEY 1. The Contractor shall carry out a survey of the sewers to be renovated to determine the position, size and angle of approach of all laterals, to accuracy appropriate to the method of reconnection. For non-man entry schemes this survey shall be by means of CCTV. Sewers to be lined shall be internally surveyed by the Contractor to establish the critical cross-section profile of the sewer and any other relevant information. The survey information and details of the critical cross-section profile shall be submitted to MWC for approval. Localized areas of damage shall be repaired where possible to maximize the critical cross-section profile. 2. The Contractor shall carry out a survey of the water mains to be renovated to determine their position and size and the position and condition of fittings. 3. Where described in the Contract a survey of the current structural condition of the sewers or water mains shall also be carried out. 4. Valves and hydrants shall be checked to ensure that all are accessible and operable.
9.3
PREPARATION OF EXISTING SEWERS AND WATERMAINS 1. Sewers and watermains to be renovated shall be prepared so that the installation and performance of the renovation system is not impaired. 2. The Contractor shall take all precautions necessary to prevent debris being carried downstream whilst preparing or working in existing sewers and watermains. 3. Before lining or renovation work commences the following operations must be carried out in the sequence below: i) ii) iii) iv) Desilting Repair of any damage to the existing sewer or water main in locations determined by MWC Establishment of lining dimensions (if appropriate) Cleansing and degreasing by low volume high pressure jetting, or other appropriate and MWC approved methods.
All material generated by the above activity shall be disposed of as described in the Contract Document. 4. The Contractor shall submit details of his proposed method of desilting to MWC for comment. 5. Adequate notice shall be given to enable MWC to inspect surfaces prepared for lining. Lining works shall not proceed until such surfaces have been approved by MWC.
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9.4
JOINTING GENERALLY 1. Jointing surfaces and components shall be kept clean and free from extraneous matter until the joints have been made or assembled.
9.5
CONNECTIONS 1. All laterals branches and service connections shall be reconnected and any circumferential lining joints shall not be made at or within 100 mm of a connection. 2. Each finished connection shall be made flush with the lining and shall provide a smooth transition. 3. No connection shall be made to a sliplining system until the latter has relaxed sufficiently to prevent damage.
9.6
INTERMEDIATE CHAMBERS 1. The Contractor shall ensure that at intermediate chambers the edges of the lining are adequately sealed where applicable and the benching made good.
9.7
RELEASE OF CURING WATER 1. Whenever hot water curing of a lining system is carried out the water shall not be released 0 until it cools below 40 .
9.8
ANNULUS GROUTING GENERALLY 1. Annular space between the outside of the lining and the inside of the existing sewer shall be filled with grout. This operation is referred to as annulus grouting. 2. Adequate venting shall be provided to ensure the whole of the annulus is filled with grout. A minimum of two air vents, equally spaced, shall be provided. These vents are to be plugged when all air, water and contaminated or watery grout has been expelled from the annulus. The grout injection pressure shall be continuously measured by a gauge with a full scale 2 deflection not exceeding 100 kN/m max/min. The grouting pressure shall not exceed that given in the Contract Specific Document. 3. The quantity of grout injected at each injection point and the maximum pressure at the nozzle at that point shall be recorded. 4. In man entry sewers the grout shall be injected thorough a minimum of three holes per 5m length of lining. The holes shall be at the haunches and crown of the lining section. 5. Communication between the nozzle operator and pump operator shall be continuously maintained during grouting. A means of rapidly stopping the grout flow shall be provided. 6. Lining units shall be strutted and supported during grouting to prevent stresses being induced in the units, maintain tolerances and prevent deformation. 7. Prior to the commencement of lining works the Contractor shall submit to MWC details of his grouting and strutting proposals. 8. All grouting equipment and hoses shall be thoroughly cleans after each use. 9. The distance the grout is to travel, whether in hose or annulus, shall not exceed 100m.
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10. Unless otherwise agreed by MWC annulus grouting shall closely follow the placing of lining and shall be undertaken in one continuous operation at least once per shift. 11. Segregation of the grout shall not take place during pumping operations. 12. Loss of grout to live sewers is not permitted; the Contractor shall collect and dispose of such grout immediately after each grouting operation. 9.9 INSPECTION AFTER GROUTING 1. Immediately after each grouting operation the Contractor shall inspect the sewer main, branches or laterals and clean out any excess grout. 9.10 LINING THROUGH VALVES 1. Any valves lined in-situ shall be operated throughout their full level several times immediately after lining in order to ensure free operation. There shall be no in-situ lining through valves of pipelines of non-man entry sizes. 9.11 INSPECTION AFTER RENOVATION 1. On completion of the renovation the Contractor shall undertake a survey and provide a record of that survey to MWC. 2. The Contractor shall take and provide MWC with pipe samples in order to check lining performance and to determine thickness. The Contractor shall make good after the samples have been taken. The monitoring of renovation will be used to determine the location of samples. 9.12 BRINGING RENOVATED WATER MAINS INTO SERVICE 1. Before returning any renovated water main into service, the Contractor shall clean and disinfect it in accordance with Section 7. 9.13 LINING TEMPLATE 1. The Contractor shall construct a three dimensional template based on the approved critical cross-section profile less 25 mm all round to allow for the grouting annulus. The template shall have a minimum length equal to that of the proposed lining units and be covered in 2mm thick plywood internally reinforced and strutted as necessary. The length of the template shall be increased and its cross-sectional dimensions reduced as necessary to take account of the deflection limits of the lining section joints and the variations in line, level and cross-section of the sewer. 2. The template shall be drawn through the sewer prior to ordering the lining sections in order to proved the suitability of the profile. If necessary the template shall be adjusted and the proving operation repeated until a suitable profile is established. 3. The Contractor shall supply the lining manufacturer with drawings and dimensions based on the template dimensions. Copies of the information supplied to the lining manufacturer shall be submitted to SM. 4. For non-man entry schemes, immediately prior to installation, a proving pig with solid ends of sufficient rigidity and length to represent the proposed lining system shall be passed down the sewer length to be relined.
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9.14
TOLERANCES FOR PREFORMED LININGS 1. All preformed lining units shall be within the tolerances stated in the Contract Specific Document. Lining units shall readily fit together within the existing sewer. 2. The manufacturer of the lining units shall supply a standard unit of agreed dimensions for each length of sewer involving a different cross-section. All units subsequently delivered will be checked for fit, tolerance and joint deflection limitation against these standard units. The standard units shall be clearly marked and dated by MWC, the Contractor and the manufacturer. MWC will retain the standard units on completion of the Works. 3. Lipping between adjacent edges of units shall not exceed 5 mm. 4. The position of the internal face of any unit shall not deviate from that detailed in the Contract by more than; Line 20mm Level 10mm
No unit shall have a backfall. 9.15 CUTTING OF SEWER LININGS 1. Holes shall be formed using approved drilling techniques and precautions taken to avoid delimitation and spalling. The Contractor shall submit details of his proposed cutting methods MWC. 2. Where lining units are cut the exposed face of the lining material shall be suitably treated to ensure that the integrity and long term durability of the unit is maintained. 9.16 TREATMENT OF SEWER LININGS AT INTERMMEDIATE MANHOLES
At intermediate manholes the lining soffit shall be removed. The edges shall be sealed and the benching made good with a mortar compatible with the chemical resistance of the lining material. 9.17 PLACEMENT OF SEWER LINING GENERAL 1. The lining shall be placed centrally within the sewer unless it is necessary to have a degree of eccentricity to maintain line and level. Spacers shall be used to hold the lining in position prior to grouting to ensure that the minimum grouting annulus of 25mm is maintained. Spacers shall be chemically inert and of strength no greater than the grout used. Spacers shall occupy no more than 5% of the surface area of the sewer. 2. Prior to jointing, surfaces to be mated shall be clean and free from extraneous or deleterious matter. 3. Unless otherwise agreed with MWC lining shall proceed from upstream to downstream with any sockets facing downstream. 4. At the upstream end of the lining the existing invert shall be broken out and the lining laid on a suitable mortar bed so that the inverts are level. At all other points the existing sewer shall be suitably prepared and a smooth transition made with suitable mortar. 5. All exposed edges and ends of polyethylene or polypropylene linings shall be mechanically anchored using suitable fixings.
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9.18
PLACEMENT OF CAST POLYESTER RESIN LININGS (INSITUFORM) 1. The lining shall be transported to site under controlled environmental conditions. The Contractor shall decide when to transport the impregnated lining to the site and when to commence insertion with regard to the weather conditions. 2. For sewers with running infiltration a prelining shall be installed prior to lining inversion. 3. The lining shall be inverted from upstream to downstream into the prepared sewer using cold water. 4. The Contractor shall ensure that the pressure in the lining exceeds both the pressure due to the groundwater head and any pressure due to sewage in laterals. 5. As soon as the lining has been fully installed the resin shall be cured by raising, maintaining and then lowering the internal water temperature in a pre-determined manner to suit the resin 0 system used. The rate of temperature change during heating shall not exceed 1 C/minute. 0 Curing water shall not be released until it has cooled to below 40 C. 6. When the resin has cured the lining ends and any connections shall be cut out and samples removed for quality assurance testing. The installed lining shall generally be free of wrinkles except where a specific degree of wrinkling is agreed between MWC and the Contractor.
9.19
SLIPLINING 1. Details of the Contractors proposed method of winching should be submitted to MWC at least 7 days before insertion begins. 2. The winch shall be fitted with a direct reading load gauge to measure the winching load. At the end of each days winching the Contractor shall provide MWC with records of the forces at the start or restart after temporary stops of any pull and during the pull at increments of 20m winching distance. 3. The winching cable shall be of sufficient length to allow continuous pulls between approved winching points. Guide pulleys and bracing shall be provided at intermediate manholes to minimize cable contact with existing sewer. 4. A nose cone shall be fixed to the first pipe to be inserted. The nose cone shall be attached to the cable using a swivel attachment. 5. Where lubrication is used to ease the pull it shall be water and/or bentonite. 6. Supports to trench sheets shall remain completely separate from the pipe support system and shall be designed so that neither the pipe nor which cable comes into contact with them. 7. Polyethylene pipes shall be supported by a system of rollers at intervals not exceeding 4m. The rollers shall be firmly anchored and capable of vertical and horizontal adjustments where required.
9.20
VOID GROUTING 1. Grout shall be mixed in a paddle, high shear or colloidal grout mixer. Grout pumps shall be diaphragm, centrifugal screw or ram type. An approved method of controlling grouting pressure shall be incorporated at the delivery nozzle of the grouting apparatus. 2. Void grouting may only be carried out in any particular section of sewer when all renovation or relining work has been completed.
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3. Void grouting may only be carried out using holes and drilled through the full thickness of the sewer and lining where appropriate. Holes shall be sufficient number and size to ensure the total removal of air and complete filling of voids. As a minimum holes shall be drilled at 5m intervals along both sides of the sewer at springer level. At the mid-point of the 5m intervals a hole shall be drilled in the sewer invert. 4. Temporary hardwood plugs shall be inserted into the grout holes as each hole is bled. When it is evident to MWC that grouting has been effective, the temporary plugs shall be removed and the holes filled with Class M1 mortar. 5. Grouting plant employed shall be capable of pressures up to 500 Kn/m. The pressure used shall be monitored to prevent loss of grout to the surrounding ground or damage to the sewer. 6. The Contractor shall submit to SM daily records of grout used and pressures obtained throughout the grouting process. On receipt of this information MWC may deem it necessary to vary the grout mix or injection technique. 9.21 CORE SAMPLING 1. Were required by the Contractor the efficiency of annulus grouting and pressure pointing shall be tested by core drilling. 2. Cores shall be 50mm diameter and shall extend through to the outer face of the sewer and 100 mm beyond. Core samples shall be taken at location to be determined by MWC. 3. If voids are discovered within the annulus further cores shall be taken to establish the extent of the deficiency and the affected area re-grouted. 4. If voids are discovered behind the outer face of the sewer further cores shall be taken to establish the extent of the void and the void filled by void grouting.
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SECTION 10 PROTECTIVE COATINGS TO METAL WORK General Note This section does not include the protection of buried pipework. Buried pipework protection is included in Section 5. 10.1 COATING SYSTEM GENERALLY 1. Surface preparation and coating shall be carried out in accordance with this specification. The storage, mixing and use of all coating shall be in accordance with the manufacturers instructions. 2. Preparation and coating methods shall be selected from the table below. Where relevant, the appropriate exposure classes are given in the Contract Specific Specification. The Contractor shall submit completed PC.1 forms (an example form is included at the end of this section) for each intended coating system. Wherever possible a coating system shall use the product of one manufacturer only. CLASS A ENVIRONMENT NON-IMMERSED AGGRESSIVE Substrate Surface Shop Applied (min DFT m) Preparation First Coat Second Third Coat Coat
Galvanized Steel
Degrease Abrade Sweep blast Manufacturers requirements
Steel HZS (100 um)
General purpose epoxy primer (75) MIO Pigmented two pack (50) General purpose epoxy primer (50) General purpose epoxy primer (75) Zinc rich epoxy primer (60)
High build polyamide epoxy (100)
N/A
Site Applied Final Min. Total Coat DFT m (min DFT m) High 215 build two pack urethane gloss 190 (40)
Aluminum
Degrease and Abrade
High build polyamide epoxy (75)
165
Ductile & Cast Iron
Blast SA 2 1/2
265 High build polyamide epoxy (75) MIO Pigmented epoxy (75) 250
Mild Steel
150
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CLASS B ENVIRONMENT IN CONTACT WITH NON-POTABLE LIQUIDS Substrate Surface Site Applied Shop Applied (min DFT m) Preparation First Coat Second Third Coat Final Coat Coat Galvanized Degrease and General High High build Touch up damaged Steel Abrade Sweep purpose areas with third coat build epoxy blast epoxy epoxy resin (150) primer (75) resin (150) Steel HZS Manufacturers MIO requirements Pigmented (100 m) two pack (50) Ductile & Blast SA 2 1/2 General High High build Cast Iron purpose build epoxy epoxy epoxy resin (200) primer (75) resin (200) Mild Steel General purpose epoxy primer compatible with cathodic protection (75) CLASS C ENVIRONMENT IN CONTACT WITH POTABLE LIQUIDS Substrate Surface Site Applied Shop Applied (min DFT m) Preparation First Coat Second Third Final Coat Coat Coat Galvanized Degrease and General High build High build Touch up damaged Steel Abrade Sweep purpose areas with third coat epoxy epoxy blast epoxy (150) (150) primer (75) Steel HZS Manufacturers MIO requirements Pigmented (100 m) two pack (50) Ductile & Blast SA 2 1/2 General High build High build Cast Iron purpose epoxy epoxy (200) (200) epoxy primer (75) Mild Steel General purpose epoxy primer compatible with cathodic protection (75)
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Substrate
Class D Environment Non-immersed, non aggressive Surface Site Applied Shop Applied (min DFT m) Preparation Primer Coat Final Coat Min. Total (min DFT m) DFT m Degrease and Abrade Sweep blast Blast 2 General purpose epoxy primer (75) High built two pack urethane gloss (40) 115
Galvanized Steel
Ductile & Cast Iron mild steel
Substrate
Class E Environment Elevated Temperature 100-400 C Surface Shop Applied (min DFT Site Applied Preparation m) First Coat Final Coat Min. Total (min DFT m) DFT m Blast SA 2 1/2 Two pack inorganic zinc silicate (min DFT 75, max 125) Silicone resin applied until surface is sealed (min DFT 100) Silicone resin (40) Min 115 Max 165
Mild Steel
Steel HAS (100 m)
Manufacturers requirements
Touch up damaged areas
STRUCTURAL STEEL WORKS FOR BUILDINGS Shop Applied (min DFT m) Surface Preparation Primer Coat
Site Applied Final Coat Min. Total (min DFT m) DFT m High build alkyd finish (6) 115
Blast 2
Zinc rich blast primer (20)# and high build zinc phosphate (75)
Or Hot dip galvanize (85)
85
# Blast primer may be omitted if blast cleaning is performed after fabrication. Cold formed components such as purlins and cladding rails shall be formed from galvanized steel. Blast SA 2 - SSPC SP10 or Grade 2 NACE TM 0170/017T NOTE: For Class C environments, second, third and final coats. All products and substances, which may come in contact with raw water to be treated or potable water, shall not be used without prior approval of the CO.
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3. 10.2
The exposure class to be used for the galvanizing of the structural steelwork shall be Class D Environment.
BLAST CLEANING 1. Prior to blast cleaning all weld flux slag, weld oxides, weld spatter, slivers and other defects shall be removed. 2. Sand shall not be used for abrasive cleaning. 3. The surface profile after blast cleaning shall have an average peak to trough measurement not exceeding 50 m. The maximum measurements shall not exceed 75 m. 4. The cleanliness and surface profile achieved by blast cleaning will be judged against the pictorial standard in SSPC VIS 1-89-05 or NACE TM0170/TM0175. 5. The abrasive employed shall produce an anchor pattern on the steel that meets the requirements of the paint manufacturer. 6. Blast cleaning shall not be carried out in close proximity to painting operations or near any equipment or surface susceptible to dust contamination. 7. Any steel not primed on the day of blast cleaning shall be re-blasted before coating.
10.3
CLEANING 1. Oil, grease, salts and other contaminants shall be removed before blast cleaning. Test shall be carried out to ensure such contaminants have been completely removed. If any contaminants remain after blast cleaning they shall be removed and the area reblasted. 2. All contaminants must be removed before any coating is applied. In the event of any contaminant being found in or under a coating layer the area shall be completely reprepared and coated. 3. Data sheets of any detergents to be used shall be submitted for approval.
10.4
PAINTS 1. All paints must be restored, mixed and applied in accordance with the manufacturers instructions. Paints shall be stored in the paint manufacturers original labeled containers. Equipment used shall be that recommended by the paint manufacturer. 2. Paints shall not be used if their shelf or mixed life has expired. Paints that have deteriorated in storage shall not be used. 3. Mixing of multi-pack paints is only to be done on a complete container basis.
10.5
PAINTING 1. Paint coats shall be applied after approval of, and before any deterioration of, the substrate or previous coat. 2. Painting shall not be carried out when metal surface temperature is less than 3 C above the dew point. The dew point and metal surface shall be determined prior to commencement of painting and at intervals not exceeding 4 hours thereafter.
0
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3. Painting shall not be carried out when the relative humidity is greater than that recommended by the paint manufacturer. Painting shall not be carried out during weather conditions that are likely to impair the application or drying of the paint. 4. Each paint coat shall be a different color, of uniform thickness, free from runs, dry over spray, mud cracking or other imperfections. 5. All angles, weld, edges, bolts and nuts shall be stripe coated with the first two coats of the paint system. The stripe coats shall be brush applied after the primer has been applied. 6. Final coat colors for non-buried pipework shall be silver. Colors for other items are given in the Contract Specific Document. 10.6 METALLIC COATINGS 1. Galvanizing shall conform to ASTM A153 or ASTM A123 2. Aluminum and zinc spraying shall be in accordance with ISO 8179. 10.7 TOUCHING UP AND REPAIR 1. Areas where rust is breaking through or where there are rust blisters below the coating shall be cleaned by removing the damage coating and prepare the surface in accordance with this specification. The prepared area shall then receive the complete coating system. The finish of the repaired area shall be indistinguishable from the surrounding coating 2. Coatings damaged or roughened in delivery, erection or by any site operation shall be treated in the same way as rusted areas. 3. Damaged area of fusion bonded epoxy coating shall be repaired using the manufacturers recommended method. 4. All touching up shall be recorded on forms PC3 and PC4. 5. Final coats shall be applied following any necessary touching up after delivery and erection. 6. Where identification marks signs or labels have been removed or obliterated in the coating process they shall be replaced using the original fixing method. 10.8 QUALITY PLAN 1. The Contract shall follow the surface coatings quality plan flow chart. The Contractor shall complete forms PC2A, PC3 and PC4 and submit them to MWC at the appropriate stages. 2. Example forms and the quality plan flow chart are included at the end of this section. 3. Forms PC2 shall be submitted giving 4 working days notice of the completion of any coating stage ready for inspection. MWC of the nominated inspector shall then carry out their inspection and sign for PC2 if satisfied. 4. Form PC3 and PC4 shall be submitted at the time of delivery of any coated plant. These forms must also be submitted in respect of any site-applied coats. 5. The Contractor shall arrange inspection visits by a technical representative of the coatings manufacturer.
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SUBMIT PAINT MANUFACTURER AND
ENGINEERS APPROVAL OF
NOTIFICATION OF STAGE
OPTIONAL ATTENDANCE
SURFACE PREPARATION
INSPECTION
CORRECT DEFFECTS
NO
PASSED
CERTIFICATION
FINAL INSPECTION
PROCEED WITH THE PRIMER COAT
OPTIONAL ATTENDANCE NOTIFICATIONOF STAGE COMPLETION (FORMPC2A) NEXT COAT/STAGE
INSPECTION
CERTIFICATION NO IS THIS THE FINAL COAT/STAGE
NOTIFICATION OF STAGE
FINAL INSPECTION
CORRECT DEFFECTS
PASSED
NO
FINAL CERIFICATION
HANDOVER DOCUMENTATION
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SURFACE COATINGS Quality Plan Flow Chart Form PC.1 (See Clause 10.12)
Surface Preparation and Coating Application Records for Quality Assurance Project_______________________________________________________ Project Title__________________________________________________ Contract N ___________________________________________________ Main Contractor________________________________________________________________ Sub-Contractor/Applicator________________________________________________________ Coating Manufacturer____________________________________________________________ _____________________________________________________________________________ Equipment Description
o
Coat Primer Second Coat Third Coat Final Coat Primer Second Coat Third Coat Final Coat Primer Second Coat Third Coat Final Coat
System Spec. Table
Substrate
Coating Type
Data Sheet o N
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Form PC.1 (See Clause 10.12)
Surface Preparation and Coating Application Records for Quality Assurance Project_______________________________________________________ Project Title__________________________________________________ Contract N ___________________________________________________ Equipment Description
o
Item Ref
Equipment Description
Surface Preparation and Standard
Date of Inspection
Time of Inspection
Name and Signature of Inspector
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Form PC.2A (See Clause 10.9.2) Manila Water Company 489 Katipunan Road, Balara Quezon City FAO:Four Days Notification for Stage Completion of Surface Coating Project Title Project No Contract Number : : :
Date:
Equipment Description :
Stage of Surface Coating: Date of available for Inspection: Address for Inspection:
Contract Name: Tel: Fax:
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Form PC.3 (See Clause 10.9.3)
Coating Application Records for Quality Assurance Project_______________________________________________________ Project Title__________________________________________________ Contract N ___________________________________________________ Equipment Description (Itemized)
o
Item Ref
Equipment Description
Coat
Date
Time
Batch No
WFT um
DFT um
Approved Initials
Final Approval Inspectors Signature
Date
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Form PC.4 (See Clause 10.9.3)
Environmental Conditions during Coating Application Records for Quality Assurance Project_______________________________________________________ Project Title__________________________________________________ Contract N ___________________________________________________ Equipment Description (Itemized)
o
Item Ref
Date
Air Temperature Min. Max.
Substrate Min. Max.
Dew Point Min. Max.
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SECTION 11 DESIGN 11.1 APPLICATION The following clauses refer to those elements of the Permanent Works for which the Contractor has design responsibility. 11.2 DESIGN STANDARDS 1. Design shall be carried out to the requirements of the National Building Code of the Philippines and National Structural Code of the Philippines. 2. Materials used and appearance of structures etc. shall be consistent across the works regardless of the design origin. Plant shall be designed and manufactured to ensure maximum standardization of individual components. 3. All plant and materials shall be suitable for use at ambient temperatures. 4. Where MWC has preference on subjective choices within standards these have been specified below. If no choice is specified the Contractor is free to decide which to use. 5. Where possible the design shall avoid the creation of hazardous areas. 11.3 SLIDING 1. Throughout construction and overall life of the Works, discrete elements and complete structures must have a factor of safety at least 2 against sliding effect of applied forces. 11.4 OVERTURNING 1. Throughout construction and overall life of the Works discrete elements and complete structures must have a factor of safety at least 2 against overturning effect of applied forces. 11.5 FLOTATION 1. Throughout construction and the overall life of the Works elements and complete pipework, discrete elements and completed structures must have a factor of safety at least 1.1 against the uplift force caused by the displacement of ground water or inundation from floodwater. The ground water level to be used for design purpose shall be based on the results of the soil investigation 2. If the use of pressure reducing valves or drainage is allowed to overcome floatation the Contract Specific Document will give details. 11.6 SETTLEMENT 1. Throughout construction and the overall life of the Works settlement of structures shall not cause cracks wider than the design crack width and shall not make the structure unserviceable. Specific settlement limits, overall and differential, are given in the Contract Specific Document. 11.7 CONCRETE STRUCTURES 1. Concrete structures shall be designed to the requirements of ACI-318 or ACI-350 and ACI244 if applicable.
2. The following design crack widths shall be used: 0.1 mm 0.2 mm 0.3 mm Water towers and roofs to tanks containing potable water. All external walls and base slabs to water retaining or excluding structures. All internal division walls (including those subject to differential water loading), baffle walls, columns and beams to water retaining or excluding structures.
max
+ All elements in contact with chlorinated water shall be designed using W 0.1 mm as appropriate. 11.8 BUILDING DESIGN
= 0.2 mm or
1. Building shall be designed to the requirements of national Building Code of the Philippines regardless of whether formal approval is required. If formal approval is not required the Contractor shall complete the Certificate of Design Compliance. Compliance with approved document M, access for disabled people, is not required. 11.9 STRUCTURAL STEEL WORK 1. Structural steel work shall be designed to National Structural Code of the Philippines. 11.10 MASONRY 1. Masonry shall be designed to National Structural of the Philippines. 11.11 TIMBER 1. Timber shall be designed to National Structural Code of the Philippines. 11.12 FLOORING 1. Open type and plate flooring together with support beams etc, shall be designed to the relevant part of National Building Code of the Philippines for the loading it is likely to 2 experience with a minimum uniformly distributed load of 5 kN/m (unfactored). 2. Individual floor panels must be bolted down to prevent unauthorized removal and prevented from sliding sideways by means of permanent steelwork or non-removal locating studs. 3. Elevated areas of flooring shall have toe boards. 11.13 HANDRAILS AND BALUSTERS 1. Protective barriers shall comply with the provisions of National Building Code of the Philippines minimum design imposed load value of 36 kn/m run. If there are areas where other minimum design load values are applicable, the load value will be stated in the Contract Specific Document and the areas clearly defined either in the Contract Specific Document or on the Contract drawings. 2. Self closing gates shall be provided at openings in handrails at ladder heads and the like. 11.14 STAIRS AND LADDERS 1. Stairs and ladders shall be designed to the requirements of National Building Code of the Philippines being semi-public. The clear width of stairs shall be suitable for the intended use with a minimum of 800mm. Ship ladders will not be permitted.
11.15
HYDRAULIC DESIGN 1. Conduits shall be designed using roughness factors, k appropriate for the pipe material in good, average and poor condition. The reference from which the k values are taken shall be stated in the calculations submitted. 2. Sufficient freeboard (recommended minimum 100mm) shall be provided to prevent overtopping of walls under all specified flow conditions and numbers of units in service. Allowances shall be made for dynamic effects, flow round bends and lateral inflow or outflow. 3. Design velocities should be clearly stated.
11.16
PIPELINES 1. Buried pipelines shall be designed with a minimum cover of 750mm. Where less cover is available appropriate protective measures shall be taken. Thrust shall be transmitted to blocks or anchorages. Thrust blocks and anchorages shall be designed with a minimum factor of safety of 1.25. Thrust blocks for continuously welded steel pipes shall be designed to resist 0.5 of the calculated thrust. 2. Surge pressures shall be taken into account in the design of pressure pipelines. Pressure pipelines shall normally be designed to remain full while in service, inflow check valves shall be fitted where appropriate. Pressure pipelines shall be laid at gradients not less than 1 in 500 either rising or falling. 3. Air valves and air vents appropriate to the fluid in the pipeline and of adequate airflow capacity are required at high points and significant changes in hydraulic gradient. They shall be sited at field property boundaries where possible. The maximum spacing between air valves shall not exceed 500m. 4. Line valves shall be positioned where access can be gained from the roads. They shall isolate lengths of pipeline not exceeding 1500 m regardless of sizes. 5. Blow-off and drain points shall be provided to allow the pipeline to be substantially emptied to appropriate discharge points. Blow-off and drain points on pipelines containing chlorinated water shall allow for the provision of dechlorination facilities. 6. Pipework cast through the walls of structures shall be jointed either side of the wall. Flange adaptors should be incorporated to allow removal of above ground pipework. They shall be adequately supported and restrained. 7. Non-buried pipework shall be supported in accordance with the manufacturers instructions. Valves, meters, strainers and other equipment mounted in pipework shall be supported independently of the pipes to which they are connected. 8. Formed bends shall be used in the conveyance of wastewater. Fabricated bends are acceptable for clean water applications. Long radius bends shall be used in pipelines conveying sludge. 9. Pipelines conveying wastewater, chemical slurries, sludges, etc. shall be provided with rodding points and/or inspection covers to facilitate clearing of blockages without dismantling the pipework.
11.17
DRAINAGE The provisions of this clause do not apply to Main Drainage works. If any Main Drainage Works design is included in the Contract the Contract Specific Document will contain details.
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1. Surface water drainage shall be designed to accommodate the 1 in 20 years rainfall event.
2. Where geotextiles are used to line drainage trenches they shall be designed as filtering membranes.
11.18
MANHOLES The provisions of this clause do not apply to Main Drainage works. If any Main Drainage Works design is included in the Contract the Contract Specific Document will contain details. 1. Manholes shall be provided on gravity pipework at each abrupt change of horizontal or vertical direction. The minimum allowable manhole size is 1500mm diameter.
11.19
OVERFLOWS The provisions of this clause do not apply to Main Drainage works. If any Main Drainage Works design is included in the Contract the Contract Specific Document will contain details. 1. These shall be sized to pass the maximum possible flow, allowance must be made for parallel plant items being out of service. Overflows shall be designed to not operate until full utilisation of the plant is achieved.
11.20
OUTFALLS 1. Outfall pipes of 375mm diameter and above must be protected by grilles. The clear distance between the bars of grilles must not exceed 100mm. Grilles must be secure but removable by authorised personnel to allow maintenance.
11.21
ROADS The provisions of this clause do not apply to public highways. If any public highway design is included in the Contract the Contract Specific Document will contain details. 1. Road construction shall be designed assuming the design traffic loading stated in the Contract Specific Document. 2. Road widths and minimum radii shall be designed to accommodate the vehicle type specified in the Contract Specific Document. 3. Roads shall be designed to limit traffic speed to a maximum of 15 mph. 4. Road gradients shall generally not exceed 1 in 12 and nowhere shall exceed 1 in 5. Roads shall be cambered where necessary, adverse cambers shall be avoided. 5. Roads and hardstandings in chemical delivery areas and sludge tanker points shall be impermeable and have a sleeping policeman bund to prevent spillages entering the general road drainage. Drainage from these bunded areas shall be to a blind tank, sewer or to the head of the works as specified in the Contract Specific Document. 6 Aggregate subbase and base course and portland cement concrete pavement materials and methods of construction shall be in accordance with referenced sections of the "Standard Specifications for Highways, Bridges, and Airports" published by the Department of Public
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Works and Highways (Revised 1988) and ASTM D1559: Resistance to Plastic Flow of Bituminous Mixtures Using Marshall Apparatus.
A portland cement concrete pavement of 250 mm thickness of 21 MPa Concrete for the Treatment Plant area and the access roads shall be used.
Road width and minimum radii shall be designed to accommodate a 10 cu.m. Vacuum Truck.
11.22
LANDSCAPING 1. Earthwork in general shall comply with National Building Code of the Philippines and National Structural Code of the Philippines. 2. Mown grassed slopes shall not exceed a steepness of 1 in 3. 3. The Contractor shall furnish all plants, labor, materials, tools and equipment necessary for the performance of all landscaping complete to include springing, seeding, loaming, sodding, planting of trees, topsoil supply and spreading and all other incidentals which are deemed necessary in the completion of this work item. All unpaved areas shall be sodded. Border plants to be used shall be subject for approval of MWC. List of plants and landscaping materials shall submitted together with landscaping layout to be approved by MWC.
4. Plants shall be subject to inspection and approval or rejection by MWC at place of growth and upon delivery to the site at any time before or during progress of the work based on the following criteria: Quality, size and variety; Ball and root condition, Quantity of stock; and Latent defects and injuries resulting from handling, disease and infestation.
5. Plants approved at pre-planting inspection shall still be subject to rejection during planting if found to be below specifications. 6. Rejected plants shall be identified in an obvious manner, removed from the site and replaced with acceptable equals. 7. The Contractor shall submit for approval by MWC a certified report of an approved analytical laboratory showing analyses of representative samples of topsoil proposed for use. The topsoil shall not be delivered to the site until approval is received from MWC. Approval of the laboratory report shall not constitute final acceptance. Topsoil shall be subject to rejection by MWC on or after delivery if it is found not to meet the requirements of the specifications or does not conform to the laboratory test results. 8. Plants shall have been grown in nurseries which have been inspected by MWC.
9. Each sample shall be labeled, bearing material name and quality, the Contractor's name, date, project name and other pertinent data. 10. The decision of as to the quality and quantity of work and material shall be final and precedent to the Contractor's right to receive any compensation hereunder.. 11. Maintenance of Landscape Planting Prior to Acceptance (a) General The Contractor shall be responsible for protecting, wearing and maintaining all planting and irrigation systems until final acceptance of all work under the contract. At time of acceptance of the complete project, the lawn shall be totally established with no bare spots, mowed a minimum of 4 times and grass is at least 40 mm to 50 mm in height.
(b)
Watering Trees and shrubs shall be thoroughly soaked after planting and provided with additional water at intervals as necessary to provided for good health and growth of the planting. Upon completion of lawn seeding, the entire area shall be soaked to saturation by a fine spray. The new planting shall be kept watered by the watering system existing on the site during the dry weather or whenever necessary for proper establishment of the lawn. Care shall be taken to avoid excessive washing or puddling on the surface and any damage caused thereby shall be repaired by the Contractor at his own expense.
(c)
Protection The Contractor shall provide adequate protection to all newly seeded areas including the installation of approved temporary fences to prevent trespassing and damage as well as erosion control until the end of the guarantee period. The Contractor shall replace at his own expense, and in compliance with all applicable specifications, any materials or equipment damaged by himself, his employees or his sub-contractors. Occupancy of the project or parts thereof shall not relieve the Contractor of any of the requirements contained in these Specifications.
(d)
Mowing of Lawn Areas. The first mowing of lawn areas shall begin as soon as the grass reached a height of 75 mm and subsequent mowing shall be at least once a week, or as often as necessary to maintain all lawn areas at uniform height of 40 mm to 50 mm. All lawns and landscaped areas shall be fertilized every 3 weeks with 0.15 kg of general-purpose complete commercial fertilizer per square meter of area for the first 7 weeks and fertilized thereafter once each 5 months prior to acceptance and during maintenance and guarantee period.
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(e)
(f)
Maintain plants in a vigorous, thriving condition by watering, cultivating, weeding, pruning, spraying and other operations necessary. No trees or shrubs will be accepted unless they are healthy and show satisfactory foliage conditions. All planted areas shall be cultivated at least every 2 weeks and raked smooth, to present a neat appearance, and conditional mulch shall be added where necessary. Maintenance shall include, in addition to the above, cleaning, edging, repairs to stake, wire and wrapping, repair of erosion and all other necessary work of maintenance. Sidewalks and other paved areas shall be kept clean when planting and maintenance are in progress. Any and all watering lines broken or disrupted during this construction shall be replaced to proper working order prior to turn-over of the Work to MWC. Final Inspection and Guarantee Inspection of work of lawns and planting will be made at conclusion of maintenance. Written notice requesting inspection shall be submitted to MWC at least 10 days prior to the anticipated inspection date. Final acceptance of the work prior to guarantee period of the contract will be accepted upon written approval by MWC , on the satisfactory completion of all work, including maintenance, but exclusive of the replacement of plant material. The Contractor shall replace, as soon as weather conditions permit, all dead plants, and all plants not in a vigorous, thriving condition noted at the end of the guarantee period. Plants used for replacement shall be of the same size and variety specified in the plant list. Plants shall be furnished, planted, staked and mulched as specified. All work done under this contract shall be left in good order to the satisfaction of MWC and the Contractor shall without additional expense, replace any trees, shrubs, etc., which develop defects or die.
(g)
(h)
(i) (j)
12
Maintenance and Guarantee Following Acceptance (a) General The Contractor shall be responsible for a period 18 months after date of acceptance of all work under the contract for maintaining all plantings including all necessary plant or tree replacements, weeding, cultivating, fertilizing, pruning, controlling insects and diseases, re-guying and performing all other operations incident thereto. The Contractor shall provide a written guarantee to MWC from the Landscaping Subcontractor embodying the provisions of this Section of the Specifications. The guarantee shall not be binding upon the Contractor if any failure should be proved to the satisfaction of MWC to result from circumstances or negligence of parties over whom the guarantor has no control. The work covered by this subsection of the specification consists of providing all replacements of plants, labor, materials, equipment and supplies and in performing all operations in connection with maintenance and guarantees.
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The inspection of lawn areas is independent of the final inspection and maintenance period. After then lawn has been accepted and has been mowed 4 or more times, the responsibility for mowing and irrigation will be turned over to MWC, the weeding, fertilizing, and controlling of diseases of the areas shall remain the responsibility of the Contractor for the remainder of the maintenance period. All planting, planting materials and watering systems required under this contract shall be in conditions acceptable to MWC at the end of the maintenance period. All water required during this maintenance and guarantee period will be furnished by MWC.
(b)
Maintenance Watering and mowing of the lawns and other landscape areas during maintenance and guarantee period will be performed by MWC in accordance with written instructions furnished by the Contractor. The Contractor shall make any changes or adjustments necessary to the watering system during the maintenance period. The Contractor shall replace any dead or diseased plants during the maintenance period. All lawn and planting areas shall be fertilized during the maintenance period with a complete N-P-K chemical fertilizer. Amount of fertilizer applied shall be per fertilizer's written instructions on the bag. Fertilizers applied to planting areas shall be cultivated into the top 0.50 m of topsoil. The Contractor shall clean-up and remove unused or waste materials from the site and leave the area in a neat condition satisfactory to MWC whenever he performs work during the maintenance period.
(c)
Final Inspection MWC and the Contractor shall make a final inspection at the end of the guarantee period. Any plants and materials found defective at time of final inspection shall be replaced within a time agreed upon by both parties.
11.23
FOUNDATIONS 1. Rafts, piles etc. shall be designed to the requirements of National Structural Code of the Philippines.
11.24
GROUND ANCHORS 1. Ground anchors shall be designed to the requirements of as stated in the Contract Specific Specification.
11.25
BUNDS TO CHEMICAL TANKS The provisions of this clause do not apply to sludge bunds. 1. Bunds to chemical tanks must be sized to receive 110% of the volume of the largest tank contained or all tanks that could empty as a result of a single failure. Bund walls must not be
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lower than the bottom of the contained tanks. Bund walls must be designed to contain jets issuing from holes in tank sides. 2. Other than preformed plastic bunds, all bunds to chemical tanks shall have concrete floor ands walls without expansion or contraction joints. Concrete bunds, including those with liners, shall be designed to the requirements of ACI-224 and ACI-350 using a design crack width of 0.2mm. Use type II cement and fly ash as per ASTM C150 and C618. 3. Concrete bunds shall be tested for watertightness. Tanks to be lined shall be tested for watertightness before the liner is installed. Bunds shall not be put into service until all cracks have healed or been satisfactorily repaired. 4. Where liners are to be used internal angles shall be filtered and the liner installed by specialist contractors. Liners shall be spark tested as per the manufacturers instructions. 5. Bunds must be blind, outlets (including valves outlets) must not be provided. 6. All valves, pipework etc must be a minimum of 150 mm above the bund floor. Dosing pumps shall be within the bund above the 110% volume level. No pipes shall pass through the bund wall or base. Pipes conveying chemicals shall be enclosed so as to contain leakage and drain it to the bund or other holding tank. The pipe enclosure shall indicate the name of the chemical within. 7. All bunds shall have a sump. Alarmed level detecting probes must be installed over the sump. 11.26 WORKING ROOM 1. Sufficient clearance must be available for all items of machinery, panels, valves etc. to be operated, maintained and removed. All equipment must be positioned so as to be accessible for operation and maintenance.
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SECTION 12 MECHANICAL WORKS
PART 1 12.1
GENERAL SPECIFICATIONS SCOPE OF WORK
12.1.1 This Specification establishes the mechanical features with the highest level of quality required for the permanent mechanical plant in this contract. All mechanical equipment, valves and appurtenances shall be ISO certified and applicable for industrial applications under Class D environment. In the event that the Contract Specific Specification requirements conflict with the Standard Specification, then the Contract Specific Specification requirements shall take precedence. Where am equipment specification stipulates adherence to British Standards, the Contractor may be cite the equivalent International, European, American or Philippine standard for approval by the Engineer. 12.1.2 The scope of works to be provided under this contract are enumerated in Section VII Forms and Procedures of the Bidding Documents and those to be installed at the Sewage Treatment Plant are to be designed and installed in accordance with this Section and Section 15, Performance Specifications. 12.1.3 Wherever the supply and installation of submersible centrifugal pump is called for by a pay item in the Price Schedules, it shall be construed to include the motor set, complete with guide rails (including all support brackets); lifting chain (including shackles and securing bracket); duckfoot bend (and support bracket); rising main and associated fittings (including check and isolation valves). The Contractor shall note that also included within the scope of supply for pumps or other removable item of plant weighing 25 kg or more is one (1) lifting davit and socket suitably designed and sized by the Contractor for a load of 50 kg. A chain pulley block shall also be supplied as part of this Contract. 12.2 REFERENCES This specification shall be read in conjunction with the following standards:
AWWA C504-74 ASTM B62 ASTM B584-74 ASTM A307-74 ASTM A153-73 DIN 2532 ISO R26173
Rubber Seated Butterfly Valves Composition Bronze or Ounce Metal Castings Copper-Alloy Sand Castings for General Applications Carbon Steel Externally/Internally Threaded Standard Fasteners Zinc Coating (Hot-Dip) on Iron and Steel Hardware Cast-Iron Flanges, Nominal Pressure 10 ISO 2084-1974(e) Pipeline Flanges for General Use Metric Series Mating Dimensions ISO General purpose Metric Screw Threads General Plan
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ASTM A48/ASTM A126 Class B ASTM A167 74 ASTM B584/UNS C86700, C85800, C86200 ASTM A743/AISI 303 DIN 30677 T2 ASTM A312 ASTM D3935 ASTM D3011 ASTM D4181 ANSI/ASTM D4066
Gray Iron Casting for valves, flanges, and fittings.
Stainless and Heat Resisting Chromium Nickel Steel Plate, Sheet and Strip. Copper Alloy Sand Castings for General Application
Stainless Steel for General Application
Internal and External Protection for Grey Cast Iron Castings Seamless and Welded Austenitic Stainless Steel Pipes Polycarbonate Standard Polystyrene Standard Acetal Standard Nylon Standard is a British professional engineering body based in London, England that represents building services engineers. In the United Kingdom CIBSE is regarded as an authority on building services engineering, and has been consulted by government Specification for the design and manufacture of site built, vertical, cylindrical, flat-bottomed, above ground, welded, steel tanks for the storage of liquids at ambient temperature and above Specification for manufacture of vertical steel welded non-refrigerated storage tanks with buttwelded shells for the petroleum industry Specification for vitreous enameled steel building components Steel plate, sheet and strip. Carbon and carbon-manganese plate, sheet and strip. General specification Hot dip galvanized coatings on fabricated iron and steel articles. Specifications and test methods Clay pavers. Requirements and test methods Vitreous and porcelain enamels -- Low voltage test for detecting and locating defects Rotodynamic pumps. Hydraulic performance acceptance tests. Grades 1 and 2 Founding. Grey cast irons Copper and copper alloys. Ingots and castings Electric cables. Flexible cords rated up to 300/500 V, for use with appliances and equipment intended for domestic, office and similar environments Flanges and their joints. Circular flanges for pipes, valves, fittings and accessories, PN designated. Steel flanges Specification for shaft ends Specification for metric keys and keyways. Parallel and taper keys
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CIBSE EN 14015 BS 2654 BS 3830 BS 1449 BS EN ISO 1461 BS 1344 ISO 8289 BS EN 9906:2000. BS EN 1561 BS EN 1982 2008 BS 6500 BS EN 1092 BS 4506 BS 4235
ISO 3912. AGMA 420.04 BS 848 DW/144 DW 143 BS 5395 BS 4211 BS 4763:2004 BS 5839 BS EN 54 BS ISO 14520 BS 5306 BS EN 12094 NFPA 2001 BS 466 BS 2573 BS 4360 BS EN 1677-5 BS EN 13157 BS 1663 BS 3113 BS 3114 BS 6405 BS 2903
Woodruff keys and keyways Practice for Enclosed Speed Reducers or Increasers Using Spur, Helical, Herringbone and Spiral Bevel Gears, Dec. 1975 Fans for general purposes. Methods of noise testing Specification for sheet metal ductwork: low, medium and high pressure/velocity air systems (Appendix M revision 2002), 1998 Practical guide to ductwork leakage testing. 5th edition, 2000 Stairs, ladders and walkways. Code of practice for the design, construction and maintenance of straight stairs and winders Specification for permanently fixed ladders Fire tests on building materials and structures. Classification and method of test for external fire exposure to roofs Fire detection and fire alarm systems for buildings. Code of practice for the design, installation, commissioning and maintenance of voice alarm systems Series. Fire detection and fire alarm systems Gaseous fire-extinguishing systems. Physical properties and system design. General requirements Fire extinguishing installations and equipment on premises Fixed firefighting systems Standard on Clean Agent Fire Extinguishing Systems Specification for power driven overhead travelling cranes, semi-goliath and goliath cranes for general use Rules for Design of Cranes - Part 1: Specification for classification, stress calculations and design criteria for structures Specification for weldable structural steels Components for slings. Safety. Forged steel lifting hooks with latch. Grade 4 Cranes. Safety. Hand powered lifting equipment Specification for higher tensile steel chain Grade 40 (short link and pitched or calibrated) for lifting purposes Specification for alloy steel chain, Grade 60. Short link, for lifting purposes Specification for alloy steel chain, Grade 80. Polished short link calibrated load chain for pulley blocks Specification for non-calibrated short link steel chain (grade 30) for general engineering purposes: class 1 and 2 Specification for higher tensile steel hooks for chains, slings, blocks and general engineering purposes
12.3
DEFINITIONS API ASHRAE American Petroleum Institute American Society of Heating, Refrigerating and AirConditioning Engineers, Inc. ASME ASPE American Society of Mechanical Engineers American Society of Plumbing Engineers
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ASTM AWS FRP PSME TDH UHW-PE UV
American Society for Testing and Materials American Welding Society Fiberglass Reinforced Polyester Philippine Society of Mechanical Engineers Total Dynamic Head Ultra-high Molecular Weight Polyethylene Ultraviolet
12.4
CASTINGS AND FORGINGS Only sound castings and forgings shall be incorporated in the Works. Welding, building up, filling or any other processes to recover castings will not be permitted in respect of any casting associated with pumps, compressors, gear boxes or other such plant subject to pressure or vibration.
Machined surfaces shall be free from blemishes and other surfaces shall be carefully fettled to remove any foundry irregularities including fused on sand.
12.5
LUBRICATION, BEARINGS, SEALS AND GEARBOXES Bearings shall be selected for adequate load bearing capacity, reliability and long life. They shall be sealed for life, minimum design life of 50,000 hours operation at maximum loading, or be fitted with automatic grease or oil lubricators. Lubrication points shall be grouped with a separate nipple and pipe feeding individual bearings. Lubrication points shall be easily accessible.
Reduction gearboxes shall be robust and continuously rated and selected for reliability and efficiency over the required range of loadings. Non submersible gearbox drive casings shall be fitted with filling, level and drain points. Taps shall be fitted to the drain, and the gearbox shall be positioned such that the oil may be collected in a suitable container. Gearboxes shall have a life of 100,000 hours, be selected in accordance with the American Gear Manufacturers Association (A.G.M.A) recommendations for horsepower calculation and service factor application and employ a standard reduction ratio. Except where particularly specified the Contractor shall select a seal, compatible with his Plant and best suited for the worst conditions likely to be met when the Plant is in operation. Seal materials shall be compatible with and/or resistant to the fluid or gas being handled. Glands shall be provided with renewable gland sleeves. Glands subject to abrasive liquors or negative pressures shall embody suitably positioned lantern rings and a clean water continuous flushing system, operative whenever the Plant is in motion.
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Gland adjustment nuts shall be readily accessible for routine maintenance. Gland drain pipework shall be installed, incorporating roding facilities and adequate inclines of 25 mm minimum diameter on water reclamation plant and 12.5 mm on water supply plant, discharging to the nearest sump or drainage channel. The Contractor shall tabulate all lubrication points, the recommended grease or oil, its grade and the recommended service interval in the form of a chart. The Contractor shall include the supply all necessary oils and lubricants for the initial fill and the first 2 years operation so that testing and commissioning may be carried out without undue delay. 12.6 FIXING MACHINERY Where any Plant included in the Works is attached to building structures, the magnitude of the applied loadings must be stated by the Contractor on his drawings. Cutting of steelwork will not be allowed. Drilling, welding or stud firing into tension flanges or other steelwork subjected to tensile loads will not be permitted on plate girders or any principal steelwork member. Where attachments are allowed, proper clamps or straps will be required. The proposed attachment shall require the approval of the Engineer.
The Contractor shall satisfy himself, before installing the Plant, that the foundation levels, dimensions and alignment are correct and shall level and adjust the Plant on its foundations preparatory to suitable bedding of bases. Where fixings are used by the Contractor he shall drill the holes, providing and fixing parts, to the approval of the Engineer. The drilling through steel reinforcement shall not be permitted without the prior approval of the Engineer. The Contractor shall supply foundation bolts, packers, frames and grillages necessary for the Works. Where these items are required to be built in, the Contractor shall ensure that both details and materials are available in accordance with the Schedule. The Contractor shall make good any damage to concrete, brickwork or other finishes caused when undertaking his work. This shall be done to the satisfaction of the Engineer. Grouting of machinery bedplates and supports shall be undertaken by the Contractor. Packing/Shims shall be positioned close to and on each side of holding down bolts. Packings/shims shall be of flat stainless steel and so positioned as to be fully covered to a thickness of 60 mm after grouting in. Alternatively, mild steel packs with zinc rich protective coating are to be provided. Expansion bolts or self drill anchor bolts shall be to the approval of the Engineer, and shall not be used within 100 mm distance of concrete edges. Epoxy resin anchors can be used under such circumstances. Where expansion bolts are used they shall normally be of the type having a loose metal shell for at least 80% of the embedded length which is expanded parallel to the bolt by
means of a wedge at each end, the wedge at the lower end being part of or attached to the bolt. Proprietary fixing bolts shall be fitted in strict accordance with the manufacturer's instructions and the Contractor shall be responsible for the provision of necessary equipment to drill and clean holes and for the actual drilling, cleaning and fixing. Anchor bolts shall be stainless steel. Machinery shall be effectively guarded to prevent injury to persons, and meet current safety regulations in accordance with BS EN 953. Guards to parts of machinery which require regular inspection or maintenance shall be constructed of galvanized steel mesh or other corrosion resistant material which enables the parts to be examined and shall be attached in such a way as to permit easy removal and replacement. Guards shall be attached by means of set bolts or studs in tapped holes. Self tapping screws shall not be used. Where hinged access covers or doors are provided in covers or guards, they shall be interlocked with the electricity supply so as to prevent the operation of the machinery except when covers are in position and fixed. Warning notices labeled 'Danger - This equipment may start automatically', shall be fitted where appropriate. 12.7 ALIGNMENT, LIFTING, DISMANTLING, NOISE & VIBRATION Machinery bedplate design, packing and fixing shall be such as to minimize distortion and vibration. Aligned machinery shall be mounted on either bed or sole plates, permitting removal and reinstatement without a requirement to regrout.
Bedplates shall incorporate fine adjustment of the vertical and horizontal alignment between driver and driven members. Machinery shall be fitted with permanent lifting facilities. Large structures shall be provided with jacking points. Tapped holes or other provision must be made in main castings for the insertion of jacking screws or the fixing of drawing gear to facilitate dismantling. On items of machinery subject to frequent dismantling, bolts or studs shall be employed in preference to setscrews. A method statement for the approval of the engineer shall be produced by the contractor for any plant removal, demolition of structures, support procedure, protection measures for the existing plant that is not to be removed. The redundant designated utilities within the demolition areas shall be properly disconnected and capped. Any debris resulting from the demolition work shall be disposed off site to a designated tip or as mentioned in the particular specification.
All the demolition or plant removal work shall confirm to the local authority regulations for any contaminated or hazardous materials. The noise levels emanating from the operation of any plant shall not exceed the limit of 80 dBa when measured from a distance of 1m in any direction from the equipment. The plant operation at full load shall be considered. In case of noise levels exceeding the specified limit, suitable acoustic enclosures shall be used. These enclosures shall be aesthetically designed and shall corrosion free as per the specification. All the equipment shall be statically and dynamically balanced to avoid vibration. Mechanical vibrations levels shall be stated in the equipment technical data sheets and wherever necessary, the equipment shall be provided with vibration dampening mounts. The reference standards shall be ISO 2954.
12.8
BOLTS, SCREWS, NUTS, STUDS AND WASHERS Fixings to be used in conjunction with the works shall have thread forms which comply with BS 3643 Isometric screw threads, and also BS 4190. Exposed bolt heads and nuts shall be hexagonal and the length of bolts shall be such that, when fitted with a nut and washer and tightened down, the threaded portion shall at least fill the nut and not protrude from the face thereof by less than two threads or more than four threads. Threading, machining or cutting of threading rods at site is not permitted. Fasteners and fixings shall generally be manufactured from nickel bearing stainless steel. Pipework flange fixings shall be stainless steel. Wood screws and fixings shall be of brass with round heads.
12.9
PIPEWORK SYSTEMS All pipework associated with pumping unit and associated fittings shall be flanged to PN 16 or greater in accordance with ISO 7005-2-1/2. The pipework design shall include sufficient flanges or unions to allow for the disconnection of the major items of plant without disturbing the main pipework. The Contractor shall supply flexible couplings as necessary to achieve this requirement. Flange gaskets shall be natural rubber or equivalent suitable for river water application for the wash-down pump. All pipework installed shall be adequately supported with pipe supports of an acceptable design. These supports shall allow for removal of any section of pipework for maintenance purposes. Adequate clamping and guides shall be designed and installed.
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Pipe Sleeve shall be provided for floor and wall partition. For cast in place, it shall be provided with mild steel 4mm puddle flange. For block-out installation, 4mm thick puddle flange with 75mm (maximum) non-shrink grout all around. Pipe sleeve shall be made of SS304. It shall be provided with flanges at both ends for ease of maintenance.
ITEM NO. 1
DESIGNATION Aeration
LOCATION Above ground Inside the tank Above ground Inside the tank Lift Station Dewatering Equipment Eye Wash / Toilet Chemical Room Generator Room
MATERIALS SS HDPE / ABS SS HDPE/ ABS CI / DI SGP PVC HDPE/ TEFLON SGP
PIPES SUPPORT SS
COLOR Green
2 3 4 5 6
Sewage/Sludge Compressed Air Drinking Water Chlorine Diesel Fuel
SS 316 SS SS SS Hot-Dip Galvanized Steel
Orange Brown Yellow Blue White Brown
VALVES ISOLATION CHECK VALVE VALVE Butterfly Swing Valve Type Knife Gate / Ball Ball Valve Type Butterfly Valve Gate/Ball Valve Ball Valve Ball Valve Swing Type Swing Type Swing Type Swing Type
Note:
PIPING SYSTEM 1. Valves shall be with dismantling joint or combi flange. 2. Bands and Arrows color shall be as per PSME code 2003 Edition, page 230 3. Materials mentioned in the above table are subject to change upon instruction of MWC.
The Contractor shall be responsible for the detailed design and dimensioning of the pipework. 12.10 PENSTOCKS Penstocks shall be either hand operated by handwheel, square cap and gearbox or power operated by electromechanical actuators. In both these applications due care is necessary to establish the ability by the equipment to sustain a working head of liquid is one or both the directions. The installations shall be as follows:a) Wall Mounted
Wall mounted penstocks shall manufacture from the following materials : Frame Spindles Seating Face Door Stainless Steel Grade 304* Stainless Steel Grade 316L EPDM resilient seal mechanically fixed to frame with stainless steel fasteners Stainless Steel Grade 304 or 316*
*Grade of stainless steel shall be approved by the Engineer.
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b)
Channel Mounted
Channel mounted penstocks shall be manufactured from the following materials : Frame Spindles Sealing Face Stainless Steel Stainless Steel Grade 316L Coplastix-S with Coplastix-N backing strip (or equivalent approved) Door Carbon steel reinforced Coplastix-B and Coplastix-D (or equivalent approved) All spindles shall be of the rising type for both installation methods and shall be provided with transparent type stem cover and with maximum/minimum limit stoppers. Stoplogs shall be manufactured from the following materials: Frame Stainless steel frame to be either recessed or wall mounted Logs Coplastix B bonded to and enclosed by Coplastix D (or equivalent approved) Seals Sealing of logs to be agreed and approved by the Engineer Care should be taken while installing penstocks and stoplogs. The manufacturers installation procedure shall be fully complied with and special fixing accessories such as anchor bolts etc. shall be used wherever applicable. Before final assembly all seating shall be cleaned thoroughly of all foreign materials and final adjustments made with the gate fully closed, the clearance between seating gates shall be checked. The gate shall then be field operated from the fully closed to the fully open position to verify that the assembly is workable. Under the design seating heads, penstock leakage shall not exceed the permissible limit of 2.07 x 10-5 m3/s per meter of seating perimeter. Proprietary lifting equipment shall be supplied by the Contractor where the removal of long stop-logs is potentially difficult. 12.11 ACTUATORS Actuators shall be well proven for the anticipated environmental conditions. Actuators shall be suitable for external installation without the need for sunshades. Isolating actuators shall have short time ratings appropriate to duty cycle S2 10 min to IEC 34-1, and a maintenance free interval better than 10,000 open/close cycles.
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Modulating and inching actuators shall have a rating appropriate to duty cycle type S4 20% 1200 cycles/hour to IEC 34-1 and a maintenance free interval better than 50,000 hours in normal operation. Actuated valves and penstocks shall be driven by three phase a.c. electro-mechanical actuators. Each actuator shall be sized to produce at least 150% of the torque requirement quoted by the valve or penstock manufacturer. Valve actuators shall have an index of protection rating IP67 or above and have totally enclosed drive units and reduction gearing. Each actuator shall be provided with an integral control and starter system allowing local and remote operation, control and indication. Control systems shall include facilities for valve modulation using a 4-20 mA control signal. Local position indication shall be provided integral with the actuator housing. Actuators shall have position feedback circuits giving a 4-20 mA signal for remote indication. Modulating actuators shall also have position indication at the local control panel. Isolating actuators shall have switches to signal open and closed limit positions at the local control panel. The actuators shall also have the facility for hand operation, the use of which will automatically disengage the electric motor. The hand operation facility shall be capable of being padlocked in the in-operative state. Limit switches and torque limiting devices shall be incorporated to prevent over running. Each actuator drive unit shall be complete with integral starter, anti-condensation heater, local operating buttons, local and remote selector switch. A separate termination section shall be provided for the glanding and terminating of the supply, control and indication cables. A phase discriminator and monitor relay shall be provided. Cable entries shall be suitable for conduit and fittings to BS EN 50086-1:1994. Cable glands shall be provided for each actuator. The actuator shall have volt free contacts to indicate when the valve is fully open, fully closed or has failed.
12.12
PRESSURE GAUGES Pressure gauges shall comprise of brass or black molded phenol plastic construction with acrylic plastic or toughened glass windows. Dials shall be at least 150 mm diameter except where fitted to small pumps having branch connections 75 mm internal diameter and below. For such pumps 100 mm diameter gauges shall be fitted. Internal gauge components shall be of stainless steel or other corrosion resistant material with an accuracy of at least + 1 per cent of full scale. Gauges shall wherever possible operate about their mid scale position. No aluminum shall be used in the construction of the gauges. Diaphragms shall be fitted to gauges subjected to liquid containing suspended matter.
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Scales shall be calibrated in meters head for water and bar for air. Gauges associated with pumps shall be of the compound type for suction branches and the pressure type for delivery branches. Gauges shall be fitted with isolation valves and where measuring water pressure, they shall be equipped with a combined isolating valve and air release vent. If mounted remotely from the tapping point, an isolating valve shall also be installed at the tapping point. Snubbers shall be fitted to gauges installed on pumps and wherever subjected to fluctuating pressure pulses.
12.13
SURGE VESSELS If required pumped systems shall be provided with a hydro-pneumatic pressure vessel of suitable working capacity to provide surge protection and storage. The vessel shall be of the bladder type. The bladder shall be polyurethane and shall be precharged with Nitrogen. The vessel shall be sized to provide sufficient working volume to ensure that the pump starts are limited.
12.14
AERATION PIPEWORK / HIGH PRESSURE DUCT WORKS Ductwork, fittings and all associated hangers, supports, dampers, flexible joints, sealants, insulation, access, testing and builder's work connections shall conform to the recommendations of the HVAC as set out in the specification DW/144 unless otherwise stated. Air duct velocities in main duct shall not exceed 10 meters per second and duct aspect ratios shall not exceed 4:1. Ductwork shall be true in section independently supported and free from contact with the building structure. Internal jointing of ducting shall be avoided wherever possible, but if unavoidable, joints shall be constructed so as to minimize air turbulence at these sections. They shall give a smooth internal surface with no reduction in cross sectional area of duct. Longitudinal standing internally formed joints or stiffening may be allowed however on large section ducts. Any required angle stiffening shall be external and access covers shall be provided at each internal joint. Ductwork shall be designed to suit the environment in which it is designed to operate. Material of construction shall be stainless steel SS Grade 304. Ductwork within buildings shall be above ground level. Ductwork external to building shall be installed below ground level or below tank covers. The material of construction shall be completely suitable for operation in the prevailing internal and external atmospheric conditions. Main duct runs and branches shall be installed with damper to allow for flow regulation/balancing and for isolation purposes. Access openings shall be provided adjacent to control/isolation dampers with diameters equal to and greater than 150mm.
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Dampers shall provide airtight seal in the closed position. Pilot test holes shall be provided in all main duct runs and branches for airflow measurement to allow the complete system to be balance. Suitable grommet and sealing plates shall be fitted to the test holes. Appropriate gas sampling points shall be supplied in ducting running from each major leg at a distance of not less than four duct widths from any bend. Ports for manual sampling shall have a minimum diameter of 30mm. Removable plugs for each of the sampling ports shall be supplied. Ductwork shall be designed to be laid with falls and be complete with valves situated at low points to enable condensation to be drained. Ductwork should generally fall back to the extraction point to ensure that condensation falls back to the tanks from which odor is being extracted. The ductwork shall be designed to ensure that the total number of drain points is minimized. The ductwork installations shall be designed to avoid trappings of fumes or gases in dead ends and prevent the collection of condensation which may be formed internally at any point in the duct work and which cannot be drained through drain valves located at accessible positions. Air flow meters shall be provided to monitor the total airflow in the systems. Flexible joints shall be used at connections to items of Plant. Attention shall be given to adequate and sufficient supporting of ducting, together with accommodation of thermal expansion. Ductwork supports shall be fabricated from either stainless steel or from galvanized mild steel. Duct supports shall be held off ductwork with neoprene lining to brackets. Dampers and test points shall be accessible from ground level or from walkways and platforms. Labels shall be provided as follows: i. ii. iii. Identification of test points Identification of drain points Identification of isolation/control dampers and commissioned setting of dampers
Airflow rates shall be regulated in accordance with the recommendations and tolerances laid down in CIBSE commissioning code A. A full commissioning record shall be kept together with final airflow rates achieved. Ductwork shall be smoke tested to ensure that joints are gas tight.
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Ductwork shall be earthed to ensure that no uncontrolled static discharge can occur.
12.15
SLUDGE STORAGE TANKS - GENERAL Tanks shall be designed, erected and tested generally in accordance with EN 14015 Welded steel tanks shall be designed with a corrosion allowance of 1.5 mm. Steel plate thickness shall not be less than 5 mm. Internal roof support structures shall be protected from corrosion to maintain the design life of the tank. Tanks shall be provided with drain points that shall terminate with a Bauer type coupling. High level interconnecting pipework with an isolating valve shall be fitted between adjacent sludge storage tanks of similar purpose. High level overflows shall be fitted to tanks for emergency situations. Drilling or welding to the tank structure after the plates have been coated shall not be allowed. Tanks shall be provided with a davit operated access hatch on the side of the tank for cleaning purposes. The access hatch shall be easily opened and closed with the minimum of dismantling time. The hatch seal shall not be compromised upon operating the hatch and shall be re-usable. The seal shall be designed such that it only requires replacement after more than 15 operations. The hatch design shall provide for the safe access of personnel to the tank for all inspection and maintenance functions.
12.15.1 Tank Mixers Each sludge storage tank shall be provided with fluidic mixers, the number and size of which shall be determined such that the tank contents remain fully homogenized when full. The fluidic mixer(s) units shall be located within the tanks, however any blowers, valves and other moving parts shall be located outside the tanks. Tanks shall be provided with suitable flanged nozzles to enable connection of the associated fluidic mixer air lines. 12.15.2 Glass Coated Steel Tanks Glass coated steel tanks shall consist of a shell fixed to a concrete base. Vertical cylindrical tanks constructed of bolted sectional panels shall be supplied. Stiffening of the vertical surface of the tank shall be fixed to external surfaces. The tanks shall be classified to suit the operating pressures that can occur when in service. Superimposed loads on the tank shell, BS 2654 clause 5.3, shall be based on: internal vacuum; plus weight of roof, or 1.2 kN/m2, whichever is the greater.
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Tank flange nozzle connections shall be provided with suitable reinforcing plates for bolting to the tank shell. Tank nozzles and reinforcing plates shall be manufactured from stainless steel. Tank fittings to be galvanized shall have work carried out on them, i.e. welding, drilling, bending, etc., prior to coating. After galvanizing the surfaces shall be passivated against the formation of white rust. The sectional panels making up the tank shall be of glass coated steel (vitreous enameled), the coating being applied to both sides. The coating shall comply with the applicable requirements of BS 3830. Bolted lap-jointed construction shall be employed using an interpanel sealant to give a structure which is leak tight. The steel plates used to make up the panels shall be to BS 1449 : Part 1 'Specification for carbon and carbon-manganese plate, sheet and strip', Grade HR3 or of a higher strength steel, and in every case steel produced suitable for vitreous enameling. Machining, i.e. cutting the plates to size and shape, providing bolt holes, providing holes for flanged connections, and rolling to the correct curvature, shall be carried out prior to coating. Drilling or welding to coated panels shall not be allowed. Drifting to align holes during assembly shall not be allowed. Prior to coating, the plate surfaces shall be blast cleaned to remove all rust and mill scale then chemically cleaned if necessary to remove any grease and dirt. The panel surfaces shall be coated evenly with a three coat protection system to a minimum glass thickness of 280 microns. The coating shall be tested to 1000 volt zero defect with controlled test voltage + 1% at probe contact. Typical physical properties shall meet the following requirements:Adherence Flexibility : : glass to steel, in excess of 34 MN/m2 glass and steel to be the same 70 GN/m2
Young's Modulus:
Percentage Elongation: 0.3% Poisson Ratio: 0.2 Hardness Abrasion : : 3.5 to 6 (Mohr Scale) 0.0078 gm (Tabular Test)
Chemical Resistance: alkalis and acids, both organic and at Design Temperature inorganic (not hydrofluoric acid or sodium hydroxide) between pH5 and pH11 - complete resistance
Peeling : Chipping: Porosity :
None None None
Tank fixings which will come into contact with the product to be contained in the tank, including the gases released from the product, shall be manufactured from suitable corrosion resistant material. Tank shell stiffening rings and foundation fixings shall be of carbon steel hot dip galvanized in accordance with BS EN ISO 1461. Bolts, nuts and washers shall be high tensile grade carbon steel hot-dipped and spungalvanized. Washers shall be provided at all positions under the nuts. Bolts shall be of sufficient length such that at least one clear thread pitch protrudes through the nut on final assembly. Loading on the bolts, imposed by the panels and other tank attachments, must be taken on the shank portion of the bolt and not the threaded section. Bolt heads occurring within the tank shall be mushroom-shaped to spread the load on the glass coated steel surface. The head shall be encapsulated with polypropylene, or of a similar material, to completely seal the bolt head from the liquids and gases within the tank, and to effectively seal the assembly hole in the panel. The bolt head encapsulating material shall be suitable for being in contact with the waste liquids specified. A full-width mastic joint sealant shall be applied between the glass coated steel panel sections. The sealant shall exude through the bolt hole to completely fill the gap between the bolt shafts and the panels and along the edges of the panels. Along these edges a neat continuous fillet shall be produced which shall extend by at least 4mm across the panel face to give protection to the panel corners. The sealant shall be suitable for being in contact with the product stored. The sealant shall be non-biodegradable and resistant to both ageing and weathering under the expected service conditions which will exist. A good adhesion to the panel glass coating shall be assured. Application of the sealant shall be carried out strictly in accordance with the maker's recommendations. The panel surfaces and edges shall be thoroughly cleaned of all oil, grease and other surface contaminants prior to any sealant being applied. Quality assurance checks and inspections shall be carried out throughout the entire manufacturing process, including packing for transportation and during erection at site. Documented evidence of such checks and inspections, including Certificates of Test, shall be maintained and made available for review if requested. The tanks as finish installed at site shall be of high quality and the programme of quality assurance checks and inspections to be carried out shall take this into consideration.
Testing shall be carried out in accordance with the relevant sections of BS 1344 'Methods of testing vitreous enamel finishes', American Porcelain Enamel Institute standard PEI P306 and ISO 8289 'Vitreous and porcelain enamels - low voltage test for detecting and locating defects'. The Contractor shall provide a portable detector to facilitate witnessed defects checking on site. Damaged panels shall not be used for construction of the tanks. Panels which sustain damage prior to the take over of the installation shall be dismantled and removed from site. Only minor superficial damage to the coating and isolated porosity shall be allowed to be repaired on the panel faces. Panels with excessive porosity, cracks, crazing of the coating, deep scores, chipping or peeling evident on the surfaces shall be rejected. There shall also be a uniformity of color between panels. Details of the proposed method of repair and materials to be used for repair shall be submitted to the Engineer for approval. 12.15.3 Roofs and Covers - General Roof and covers shall be provided with inspection hatches for: viewing of the tank contents; removal of plant, and viewing of installed plant and materials including weirs and launders. Roofs and covers shall be designed to act as occasional man access to roof mounted plant and inspection hatches and for forced air purging/ventilation. Non-slip surfaces will be required for defined walkway areas. The surfaces shall be nonslip in both wet and dry conditions. Roofs and covers shall be designed in accordance with the design loadings stated in BS 2654. The BS 2654 Clause 2.1 design pressure classification shall be selected to suit the operating pressures that can be created when in service. Dead loadings shall apply to the self weight of the roof material. Superimposed loads, BS 2654 Clause 5.3, shall be based on internal vacuum, or 1.2kN/ m2, whichever is the greater
12.16
PUMPS
12.16.1 General Requirements
Materials used in the construction of pumps shall be suitable for the pump duty, the product to be handled and environment that will exist at the installed location. Cast iron shall not be used where the daily peak chloride content of the pumped medium is greater than 1500mg/litre. Pumps shall be arranged for priming by gravity, via normal suction flow path.
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Waterways through pumps shall be smooth and free from recesses and obstructions. Pumps for wastewater and raw water services shall be capable of passing solids: Suction pipework up to 100mm diameter pipework, - equal to the size of the suction
Suction pipework between 100mm and 199mm - 100mm diameter Suction pipework 200mm diameter or greater - 150mm diameter
Pump speeds shall not exceed 1800 rpm nominal. The head/flow characteristic of any pump shall be stable under all possible operating conditions including parallel operation and with maximum sump surcharge. Velocities in the suction and delivery branches shall be sufficiently low to prevent hydraulic turbulence and cavitations within the pump and the pipework and sufficiently high to prevent settlement of any suspended solids. The pump and its drive motor shall be suitably rated to allow for any increased head, due to sliming, etc., of the rising main, during the lifetime of the pump. Pump suction (except for wet well mounted submersible pumps) and discharge pipework for clean water and effluent duties shall be tapped and plugged with 25mm reducing to 12mm and fitted with a tee. The tee shall be fitted with an isolating cock, suitable for use with a pressure gauge having a 12mm connection and an isolation cock to act as a vent. The tapping shall be located between two and three pipe diameters from the pump, in accordance with BS EN 9906:2000. Pump suction and discharge connections for sludge and un-screened effluent shall be provided with 50mm flanged connections fitted with a flanged tee. The tee shall be fitted with two flanged isolation valves, one for connection of diaphragm type pressure gauge and the second to act as a vent. Open ends of valves shall be fitted with blanking flanges or plugs as appropriate.
12.16.2 Centrifugal Open Coupled Sewage Pumps a) General
Pumps shall be designed to handle sewage and run unattended for long continuous periods. They shall be capable of passing fibrous matter, rags, paper, plastics and solids. The pump and motor units shall be continuously rated. Where a major overhaul is required during the design operating life, this will be dependant upon bearing life, which shall be 100,000 hours minimum.
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Components likely to become worn in the course of normal operation, shall be capable of being easily replaced making use of readily exchangeable components. Low maintenance costs, reliability and trouble-free operation shall be prime considerations when selecting pump units. Pump units shall be provided from within manufacturer's standard range which shall meet the quantity/head duty requirements within the high efficiency band of the pump characteristics. The pump curve shall have non overloading power characteristics unless agreed otherwise by the Engineer. Pump units shall be quiet in operation, free from vibration and the shaft speed shall not exceed 1800 rpm. All rotating parts shall be statically balanced during manufacture and dynamically balanced after assembly. b) Pump Volute Casing
The pump casings shall be of close grained cast iron to BS EN 1561 free from blowholes and other imperfections. Castings shall be manufactured and pressure tested in accordance with BS EN ISO 9906. The pump casing shall be fitted with renewable suction wear rings. Access shall be provided in the pump casings in the form of large handholes, for inspection and cleaning of the pump interior. Pump casings shall be provided with a drainage cock at the bottom of the lower casing section and an automatic air release valve and cock on the top of the volute casing section. The discharge from fittings shall be piped to the station drainage system. Small bore pipes shall be heavy grade copper tubing. c) Impellers
The impellers shall be cast in one piece from close grained cast iron to BS EN 1561. The working faces shall be accurately machined and finished smooth with each impeller being balanced statically and dynamically to ensure smooth running. The impellers shall be of the single bladed open or spiral vane type or two port single entry choke resistant type. Where the two port entry type is utilized the vanes shall be supported on both sides of their entire length by the outer shroud. The impellers shall have auxiliary vanes on the outside of the shrouds to minimize the recirculation of the liquid within the pump casing and to reduce the pressure around the shaft seal. The impellers shall be securely keyed and locked to the pump shaft. The impeller diameter shall be machined to comply with the required duties and maximum efficiencies.
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d)
Fittings
Each pump shall be fitted with the following fittings as standard requirements: A combined automatic air release and syphon breaker valve shall be fitted into the pump delivery pipework; 25 mm bore gland drainage pipe from the invert of the sill on the top gland cover and leading down to discharge into the dry well drainage channel to prevent contamination of the pump casing or walkways; e) Shafts and Sleeves
The pump shafts shall be constructed from high tensile alloy steel and shall be fitted with a hardened steel sleeve extending through the full length of the shaft seal. Transmission shall utilize universal joints and a splined slip joint at the pump connection. Universal joints shall have needle roller bearings. The weight of the transmission shafting shall be carried by a thrust bearing in the motor stool. The splined shaft shall ensure that no load is transferred to the pump from the shafting. Normal shaft running speed shall be well below the first critical speed. The Contractor shall submit his calculations to confirm this.
f)
Glands
Pumps shall be supplied with soft packed glands. g) Drive Coupling
A suitably sized rubber bushed flexible coupling shall be fitted between each pump and driving motor. The coupling shall be fixed to the pump and motor shafts using keys and keyways. h) Pump Motor
The motor speed shall not exceed 1800 rpm. i) Temperature Transducer Pockets
The pump Non Drive End bearings and the pump Drive End bearings shall be fitted with temperature pockets for the reception of resistance thermometer probes. j) Pressure Gauge Tappings
Each pump set shall be provided with both delivery and suction gauge tappings such that when fitted they are in an upright position. Each tapping shall be isolated with a gun metal gauge cock.
k)
Pressure Gauges
A pressure gauge shall be provided and installed at the above suction and delivery tappings. The gauges shall be of the diaphragm operated sewage installation type. l) Guarding
The Contractor shall include for guards to completely enclose the moving parts of plant. m) Engraved Nameplates
Each pump shall be provided with engraved nameplates as follows: Duty Plate: Indicating the type, impeller diameter, output at normal duty, normal duty head, speed, serial number and pump curve number. Identification: Corresponding with the pump control panel designation e.g. 'Pump No 1'. The characters shall not be less than 30 mm high. 12.16.3 Split Case Centrifugal Pumps a) General
Pump units shall be designed to handle the process fluid and run unattended for long continuous periods. The pumps shall be electric motor driven. Pump and motor units shall be continuously rated. Components likely to become worn in the course of normal operation, shall be capable of being easily replaced making use of readily exchangeable components. Low maintenance costs, reliability and trouble-free operation shall be prime considerations when selecting pump units. Pump units shall be provided from within manufacturer's standard range which shall meet the quantity/head duty requirements within the high efficiency band of the pump characteristics. The pump curve shall have non overloading power characteristics unless agreed otherwise by the Engineer. The pump and its driving motor shall be separate machines, open coupled, using a flexible coupling to form an integral unit mounted on a suitable common rigid baseplate or base frame. A flywheel may also be incorporated in the drive train if required for surge suppression. Each component shall be dowelled to facilitate re assembly. Pump units shall be quiet in operation, free from vibration and the shaft speed shall not exceed 1800 rpm. All rotating parts shall be statically balanced during manufacture and dynamically balanced after assembly. The rotating parts shall be supported in substantial bearings of approved design. b) Pump Volute Casing
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The pump casings shall be of close grained cast iron to BS EN 1561 free from blowholes and other imperfections. Castings shall be manufactured and pressure tested in accordance with BS EN ISO 9906. The casing shall comprise of two sections, split to provide complete access to the impeller and other rotating parts without disturbing the pipework connections. The sections of casing shall be secured together using substantial stainless steel studs and nuts. To ensure accurate re alignment of the casing section stainless steel dowels shall also be fitted. To facilitate the dismantling of the casing halves equally spaced tapped holes shall be provided in one casing flange to allow jacking bolts to separate the joint. Renewable suction wear rings and interstage bushes manufactured from zinc free bronze, or LG4 Bronze to BS EN 1982 2008 shall be provided. Each pump shall be fitted with a drainage cock at the bottom of the lower casing section and an automatic air release valve and cock on the top of the upper casing section. The discharge from each of these fittings shall be piped to the station drainage system via a tundish. Small bore pipes shall be galvanized mild steel. c) Impellers
Impellers shall be manufactured from zinc free bronze, or LG4 Bronze to BS EN 1982 2008 , keyed to the shaft and securely locked in position, the whole assembly being both statically and dynamically balanced. Impeller surfaces shall be machine finished free from blowholes and imperfections. The impeller diameter shall be machined to comply with the required duties and maximum efficiencies. d) Shafts and Sleeves
Shafts shall be of mild steel protected with renewable stainless steel sleeves, where they pass through any wear inducing sealing arrangement. e) Bearings
Bearings shall have a design life of 100,000 hours. f) Glands
Split case pump units shall be supplied with soft packed glands. g) Drive Coupling
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A suitably sized rubber bushed flexible coupling shall be fitted between each pump and driving motor. The coupling shall be fixed to the pump and motor shafts using keys and keyways. h) Pump Motor
The motor shall be sized to allow for the provision of flywheels for surge suppression as necessary. i) Temperature Transducer Pockets
The pump non drive end bearings and the pump drive end bearings shall be fitted with temperature pockets for the reception of resistance thermometer probes.
12.16.4 End Suction Centrifugal Pumps a) General
Pump units shall be designed to handle final effluent and run unattended for long continuous periods. Pumps shall be Electric motor driven. Pump units and motors shall be continuously rated. Components likely to become worn in the course of normal operation, shall be capable of being easily replaced making use of readily exchangeable components. Low maintenance costs, reliability and trouble-free operation shall be prime considerations when selecting pump units. Pump units shall be provided from within manufacturer's standard range which shall meet the quantity/head duty requirements within the high efficiency band of the pump characteristics. The pump curve shall have non overloading power characteristics unless agreed otherwise by the Engineer. Tapped holes or other provisions shall be made in the main casting and impeller of the pump for the insertion of jacking screws or fixing other such drawing gear necessary to facilitate the dismantling of the pump. b) Pump Casing
The pump casing shall be of close grained cast iron to BS EN 1561 grade 14, free from blowholes and other imperfections, suitable for use with final effluent. c) Mechanical Seals
Pumps shall be fitted with a mechanical seal with both the rotating and stationary faces being tungsten carbide or other approved materials. The pump mechanical seal design should he such that prolonged periods of dry running do not affect the pump or mechanical seal. d) Pump Motor
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The motor speed shall not exceed 1800 rpm. 12.16.5 Close-Coupled Electro-Submersible Pumps Cutter Impeller. The impeller shall be of tungsten carbide tip or approved equal to the manufacturers standard grade, preferably secured to the shaft by keying. It shall be used for equalization tank and lift station. Non-Clog Impeller. The impeller shall be of stainless steel to the manufacturers standard grade, preferably secured to the shaft by keying. Vortex or channel open impellers shall both be considered acceptable. The impeller shall be capable of handling solids, fibrous materials passing a maximum of 100mm solids. If not capable of handling solids, fibrous materials that will pass a maximum of 100mm solids, cutter impeller shall be used. Pump casings shall be manufactured from close-grained cast iron in accordance with BS EN 1561 or as defined in the particular specification. An oil filled casing shall separate the electric motor from the centrifugal pump. Mechanical seals shall be fitted to the pump shafts which shall prevent water from entering the oil casing and oil from entering the motor casing. A moisture detection system shall be provided in the motor stator casing, wired to initiate an external alarm. Pump units shall be provided from within manufacturer's standard range which shall meet the quantity/head duty requirements within the high efficiency band of the pump characteristics. The pump curve shall have non overloading power characteristics unless agreed otherwise by the Engineer. The submersible pumps shall be supplied and installed complete with bolt-less self-aligning duckfoot assemblies giving automatic connection, and rising pipework to the sump top. All pipework and fittings shall be ductile iron. Each pump shall be provided and installed with its own stainless steel grade 304 guide rails, fittings and all necessary support brackets. A lifting chain, made from stainless steel and suitable or use in the process fluid shall be attached to each pump to enable the pump to be raised and removed from the wet well without the necessity for personnel entering the well Lifting rings shall be attached to the chain at 1 meter intervals. Each pump shall be supplied complete with a suitable length of submersible cable. The length of the cable shall be so as to allow connection to a connection box adjacent to the wet well. The submerged cable shall be a multi-core flexible cord, vulcanized rubber insulated with tough rubber sheath and outer PCP sheath to BS 6500. 12.16.6 Axial/mixed Flow Electro-Submersible Pumps Axial or mixed flow electro-submersible propeller pumps shall be mounted within a vertical canister under its own weight, and be capable of being removed from the canister by lifting operation only. An oil filled casing shall separate the electric motor from the centrifugal pump. Mechanical seals shall be fitted to the pump shafts which shall prevent water from entering the oil casing and oil from entering the motor casing. A moisture detection system shall be provided in the motor stator casing, wired to initiate an external alarm.
Each pump shall be supplied complete with a suitable length of submersible cable. The length of the cable shall be so as to allow connection to a connection box adjacent to the wet well. The lower end of each canister and pump shall be suspended within the pump sump, at a minimum depth in accordance with the pump manufacturers recommendations. Flow from each pump shall rise up the canister and discharge over a twin weir arrangement. Stop logs for the twin weirs shall be provided if required to enable isolation of the canister. 12.16.7 Progressive Cavity Pumps a) General
Progressive cavity pumps shall have an output characteristic that is substantially independent of change in head. Pumps shall be designed to run unattended for long periods. b) Casings
Casings shall be of close grained cast iron to BS EN 1561 capable of withstanding pressures that may be produced due to normal operating pressure surges. Flanges shall be in accordance with ISO 7005 -2 Casings shall be mounted on base plates manufactured from cast iron. Casings shall be accurately aligned and located by dowels or machined spigots. Holes shall be provided in the base plates or stools for foundation bolts. Casings shall not be integral with the stool or base plate, but shall be designed to allow the ready removal of the pump complete from the stool or base plate. Easy access to suction pipe connections must be available. Stools or base plates shall be fixed to concrete plinths. c) Glands
Casings shall be sealed against leakage along the rotor shaft by a soft packing stuffing box, which shall contain a bronze lantern ring to facilitate greasing and efficient sealing of the gland. The gland housing shall be cast iron and split to facilitate packing of the gland. A grease stauffer shall be provided for lubrication of the gland. d) Stator
A resilient stator shall be fitted into a rigid housing and be intimately bonded to it. Stators shall form a double internal helix of constant circular section in which a single helical rotor shall rotate to form progressive cavities.
Stator materials shall be compatible with the liquids and materials being pumped. Stator materials shall generally be natural rubber, nitrile rubber or Hypalon depending on the application. The stator housing shall be flanged cast iron and jointed to the casing. A flanged delivery connection at the free end of the rotor shall be flange jointed to the stator housing. The suction flange may be part of the casing or be an interleaving flanged casting between stator housing and casing. Where pumps incorporate long stator housings such housings shall be supported from the base plate. e) Rotating Parts
The rotating parts shall have a smooth finish and the materials shall be compatible with the liquid and materials being pumped. Rotors shall generally be hard chrome plated stainless steel, tool steel or nitralloy. Coupling rods shall generally be hard chrome plated mild steel or hard chrome plated stainless steel. The rod shall be joined to the rotor and input shaft by flexible joints preferably of the ball and socket type. Shaft diameters shall be to BS 4506; shaft keyways shall be to BS 4235 Part 1 or ISO 3912. The drive shaft shall be supported in heavy duty ball or ball and roller bearings. Bearings shall have life of 100,000 hours. Where variable output is required from the pump, this shall be achieved by a hydraulic speed variator fitted between pump and drive motor. Where fixed speed output is required or a compact pump arrangement is required then the drive shall be through anti static veebelts. f) Pump Fittings
Pumps shall be equipped with the following fittings as standard requirements: A drainage pipe to allow drainage of gland seepage liquid. Suction and delivery pressure gauges.
An engraved nameplate indicating material of rotor and stator, output at normal speed, and serial number. A 25 mm plugged tapping on the suction side for manual flushing the pump.
A pressure relief valve on the delivery side the discharge of which shall be piped to the suction pipe.
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12.16.8 Screw Pumps Screw pumps shall comprise a welded steel fabricated central tube with a free start cold formed screw fabricated into a smooth continuous form, welded to the centre tube and designed for minimum deflection. When it is necessary for the central tube to be constructed of more than one length of plate, a welded joint shall not be positioned in the centre of the flight but shall be positioned at each end, and all such joints shall be full penetration butt weld with fatigue design to BS5400 Part 10. Tube end plates shall be manufactured from Grade 43 steel accurately machined to carry bearing stub shafts. The central tube shall be watertight. The spiral blades shall be formed from steel plate. The blades shall be secured to the centre tube by a continuous weld and the periphery of the screw blade shall be finished to ensure a uniform clearance between the screw and trough. Bearing stub shafts of ample dimensions complete with machined location shoulders and mounting flanges shall be bolted to the tube end plates. Top stub shaft units shall extend through the bearing housings to receive the driven half coupling. Where the upper stub shaft of the screw pump passes through the structure, substantial removable anti-splash closing plates shall be installed and sealed to the structure. Plates shall be not less than 3 mm thick mild steel, split for ease of removal. The screw pump shall have a speed of rotation not greater than that given by the equation 50 = ND0.667 where N is in rpm and D is the outer diameter of the screw in meters. b) Screw Pump Bearings
The top bearing shall be arranged for plinth mounting with all loadings transmitted to the motor room floor. It shall be self aligning and designed to support all thrust loads and radial loads at the top of the screw and shall be rated for a life of 100,000 hours under all combined loadings and, where applicable, speeds imposed by the screw. The service factor shall be at least two under maximum load conditions. The bearing shall conform to BS ISO 281 The bottom bearing shall be designed to withstand all radial forces and end support loads. The bottom bearing shall be of bronze or gunmetal sleeve type. incorporate positive means to prevent rotation of the sleeve bearing. The sleeve shall
The bottom bearing shall be supported in a cast iron or fabricated steel housing mounted on a horizontal plinth. The bottom bearing shall be sealed to prevent the ingress of grit and liquid. Replacement of the bottom bearing shall be possible without the need to remove the bearing base or the screw or require the use of external cranage.
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The bottom bearing shall be suitable for continuous operation either in air or submerged and it shall be automatically lubricated whilst the screw is rotating. c) Bottom Bearing Lubricator
A positive displacement metering pump, (lubricator), shall be provided for each screw pump to provide a return oil lubrication system for the bottom bearing. The lubricator shall incorporate a means of flow control that shall have a positive minimum setting to prevent premature failure of the bearing. The flow control device shall be provided with locking facilities. The lubricator shall have an independent drive motor interlocked with the respective screw pump motor. The lubricator shall incorporate a reservoir which shall hold sufficient lubricant for seven days continuous operation of the screw at maximum lubrication rate possible from the lubricator. A lubricant contents indicator shall be provided on the reservoir in the form of a positive depth gauge. A lubricant flowmeter shall be installed within the return pipework which shall provide a pulsed output when lubricant is being returned from the bottom bearing. The flowmeter shall operate in conjunction with a pulse continuity relay which shall stop the pump upon a failure of the lubricant system. There shall also be a visible means of indication of the return flow. A filter shall be provided between the return oil pipe and the reservoir. Pressure and return pipes shall be stainless steel throughout. d) Screw Pump Drive System
The gearbox reducing the speed between the prime mover and the screw pump shall be of robust construction having the output shaft at right angles to the input and suitable for mounting on a plinth inclined at the same angle as the screw pumps to the horizontal. The concrete plinth shall be provided by the Civil Contractor in accordance with the Contractor's design requirements. The speed reducer shall be of the totally enclosed oil bath lubricated type fitted with oil level sight glass, dipstick, filler and drain plug, large inspection covers and an oil breather. Bearings shall be either splash or forced lubricated. Efficient long life shaft seals shall be fitted to all external shafts to prevent loss of lubricant. The speed reducer shall be rated for: Continuous operation, in the climate and temperature of the place of installation.
A gear design life of 100,000 hours at a service factor of 1.5 at the motor full load rating. All bearings shall be rated for a life of 100,000 hours at speed reducer full torque rating in accordance with AGMA 420.04 Specification and all other combined loadings and speeds imposed by the screw.
Where speeds reducer external cooling equipment is required this shall be a separate system to any other cooling system. Screw pumps shall be driven through flexible couplings, of the pin and buffer type to prevent end thrust and radial loads being transmitted to the speed reducer. Couplings shall be arranged to allow coupling belts and buffers to be replaced without disturbing the drive or driven shafts. A back stop device shall be fitted to the speed reducer shaft to prevent reverse rotation of the screw pump under the head of liquid in the flights when the screw pump motor is deenergized. The screw pump shall be driven by a squirrel cage induction motor. The motor shall be protected IP55. The motor shall be horizontally mounted. Power transmission from drive motor to speed reducer shall be through multiple V belts. Pulley ratios and centers shall be selected to ensure the maximum belt contact and bosses shall be a tight fit on the shafts and shall have fitted keys. Drive motors shall be mounted on slotted slide rails with belt tensioning screws and locknuts provided for adjustment. The complete drive system shall be guarded to prevent accidental contact with moving parts. e) Side Profile Plates
A side profile splash guard on the high liquid side of the screw trough shall be provided to prevent liquid running back down the side of the trough. The guard shall be fabricated from steel plate not less than 5 mm thick. The guard shall be strengthened and returned to the trough side wall to prevent build up of debris behind the guard and also allow liquid to run back into the screw. A channel section shall be provided for casting into the screw trough along the full length of the screw pump. The guard shall be securely bolted to the channel section cast into the civil structure. f) Trough Profiling
The screw pump trough shall be profiled by welding a steel strip of suitable thickness along the complete length of the screw and turning the screw using the Contract motor. Screeding of the screw pump trough to form the profile will be carried out by the Civil Contractor acting under the guidance and direction of the Contractor. Profile, finish and running clearance between screw pump and trough must be in accordance with the requirements of the Contractor. Should this not be the case the cost of any remedial work shall be split equally between the Contractor and the Civil Contractor.
g)
The Contractor shall provide dry running protection for progressive cavity pumps.
The Contractor shall submit details of the proposed system for the approval of the Engineer.
12.16.9 Chemical Dosing Pump Chemical dosing pumps shall be of the piston, piston diaphragm or mechanical diaphragm type. Pump design shall incorporate positive stroke return. The maximum stroking speed shall not exceed 100 strokes per minute. Stroke adjustment shall be manual, or by an electrical or pneumatic controlled stroke positioner with step less 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. A stroke length indicator and digital stroke counter shall be fitted. 12.16.10 a) Pump Fittings & Ancillaries Pressure Gauge Tappings
Each pump set shall be provided with both delivery and suction gauge tappings such that when fitted they are in an upright position. Each tapping shall be isolated with a gun metal gauge cock. b) Pressure Gauges
A pressure gauge shall be provided and installed at the above suction and delivery tappings. The gauges shall be of the diaphragm operated sewage installation type. c) Guarding
The Contractor shall include for guards to completely enclose the moving parts of plant. d) Engraved Nameplates
Each pump shall be provided with engraved nameplates as follows: Duty Plate: Indicating the type, impeller diameter, output at normal duty, normal duty head, speed, serial number and pump curve number. Identification: Corresponding with the pump control panel designation eg 'Pump No 1'. The characters shall not be less than 30 mm high. 12.17 VENTILATION AND AIR CONDITIONING All Motor Control Centre and Switch Gear rooms shall be air conditioned.
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Axial flow fans shall be used for general ventilation duties. The performance of the fans shall be determined by the Contractor in accordance with BS 848. Fans shall be of the single stage or multi-stage contra-rotating types. Fan blades shall be of aerofoil section. Blades shall be removable and the pitch angle shall be adjustable. Each fan shall be provided with insect screens and removable air filters. The Contractor shall be responsible for the complete and proper closure of openings provided by the Civil Contractor for this purposes. Roof mounted packaged air conditioning units where specified shall be thermostatically controlled from the respective MCC room. The system shall handle predominantly reticulated air with a controlled quantity of fresh air introduced at the unit. Supply and return air distribution ducts shall be located in the suspended ceiling serving supply and return air diffusers. Supply air handling plant shall include sand trap fresh air intake louver, insect screen, pre filter, bag filter, electric air heater battery, fan and distribution ductwork. External conditions for the calculation of duties for the mechanical services plant shall be with mean monthly maximum and minimum values as detailed elsewhere. All items of plant and equipment for building services shall be designed to operate without malfunction up to a maximum ambient condition of 52 oC dry bulb and a minimum ambient condition of 1 oC dry bulb with instances of 100% relative humidity. The air conditioning system shall be capable of maintaining internal conditions in the respective buildings within the following bands: 22 +/- 2 oC dry bulb 40 - 55 % relative humidity The air conditioning shall be arranged to introduce a fresh air quantity equivalent to 10% of the total air volume handled with a minimum of 6 air changes per hour and maximum of 12 air changes per hour. Air exchange rate should be minimum of 6 air changes per hour in enclosed area such as offices, laboratory, and administration building and control room. For enclosed process area the minimum air exchange rate shall be 12 air changes per hour. The system shall maintain a positive pressure internally of 6 mm water gauge. The grills and differences shall be arranged in such a way that a uniform air supply is maintained throughout the air-conditioned areas. The supply and return air ducting system installation shall be in accordance with DW/144 and all testing to follow DW 143 and CIBS Guides. The Contractor shall be responsible for the complete and proper closure of the openings provided by the Civil Contractor for ventilation purposes. The refrigerant used in air conditioning plant shall be HCFC-free, such as R134A. The HCFC-free refrigerant used shall be suitable for the plant provided and shall be approved by the Engineer..
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Condensate water shall be piped from air conditioning units to approved drainage points. The free discharge of condensation onto the ground shall not be permitted. External ducting shall be protected by aluminum cladding. Final connections to the diffuser shall be by flexible ducting of maximum length 1 meter. Volume control dampers shall be provided at readily accessible locations, at all branches, and where necessary to adjust the flow to achieve satisfactory distribution. Unless restricted by the dimensions of the ducting, duct access panels shall be minimum 450 x 300mm. Fire dampers compliant with BS 476, and 2 hour rated, shall be provided. Extract grills and diffusers shall be anodized aluminum, to match the existing finish. Where required, fiberglass insulation shall be minimum thickness 50mm, and secured to the ducting with non-corrosive metal pins. Where incorporated in air conditioning units any copper parts shall be coated with ACAD/HERESITE for protection against corrosion.
12.18 SUSPENDED CEILINGS
OWA suspended ceiling systems shall be used comprising OW Alux 64/2 white tiles. Suspended ceilings shall be installed fully in accordance with the manufacturers recommendations. Full installation Drawings are to be submitted for the approval of the Engineer in advance of the commencement of installation.
12.19 HANDRAILING, WALKWAYS, FLOORING AND LADDERS
The design of handrailing, walkways, flooring and ladders shall take into account access to items of plant requiring regular maintenance. Any item requiring maintenance shall be provided with permanent access and associated flooring and handrailing. Heavy duty aluminum tubular handrailing in accordance with BS 5395 shall be provided. The handrailing shall have a hand rail 1100 mm above the floor or walkway and an intermediate rail 550 mm above the floor or walkway. Handrailing shall be to the approval of the Engineer. Handrailing (including toe plate) shall be manufactured from aluminum with an anodized finish.
A 150 mm deep aluminum kick strip shall be provided with all handrailing clipped to the handrail standards. Drilling of the handrail standards shall not be permitted. The kick strip shall be discontinuous to a width of 25 mm across concrete joints where plastic inserts or some other approved system shall be used to close the nominal gaps. Walkways, stairways and platforms shall comply with BS5395 Part 3. Standard structural hot dip galvanized mild steel to BS EN ISO 1461: 1999 or marine grade aluminum sections shall be used. Allowance shall be made for the fitting of equipotential bonding conductors with any lugs welded or holes drilled prior to galvanizing. Walkways shall have an effective width of not less than those stated in BS 5395. Open mesh flooring shall comply with BS 4592. Toe plates of not less than 150mm height shall be provided on all walkways. Floor panels shall be sized to not exceed 25kg for single person lift or, where there is adequate space for movement around the panel (as detailed in the Manual handling Operations Regulations 1992), 35kg for a two person lift. Stairway inclination shall be between 30deg and 42deg with the 'going' of stair treads not less than 250mm and landings situated after not more than 16 risers in any one flight. Floor loading shall be as detailed in Table 3 of BS 5395 but not less than a general duty of 5.0 kN/m2. Plating shall be of the non-slip, self draining pattern securely fixed to the supporting structure. Outdoor stairways shall have open mesh treads. 12.19.2 Aluminum access ladders Aluminum access ladders shall be vertical single rung ladders designed in accordance with BS 5395. 12.19.3 GRP Ladders GRP ladders shall be of approved design and obtained from an approved manufacturer. They shall comply with BS 4211. 12.19.4 Emergency access ladders Emergency access ladders shall be designed in accordance with BS 5395. Emergency access ladders shall be manufactured from galvanized mild steel. 12.19.5 Flooring Flooring shall be either aluminum chequer plate or aluminum open mesh as indicated on the Drawings. Flooring shall be designed to support a minimum load of 5 kN/m2 or to the manufacturer's standard specification whichever the greatest. All flooring frames are to be handed to the Civil Contractor, who shall be responsible for building these into the Works. Floor panels shall be designed to be easily lifted and handled by one man. 12.19.6 Support Steelwork
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Support steelwork shall be provided to support floor panels wherever necessary. The steelwork shall be designed in accordance with BS 5395. Steelwork shall be hot dip galvanized in accordance with BS EN 1461. Modular computer type flooring shall consist of easily removed flooring panels supported on galvanized mild steel pedestals. The flooring shall be capable of supporting a minimum distributed load of 2500 kg/m2 and a concentrated load of 400 kg. These loads shall be increased if required by the Contractor's design. Flooring panels shall be easily cleaned with a non slip, grey colored, anti-static surface. Pedestals and stringers shall be hot dipped galvanized in accordance with BS EN 1461 or equivalent. The flooring system for each room shall incorporate ventilation outlets to assist with heat dissipation from the underside of the floor. The flooring panels shall be fire retardant in accordance with class F30 of BS 476 or equivalent. Specialist tools required for access and maintenance shall be supplied to the Employer as part of this Contract. Four spare tiles per floor area shall be supplied to the Employer.
12.20 PORTABLE FIRE EXTINGUISHER All apparatus shall be suitable for operation by one person alone and shall be easily recharged. The discharge shall be non-corrosive and free of chemicals prone to give off toxic gases when heated. Extinguishers shall be of the carbon dioxide or carbon dioxide propelled dry power type. Operating instructions shall be clearly printed on each unit (or adjacent to each unit) in English. A label for test date shall be provided for each extinguisher. Fire Hose Reels shall be provided in accordance with the manufacturers and relevant authority requirements. 12.21 AIR CONDITIONING Outdoor roof/floor mounted packaged DX air conditioning systems shall be supplied for all: Motor Control Centre rooms; Switch gear rooms; Soft starter rooms FM 200 cylinders and fire alarm panels rooms Administration/mess building
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Each A/C system shall be designed such that the maximum room temperature in summer does not exceed 22 2C.
Design Criteria The design of HVAC system shall be based on the following design criteria.
Ambient Temperatures
Summer Dry Bulb Wet Bulb Daily Range 40C 30C 9.7C
Winter Dry Bulb 10 C
HVAC system description 2 no. units shall be installed to serve each of the above mentioned spaces and shall operate in duty/assist configuration, each unit sized for 50% of the AC load; The units shall circulate the air to the spaces through a network of ductwork fabricated from insulated galvanized sheet metal ducts or other approved material and distribute to a suitable terminal such as grilles, diffuser etc; Motorized smoke/fire dampers shall be installed on the supply and return duct work penetrating the room wall/roof in accordance with the requirements of local regulations to ensure the room integrity during fire mode (FM200). Damper operation shall be controlled via the FM200 control panel; The operation of the A/C units shall be interlocked with the fire alarm and FM200 control panel; Common supply and return duct work shall be connected to the A/C units and motorized dampers shall be installed on each A/C unit supply duct to provide a smooth change over between the A/C units; The A/C unit shall shut down in the event of a fire within the served room where continued operation of the A/C plant would adversely affect the performance of the fire extinguishing system or result in propagation of the fire; The Maximum acceptable sound level in the MCC room shall have a noise rating (NR) of 40 dBa, appropriate air balancing shall be performed. The refrigerant used in air conditioning plant shall be Freon Grade R22 or other as approved.
Ductwork
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The ductwork sizing and room air distribution shall be in accordance with SMACNA Standards and "Carrier System Design Manual Part 2 - Air distribution. Friction loss and velocities shall generally be as follows: Friction loss through low pressure (LP) ductwork shall not exceed 1 Pa/m of equivalent duct length; Air velocity in Low Pressure Main Ducts shall not exceed 6 m/s for supply/return; Duct work shall be provided with the required volume dampers for proper balancing of air system; All supply and return duct work shall be insulated.
12.21.2 Ventilation Ventilation fans shall be provided in the manned areas listed below to give the air changes shown in the following table: Type of System Location Transformer rooms Switch gear room Enclosed accessible spaces in process plant Storage rooms Work Shop/Admin. Building Intake Natural via louvered door Natural via louvered door Natural via wall louvers Natural via louvered door Natural via louvered door Extract Mechanical Mechanical Mechanical Mechanical Mechanical Air Change Rate Per Hour 10 10 10 6 6
12.22 GAS DETECTION AND ALARM SYSTEMS A gas alarm system shall be provided in all enclosed process areas, including but not limited to: Inlet works/preliminary treatment Sludge treatment/dewatering;
A gas detector control panel shall be located outside the main entrance to each building or area listed above.
Gas Detection System
A gas detection system shall be provided to monitor the atmosphere within the above mentioned areas. The following three gases shall be monitored:
Methane (high level) - 0 to 100% LEL (5% v/v, 50,000 parts per million) with a resolution of 0.1% up to 10% LEL. Hydrogen Sulphide (high level) 0 to 100% LEL (4.3% v/v, 43,000 parts per million) with a resolution of 0.1% up to 10% LEL. Oxygen (low level) 0 to 25% v/v with a resolution of 0.1%.
Detectors shall be certified as intrinsically safe for use in a zoned hazardous area. The detector housing shall be to IP66 enclosure standard. The locations and number of the detectors shall be suitable for the gases being detected and shall take into account the layout of the areas to be monitored and the layout of the equipment. The detectors for each gas shall be arranged to provide two independently adjustable alarms. The following alarms and indications shall be provided for each gas: Orange light outside the entrance to each building at the first stage alarm, set for gas concentration having reached the 8 hour H2S occupational exposure limit (10ppm ); Red light outside the entrance to the each building and internal audible alarm at the second stage alarm, set for 15 minute H2S occupational exposure limit (15ppm), low O2 level (<20% v/v) and 25% of methane LEL (1.25% v/v); Green light outside the entrance to each building when no alarm present. All indications shall be repeated on the building gas detector control panel and at the STW Control Room via the site SCADA system. Facilities shall be provided for the testing of the systems and the calibration of the gas detectors. 12.23 FIRE ALARM AND FIRE EXTINGUISHER SYSTEMS A general fire alarm system to BS 5839 and BS EN 54 shall be installed throughout all indoor plant areas of the facility. For the LV switchgear room(s) including all MCC/MDB and control rooms, FM 200 total flooding system complying with BS ISO 14520, BS 5306, BS EN 12094 or NFPA 2001 shall be installed. Rooms shall be made gas tight and ductwork penetrations provided with gas tight dampers operating on spring shut and motor open mode. This system shall be interfaced with the general building alarm so one detector from each system has to be activated for the FM 200 system to operate. The Contractor shall design the maximum capacity requirement of FM 200 agent together with the complete mechanical operational system including bottles, manifold, distribution pumping valves, pressure switches, flexible connection nozzles and fusible link etc. Hand-held fire extinguishers shall be provided throughout in accordance with BS 5423, BS 5306 or NFPA 10.
Operating instructions for all systems shall be clearly printed on each unit (as adjacent to each unit) in English. All indications shall be repeated at the STW Control Room via the site SCADA system. 12.24 ESCAPE ROUTES Structures shall be provided with signs showing the direction to the nearest exit. 12.25 LIFTING FACILITIES 12.25.1General Overhead lifting facilities, that may include overhead travelling cranes or jib cranes, shall be provided for items of maintainable plant greater than 250 kg or of a size that precludes the use of a lifting davit. Lifting davit sockets shall be provided for maintainable plant greater than 25 kg but less than 250 kg. Two portable lifting davits rated for a Safe Working Load of 250kg shall be provided for the works. Maintainable plant shall be defined as machinery with moving parts whether motor driven or manually operated. 12.25.2 Electric Over head Travelling Cranes a) General Electric overhead travelling cranes shall be of the flush mounted type. Cranes shall comply with BS 2573 Part 1 and BS 466. The crane classification shall be Class 2 of Utilization U2, Group Classification A2, Mechanism Classification L2, H3. The bridge girders, end carriages and runway beams shall be fabricated from Grade 43A structural steel sections to BS 4360 Specification for weldable structural steels. End stops shall be fitted at the ends of the runway beams. The end carriages shall be fitted with double flanged track wheels. Rails shall be the flat top type.
b)
Operation The long travel motor shall drive both end carriages through continuous shafting to avoid skewing of the bridge assembly. An electric hoist assembly shall be mounted on a cross travel trolley. The trolley shall run on the bridge assembly. The cross travel trolley shall be powered by an electric motor. Trolley end stops shall be fitted to the bridge. The electric hoist unit shall be provided with two speeds for lifting and lowering. The hoist shall be smooth running in both directions and speeds. Travel and hoist speeds shall be submitted to the Engineer for approval. Power supply to the crane shall be via a shrouded bar conductor system with supply to the cross travel trolley via a festoon cable system.
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Control of the crane shall be from a moveable pendant supported on a rail attached to the bridge girder. The lifting hook shall comply with BS EN 1677-5 and shall incorporate a safety catch and be capable of swivelling through 360 . Transverse & long travel to be provided with safety limit cut-outs by means of electrical control in addition to final stop logs as final resort. 12.25.3 Manual Hoist/Monorail Beam Hand operated monorail cranes shall be supplied complete with the runway beams to be fitted to the building structure and shall comply with BS 2573 Part 1 and BS 466 where applicable. The crane classification shall be Class 2 of Utilization U2, Group Classification A2, Mechanism Classification L2, H3. The chain pulley blocks shall comply with BS EN 13157 with a state of Loading L3, Safe Working Load M1 and shall incorporate automatic load brakes which apply when the hand chain wheel effort ceases. A hoist chain box shall also be provided. The load chain shall be Grade 40, 60 or 80 alloy steel chain to BS 1663, BS 3113 or BS 3114 as appropriate. The chain shall be fitted with a lifting hook which shall comply with BS EN 1677-5. The hook shall incorporate a safety catch and shall be capable of swivelling through 360 . Hand chains shall be Class 2 Grade 30 mild steel to BS 6405. The chains shall be galvanized. The length of the chain shall be such that they clear the floor by 600 mm. 12.25.4 Pillar Jib Crane a) General Electric pillar jib cranes shall be of the floor mounted type. Cranes shall comply with BS 2573 Part 1 and BS 466. The crane classification shall be Class 2 of Utilization U2, Group Classification A2, Mechanism Classification L2, H3. The pillar and jib beam shall be fabricated from Grade 43A structural steel sections to BS 4360 Specification for weldable structural steels. An end stop shall be fitted at the end of the jib beam. The trolley carriage shall be fitted with double flanged track wheels. Rails shall be the flat top type. b) Operation An electric hoist assembly shall be mounted on the trolley. The trolley shall run on the jib beam assembly and shall be powered by an electric motor. The electric hoist unit shall be provided with two speeds for lifting and lowering. The hoist shall be smooth running in both directions and speeds. Travel and hoist speeds shall be submitted to the Engineer for approval. Power supply to the trolley shall be via a festoon cable system.
Control of the crane shall be from a moveable pendant attached to the pillar. The lifting hook shall comply with BS 2903 and shall incorporate a safety catch and be capable of swivelling through 360 .
12.26 SUBMITTAL 12.26.2 Drawings In addition to the drawing requirements, the following drawings and documents shall be submitted for review: a) Pump mounting and general arrangement drawing, complete with parts and materials listing, dimensions and weight; b) Pump sectional drawings detailing all internal components and associated parts lists; c) Performance curves; d) Pump data sheet; e) Valve and actuator data sheets. Each datasheet shall incorporate all relevant data associated with each specific valve which shall include but not be limited to:a) b) c) d) e) f) Certification The Contractor shall submit three (3) fair copies of all Test Certificates (including results of tests) as required by the Contract. PART 2 PRODUCT SPECIFICATIONS principal dimensions; any pertinent construction details; materials used for all parts; torque limits; pressure rating; connection details.
12.27 COARSE RAKED BAR SCREENS
Automatic self-cleaning front raked coarse bar screens shall be installed at the head of the sewage treatment plant. Each screen shall have bar spacings of 20mm. Each screen shall consist of a bar rack, a powered raking mechanism and a rake cleaning device.
The rack shall consist of a number of stainless steel bars of tapered section supported on a framework, which shall be fixed to the channel walls. Each bar shall be individually supported at the bottom and at a point above top water level in the channel. The bar rack shall be inclined in the direction of flow. Sewage shall be prevented from passing around the sides or underneath the screen by heavy sealing rubber strips protected by stainless steel guards (or other suitable sealing device). The support framework shall be designed to ensure that the bars are held at the required spacing. The framework shall not interfere with the cleaning mechanism. The framework shall be capable of supporting the rack in a blinded condition with an unbalanced level of 2.0 m. The support framework shall be manufactured from stainless steel and shall be designed in accordance with BS 449. The raking mechanism shall be of a positively driven type. The rake shall be driven into engagement with the rack, shall sweep the complete extent of the rack, to lift screenings into the collection trough. A stainless steel cleaning blade shall remove any screenings from the rake tines and deposit them in the trough. The raking mechanism shall be such that no bearings or linear bearing surfaces shall be immersed in the sewage flow. The rake shall carry a tine plate fabricated from minimum 18 mm thick stainless steel plate. The tine plate shall be detachable. The tine tip loading shall be at least 1500 N/m tine length. If the raking mechanism encounters an obstruction which exceeds this loading, the tines shall be allowed to profile round the obstruction and reengage with the rack above the obstruction. The raking mechanism shall park above top water level when not called to run. The headgear shall include an electric motor, gear reduction unit and drive shafts. The drive motor shall be suitable for a Zone 2 Hazardous Area and shall incorporate torque overload protection. The drive motor shall be a fully weatherproofed totally enclosed squirrel cage continuously rated motor. The motor shall be to IP68. The gearbox shall comply with BS 4517. The motor/chain drive shall be a roller chain with adjuster. The drive shaft shall be carbon steel zinc plated. The drive sprocket shall be carbon steel or better with stainless steel grade 304 outer (wearing part) split unit designed for simple replacement. Moving parts shall be guarded. Guards shall be locked in place or should require a tool to remove them. Where possible, guards shall be hinged. Guards shall be in accordance with the Health and Safety at Work Act 1974 and British Standards reference PD 5304:2000.
12.28 SCREENINGS TRANSPORTATION AND TREATMENT
Screenings removed from the flow by the coarse bar screen shall be discharged into a screw auger, which shall transport the screenings from the screen to a washing/compaction plant. This will remove the bulk of organic material from the screenings and dewater them, prior to discharging treated screenings to sealed plastic sacks. The screw auger shall be fabricated from a semi-circular section trough housing a powered auger screw. The trough shall have a minimum diameter of 350mm. Troughs and covers shall be fabricated in stainless steel 316, which shall have a minimum wall thickness of 4 mm. The troughs shall be stiffened and supported as required to prevent low points occurring. The inside surfaces shall be smooth and shall not present any steps or ledges to the screening flow. The trough shall be dowelled during fabrication to prevent misalignment on installation. The screw auger shall be designed with a fall of not less than 1 in 20, and to handle a peak flow of screenings equivalent to 150% of the peak screenings load. At the entry point from each screen, removable inspection covers shall be provided. A 150mm square mesh shall be provided to prevent large objects such as pieces of timber etc from entering the auger and jamming it. The washer/compactor unit shall receive raw screenings and then wash, dewater and compact them prior to discharging the compacted screenings into a wheelie bin. The rags and fibrous material will be separated from the liquid in a screen section and dewatered/compressed in a screw compaction unit. Water draining from the compactor section shall drain back into the screenings channel down-stream of the screens. Screenings washing shall be accomplished by high pressure spraying of the screenings within a perforated stainless steel trough section. The dirty washwater/broken down organic material will then drain off, back into the screen channel down-stream of the screens. The washed screenings shall be retained, dewatered and compacted by a screw auger. Compacted screenings shall be discharged via a stainless steel chute into a wheelie bin adjacent to the plant. The discharge chute shall be provided with a large diameter jubilee clip or similar fixing system, to enable heavy-duty plastic sacks to be attached to it. Screenings shall be discharged into the sacks, which when full shall be manually changed and sealed for removal from site. The compactor shall be sized to handle a minimum of 150% of the maximum raw / uncompacted screenings per hour at peak flow, and shall be of a minimum width of 350mm. 12.29 MECHANICAL FINE 3 MM SCREENS
The screens shall consist of continuous belt of linked perforated stainless steel plates mounted in the inlet channel at an angle. Debris and suspended solids present in the wastewater flows shall retained by these perforated plates. Each end of the perforated plate shall be connected to a drive chain which is driven by chain wheels. Each chain shall be driven by a sprocket on a common shaft and a flange mounted geared motor. The screens shall be designed to prevent long fibers from passing through and shall be able to cope with a significant amount of gravel and grit. At their upper turning point the perforated plates shall be continuously cleaned by a high speed rotating brush which shall remove the screenings from the perforated plates. The
cleaning action shall be supplemented by an integrated spray bar that jets the screenings from the panels from inside to outside. Rake bars shall protrude from the panels over the full width of the screen, and in combination with the screens installation angle shall prevent formation of screenings rolls in front of the screen. Any large debris shall be lifted by the rakes. Screenings removed by the fine screen cleaning mechanism shall be discharged into a launder trough, such that none pass back into the main flow or outside the trough. Screenings shall be transported along the launder trough via the flow of wash water, to the screenings handling plant for dewatering/compaction and disposal into skips. The screens shall be designed so as to facilitate safe inspection, cleaning, lubrication and repair to ensure safe and satisfactory operation under all service conditions. The screens shall be able to tilt by means of a pivot out of the channel to allow the sections normally located below the coping level to be inspected and maintained. Electrically actuated penstocks shall be provided upstream and downstream of each screen for isolation and to allow each screen to be taken out of service for maintenance/repair. 12.29.2 Frame The screens frame shall be stainless steel grade 316 construction. The frame shall be secured to the coping of the channel. There shall be no fixings below coping level. Wear resistant plastic elements shall provide sealing between the traveling screen elements and the frame whilst the perforated plates are moving. The plastic and screening elements shall be easily replaceable. The screens shall be completely enclosed with easy to remove covers for odor control purposes. The material of construction for the drive chains, hollow pins and side bars shall be stainless steel grade 316. The chain wheels and the protective rollers shall be made from polyamide. The upper flange bearings shall be maintenance free and the lower ceramic bearings shall be wear resistant and maintenance free. The upper chain tensioning units shall be easily accessible from outside. 12.29.3 Drive Motors The headgear of the screens shall include the main drive and brush drive motors, with associated gear reduction units and drive shafts. The drive motor shall be a fully weatherproofed totally enclosed squirrel cage continuously rated motor. The motor shall be to IP55 to BS 4999 with anti condensation heater. The gearbox shall comply with BS 978 or equivalent. The clutch shall be a friction element clutch on the gearbox output drive shaft. The drive shaft shall be carbon steel zinc plated.
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Overload equipment shall be provided to limit torque and prevent damage to mechanical components or electric drives in the event of the screen components becoming jammed. Electrical cut-out and volt-free contacts for alarm purposes shall also be incorporated in the overload device. 12.29.4 Guards Moving parts shall be guarded to at least 150 mm below the coping level or to meet the channel covers. Guards shall be manufactured in clear polycarbonate for inspection purposes and shall be locked into position such that a tool is required to remove them. The guards shall be hinged where possible. Guards shall be in accordance with all relevant statutory standards and laws. Rotating or moving parts shall be close guarded to prevent injury to personnel. 12.29.5 Side Sealing Rubbers The side sealing rubbers shall be a continuous heavy duty rubber strip with a grade 316 stainless steel cover strip. 12.29.6 Spray Washwater Supply Washwater shall be used to supply the screen spray bar nozzles to facilitate removal of screenings. Cleaning brushes shall have polypropylene bristles in a stainless steel holder. The sparge pipe shall be made from stainless steel 316, with spray nozzles angled appropriately to direct the washwater on the screen, and a quick link removable hose connection. An isolating valve, solenoid valve, pressure reducing valve (to eliminate spray) and in line strainer shall be fitted. 12.29.7 Wash/Launder Troughs/Sparge Water Screenings launder troughs shall be provided for transporting screenings away from the 6mm Inlet Screens. Each launder shall be sized for 150% of the maximum screenings load. The wash water shall be discharged into trough from the site washwater system at a minimum pressure between 3 and 5bar, at the end opposite to the screenings treatment plant, and the trough inclined such that the washwater/screenings flow freely to the screenings treatment plant. In the event that washwater is unavailable, clean water shall be used. The washwater flow into the launder shall be limited such that the maximum flow that can be received by the screenings treatment plant is not exceeded. The washwater connection to the launder trough, completely mounted on to the unit shall include solenoid valves, strainer (suitable for wash water with particle less than 200m), hoses, pressure reducing valve for regulation and all required fittings. The length of the launder shall be sufficient to transport the collected screenings to the screenings treatment units installed. The trough and the supports shall be manufactured from stainless steel grade 316 material and shall be acid treated in a pickling bath. 12.30 GRIT/GREASE REMOVAL SYSTEM
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12.30.2 General The grit and grease removal system shall receive flows from the 20mm Coarse Inlet Screens The equipment is intended to separate settling solids and grease from the wastewater. The system shall consist a number concrete aerated grit channels operating. Each channel shall be designed to remove 95% of grit present with a diameter of (0.2-.25) mm or greater from the flow. Actuated penstocks shall be provided upstream of each grit channel for isolation and to allow each channel to be taken out of service for maintenance/repair.
12.30.3 Grease Traps Automatic grease traps shall be laterally arranged in parallel to the grit channel and shall be of the same length. Floating grease shall be scraped into a pump sump located at the inlet to each channel.
12.30.4 Grit washers/classifiers Grit washing/classifier units shall be provided to classify and at the same time treat the grit/water mixture. Grit classification shall be achieved by separating the organic material by means of integrated automatic air intake system creating a rotary effect. Each unit shall be designed for a separation capacity of 97% for grit with a grain size of 0.2mm. All components of the grit units in contact with the medium shall be made from stainless steel 1.4541/1.4301 or equivalent material and shall be acid treated in a pickling bath. 12.31 SCREENING AND GRIT DISPOSAL Conditioning and cleaning of screened material shall be undertaken such that there is no visual faecal matter and that the screenings are in a suitable condition for road transport and ultimate off site disposal. The following table indicates the screenings and grit conditioning quality required. Screenings Capture rate (fine screens) 70% Screenings Dry Solids content 30% Screenings Organic content 5 % Grit Separation efficiency (particle range 0.2-0.25mm) 95 Grit Dry Solids content 70% Grit Organic content 5 % 12.32 SUBMERSIBLE MIXERS Submersible mixer shall be sufficient to ensure homogenous mixed liquors. The submersible mixer units shall comprise a motor driven blade type propeller. Units shall not be provided with a shroud around the propeller, in order to minimize the risk of rag and debris becoming caught and jamming the propeller. The mixer shall be sized to give sufficient thrust to ensure suspension of floc and homogenous mixing of liquors. The flow
generated shall be in line with the lane flow direction. The pressure loss shall be minimized and a characteristic curve of pressure loss against the flow shall be provided. Mixers shall be mounted on stainless steel guide rails and provided with stainless steel lifting chains for lifting and support of the unit. Cabling from the mixer drive motors shall be of suitable length to terminate at a junction box located at the top of the tank. Permanent lifting davits shall be provided and fixed to the concrete structure to facilitate installation/removal of the submersible mixers. All materials of construction and surface protection shall be suitable for the liquid to be mixed. The wetted parts of the installation shall be grade 316 Stainless Steel. The integral brackets, shackles and lifting eyebolts shall be stainless steel and certified by an approved testing authority for the required Tensile strength. The propeller shall provide uniform flow velocity across the full diameter. The leading edge vanes shall be swept back to minimize the risk of rag and debris becoming caught on the blades. The propeller shall be of one piece construction and positively driven by the shaft. The propeller assembly shall be dynamically balanced. Machining of holes in the blades shall not be used to balance hydraulic forces. The first critical shaft speed shall be at least 25% above the maximum running speed. The shaft stiffness shall be such that under the most severe operating conditions, the total shaft deflection at the seal does not exceed the seal manufacturers specified tolerances. The mixer motor shall be IP68 rated with a winding insulation of class F and equivalent temperature rise of class B. The mixer motor shall include sealed for life grease lubricated rolling element bearings. The motor shall be sized for continuous operation in the worst case combination of viscosity and density. 12.33 AIR DISTRIBUTION PIPEWORK Distribution pipework shall be made from grade 316 stainless steel pipe of sufficient gauge to prevent collapse due to the hydrostatic loads within the process lane or unit and withstand the mechanical forces generated in operation and during the installation. Additionally, the gauge of the pipes to which the diffusers are to be fitted shall be sufficient to allow the use of screw fit or glued aeration disc base plates and to withstand local forces generated at the joints by the flow of effluent over the discs. The pipework grid shall be broken down into sections. The connections between each section shall be made by means of push-fit connectors, or compression couplings.
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Coupling seals shall be manufactured from a rubber compound suitable for long-term immersion in aerated effluent. If push-fit connections are used they shall be of a design which inhibits the removal of the spigot piece once inserted into the socket. Pipework grids shall rest on the concrete floor of the process units by means of grade 316 stainless steel pipe supports and be located under its own weight. Pipe supports shall provide a means of fine adjustment of the level of the aeration grid. The pipe supports within the tanks shall be fixed using chemical anchor bolts. Each pipework grid shall be provided with a means of isolation from the rest of the aeration system, the quantity of pipework supports shall be sufficient to support the grids without sagging and to allow the pipework to resist mechanical, hydrodynamic and hydrostatic loads without generating excessive loading in the pipework. It shall be possible to isolate and remove a grid from the aeration tank, without having to drain down the aeration tank or otherwise take out of service. Each process unit shall be provided with condensate drains and purge pipes. Protection against siphoning of the effluent into the air main shall be provided. Self sealing diffusers shall not be considered to meet this requirement.
12.33.2 Air Flow Control and Isolation a) Modulating Control Valves
Aeration zone flow modulation valve shall be of an eccentric plug type or needle type with a linear characteristic across their design flow range. b) Grid isolation
Each individual aeration grid shall be provided with a butterfly type isolation valve. The butterfly valves shall be of lugged wafer type and shall have seat and gasket material suitable for a high temperature application. The isolating butterfly valves may be either lever type or gear type depending upon the size of the valve. In either case the force required on the valve lever or the wheel, to close or open the valve shall not exceed 120N.The valve operators shall have position indicators into which it can be located and locked.
12.33.3 Air Diffusers a) General
Fine bubble type air diffusers shall be installed on the distribution pipework. Diffuser holders shall be manufactured from materials compatible with the distribution pipework. The diffusers shall be selected for long service, at least two years, between cleaning operations. Diffusers that can be cleaned in situ are preferred. b) EPDM Membrane Fine bubble air diffusers
Membrane diffusers shall be either disc or tube types manufactured from EPDM. The holders shall be grade 316 stainless steel.
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The diffusers shall have an airflow control orifice to allow a uniform airflow distribution throughout the diffuser surface. The diffusers shall be clog free and suitable for continuous extended aeration process. There shall be no ingress of the mixed liquor into the air pipework following the sealing of the flexible perforated rubber membrane and supporting member and the diffuser slits shall prevent any passage when the air is turned off. The membranes shall be fully supported by the base plate in order to prevent back flexing. The diffuser and holder shall be designed to provide full surface uniform air distribution. The airflow through individual diffusers, mounted on a common header shall not differ by more than +/- 5%.The slits or the perforations punched on the membrane shall be such as to provide greater resistance to elongation and tearing. The design of the diffusers shall consider the contractions and expansions resulting from temperature variations. The diffusers shall be declared failed if any one of the following occurs: A 3KPa increase in the headloss across the diffuser membrane; A 15% decrease in the standard oxygen transfer rate and standard aeration efficiency when tested in clean water; Deterioration in the membranes which allows the ingress of the mixed liquor into the air distribution network; Deterioration of the membrane which changes the bubble pattern from s fine evenly distributed pattern.
12.33.4 Aeration System Standard Oxygen Transfer Test Oxygen transfer (Aeration) tests shall be carried out in accordance with the A.S.C.E Standard Measurement of Oxygen Transfer in Clean Water, July 1984, published by the American Society of Civil Engineers, New York, U.S.A (Abbreviated as ASCE standard hereunder) to verify the aeration system guaranteed SOTR (kg/h) and SAE (kg/kWh). SAE (Standard Aeration Efficiency) is SOTR per unit power input. Power input is based on motor input power (wire power). To alleviate the volume of potable water required for the oxygen transfer test, the above test shall be undertaken by the Contractor at the diffuser factory at pilot scale, using a small number of diffusers. However, the Contractor shall undertake an aeration pattern test at full scale, whereby each aeration tank will be partially filled to cover the diffuser domes, and the air distribution across the tank assessed. 12.34 POSITIVE DISPLACEMENT (ROTARY LOBE) AIR BLOWERS Positive Displacement Air Blowers maximum speed shall be 2500 RPM.
Casing: The cylinder and headsplated shall be manufactured from high grade cast iron. Impeller and Shafts: Impeller shall be ductile iron with integral shafts or steel stubs shafts and shall be dynamically balanced to close tolerances. It shall be made of 3 lobe type impeller blower. To reduce the noise and power loss, it shall be provided by wrap-around plenum. Bearing: The bearings shall be of generous proportions to give long operational life. Oil lubricated cylindrical roller bearings shall be used at the drive and gear end of the blower. In addition to normal duty of carrying radial loads associated with the differential air pressure on the rotating impellers, bearings shall be provided with axial location of the impellers. All bearings shall be heavy duty type grease packed and sealed-for-life and shall be designed with minimum life of L10, 100,000 hours at the guaranteed duty point. Lubrication: Both drive end and gear end shall be splash oil lubricated. It shall be provided with maintenance free oil throwers fitted behind each bearing in the gearcase to prevent leakage of oil. Direction of Rotation: It shall be detachable mounting feet enable the blower to be positioned for either vertical or horizontal airflow. Standard machines shall have a left hand drive shaft, top inlet, for vertical airflow and a bottom drive shaft, left hand inlet, for horizontal air flow. Package Units: It shall be enclosed type unit suitable for the system and as per manufacturers standard. The unit shall be designed as prime package units. All package units shall be designed to achieve sound pressure levels below 80 dBA (measured at 1 meter) without the use of inlet or discharge silencers. The sound pressure shall be reduced to an acceptable level at the site boundary. It shall be original and directly supplied by the blower manufacturer. Characteristic curves for the aerator performance shall be submitted by the Contractor and appended to the completed data sheets. Bolts and nuts required for fixing shall be stainless steel grade 316 complete with nylon washers to prevent galvanic reaction, and shall not be painted. 12.35 CENTRIFUGAL AIR BLOWERS 12.35.2 Design Centrifugal air blowers shall comprise modulating powered guide vanes and diffuser blades, gearbox, lubrication system, electric drive motor and suction and discharge connection flexible grade 316 stainless steel compensators, mounted on a common baseplate. The sets shall be installed on flexible machine mounts. Each blower set shall be provided with an acoustic enclosure and a surge protection system. The acoustic enclosure shall limit the noise level to 80dB (A) when measured at a distance of 1 meter from the Blower enclosure, in any direction. The enclosure shall be designed to ensure that adequate cooling of the blower is maintained. The enclosure shall be designed to allow for ease of access to the blower set without the necessity to lift the complete enclosure, to allow for routine inspection and maintenance procedures.
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The modulating guide vanes shall be capable of varying the delivery rate down to 45% of the normal rated output without causing the blower to go into surge. A high operating efficiency shall be maintained throughout the flow range. The blower sets shall be of a proven design with at least five years operational experience in similar applications. In addition to single duty applications, the design shall be proven in applications where two or more units are automatically controlled to meet the varying air demand. Materials and equipment of construction shall give a design running life of at least 100,000 hours before major maintenance is necessary. Gearbox bearings may have a reduced operational life, which shall not be less than 18,000 hours, provided the work necessary to change the bearings can be safely carried out by general maintenance technicians who have limited skill and the work does not involve the precision setting of tolerances. The impeller, gears and shafts shall be dynamically balanced. The first responsive critical speed of the rotating assembly shall be at least 10% above the maximum operating speed. The gearboxes shall be of the parallel shaft high speed helical type. The gears shall have a minimum AGMA service factor of 1.5. A labyrinth oil seal shall be fitted to each shaft to prevent oil seepage from the casing under operating and static conditions. The seals shall be designed to ensure there is no contamination of the process air. The baseplate shall be provided with lifting lugs designed to allow the complete set to be lifted and handled using chain slings. Instrumentation for the safety monitoring of air blowers shall include oil temperature, oil level, air temperature at inlet to the blower, air pressure in the blower casing, surge conditions, bearing vibration and motor running current, Motor winding temp., low air pressure. The instruments shall provide signals for the shutting down of air blowers if unsafe conditions arise and for visual indication of the fault. Each blower shall be performance tested at the manufacturer's works, using the contract motors, to BS ISO 5389:2005 'Code for acceptance tests for turbo-type compressors and exhausts'. Air flow measurement for these tests shall be carried out in accordance with PD ISO TR 12767:2007 Measurement of fluid flow by means of pressure differential devices'. Blower casings shall be works hydrostatically tested to 1.5 times the maximum working pressure. The blower and the motor shall be mounted on a base frame incorporating an integral silencer, return valve, pressure relief valve, isolating valve, discharge connection with the flexible joint and flexible mounting pads. Vibration dampers shall be placed under the blower mounts. 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. In addition each blower shall be fitted with a suitable pressure switch which shall monitor the discharge pressure of the blower and it shall be set to shut down the blower in event of excessive discharge pressure. The pressure setting of the blower shall be lower than the set pressure of the pressure relief valves The pressure switch shall be adjustable over a range of 10 150 kPa and shall have two sets of change over contacts with a minimum rating of 240 V AC, 2A.The switch housing shall be of metal with a degree of protection not less than IP56.
The blower house building shall be suitably ventilated by negative pressure caused by the blowers themselves and no need for extra ventilating system for blower houses exclusively. 12.36 BLOWER PIPEWORK & DUCTING 12.36.2 Intake Ducting Individual air intake ducting shall be supplied for each blower. The interconnecting ducting shall be of grade 316 stainless steel pipe. Supports shall be of steel hot dip galvanized after fabrication. The ductwork to each blower shall include two stages filters (coarse filters and fine (bag) filters, silencer and air intake. The air filter system shall be suitable for use in tropical conditions. The air intake for each blower shall be located inside the blower building and at least 2 meters above floor level. Proper separation from intake ducting and the building wall shall be achieved for room ventilation. The combined efficiency for particle removal by the two filters shall suit the requirements of the process. The filters shall be of the pad or dry pocket type. The filter enclosures shall be fabricated from galvanized steel and shall be designed for ease of access to the filter elements for inspection/replacement without dismantling the ductwork. The silencer shall ensure that the noise level described for the blowers is not exceeded. The casing can be a separately mounted unit or mounted on the common base plate with the blower assembly. The casing shall be galvanized steel. Fixed blade weather louvers complete with bird screen and sand trap shall be mounted in the blower house plant room wall in front of each blower intake. Louvers shall be designed by the Contractor to prevent rain from entering the blower building. The louvers shall be fabricated from grade 316 stainless steel or other equivalent. Filters shall be tested in accordance with BS EN 779:2002 at the manufacturer's works. 12.36.3 Discharge Pipework Each blower shall be provided with individual discharge pipework which shall be connected to a common manifold. The discharge pipes shall be supported from the blower house plant room floor. Discharge pipework shall be grade 316 stainless steel. The supports shall be of steel galvanized after fabrication. Site welds for galvanized supports will not be allowed. All indoor pipes shall be externally insulated with Rockwool with proper density and covered with a stainless steel jacket. Each discharge pipe shall be provided with a suitably sized blow-off valve, non-return valve and isolation valve. The blow-off valve shall be an actuated butterfly valve and shall be fitted with an exhaust silencer. The discharge from the silencer shall be at least 2 meters above floor level and shall be directed vertically upward or mounted in the horizontal plane. The silencer shall
ensure that the noise level of the exhaust does not exceed the level described for the blowers. The non-return valve shall be of the wafer check type. Butterfly valves shall be provided for isolation of the individual pipelines. The valves shall be gearbox driven to suitably limit the rate at which the operator can shut off the valve. The valves shall be capable of being operated with the operator standing at floor level. A mobile platform shall be provided to enable operation of any valves or damper located higher than 2 meters. All valves and couplings installed in the discharge pipework shall be suitable for the high temperature application equivalent to the discharge air temperature of the blowers. All valves shall be as per the standard mechanical specifications. 12.36.4 Blower Manifold Individual blower discharge pipework shall connect to a common manifold using tee connections. The manifold shall be installed outside the blower house plant room and shall be supported from the floor or wall. The manifold shall be sized for the duty blowers operating simultaneously delivering air at their maximum output. Manifold pipework shall be grade 316 stainless steel. The supports shall be of steel, hot dip galvanized after fabrication. A valved tapping shall be provided for the fitting of a pressure transducer for monitoring the pressure within the manifold. If necessary, a silencer shall be installed within the manifold to ensure that the noise level outside the building, transmitted via the pipework, does not exceed 80 dB (A) measured 1 m in any direction, from the pipework, when the duty blowers are delivering at their maximum rated output. Automatic condensate drain traps shall be installed at any location where water can collect in the discharge pipework/manifold assembly. 12.36.5 Air Supply Main A supply main shall be provided and shall connect the blower house manifold to the distribution pipework. The supply main shall extend from the blower house to the biological treatment process units (Membranes and Aeration lanes). The supply main shall be elevated above ground for its complete length and terminated with a tee for connection to the distribution pipework described below. Air supply main pipework shall be grade 316 stainless steel. The supports shall be of steel, hot dip galvanized after fabrication. The supply main shall be sized for the duty blowers operating simultaneously delivering air at their maximum output.
A dirt pocket with an automatic condensate drain trap shall be installed to collect and drain water at the lowest position on the supply main. A chamber for access to this condensate drain trap shall be provided. The supply main shall be laid to an even grade sloping back to the condensate trap. Elevated pipework over roads shall be arranged with a minimum ground clearance of 4.5m. Goal post type supports shall be located 10m back from pipe bridge crossings on both sides. Dissimilar metal contacts shall be avoided. 12.36.6 Blower enclosure ventilation ducts Each blower shall be provided with individual ventilation duct to discharge air from inside blower enclosure via built in fan to the outside wall of the building. Fixed blade weather louvers complete with bird screen and sand trap shall be mounted in the blower house plant room wall and be connected to each enclosure ventilation duct. Louvers shall be designed to prevent rain from entering the ductwork. The louvers shall be fabricated from grade 316 stainless steel or other equivalent.
12.37 DECANTING CENTRIFUGE 12.37.1 General Each centrifuge shall be a solid bowl, continuous feed, scroll type centrifuge including drive, back (recovery) drive, controls and accessories as shown on the drawings and specified herein. Each centrifuge shall have (but not exhaustive): Bowl Conveyor Casing Gear box Pillow block bearings Vibration sensors and monitoring equipment Drive motor Backdrive system Oil lubrication system
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Flexible connections Electrical enclosure Painting Accessories Controls and instrumentation. Centrate and discharge chutes (independently supported)
12.37.2 Washwater system Air leakage in or out of the main body shall be controlled through provision of gaskets and seals on casting flange, hub ends and if required a seal on the feed tube. The vibration velocity shall not exceed 6mm/s measured at any point on the installation. Each centrifuge shall be fitted with a removable feed tube having the manufacturers standard flanged feed connection for the unit provided. 12.37.3 Materials Selection The equipment shall have a guaranteed life. The materials of construction shall be selected to suit the local environmental conditions including a high grit proportion in the sludge Metalwork coming into contact with sludge material shall be constructed in stainless steel (SS) 316L (including bowl and scroll). The bowl shall be supported at either end on a spherical or cylindrical roller type bearing mounted in pillow blocks or supported by the cast iron housing in a closed installation. Surfaces that are subject to the abrasive nature of the feed sludge, cake or centrate shall be required to have additional hard surfacing protection. As a minimum this shall include: Conveyor flights; Sludge feed zone; Bowl wall area; Solids discharge ports;
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Solids compartments in the upper and lower casings; and The solids discharge wear edge.
The following minimum shall be considered (where appropriate) Tungsten carbide alloys (i.e. nickel-chromeboron) used as a protective coating on high wear zones (flame sprayed and fused); Sintered tungsten carbide wear sleeves and rings (part replacement); Sintered ceramic tiles tungsten carbide alloys.
The supplier shall be required to submit testing details/report for the associated hard surfacing selection, and details of similar installations. 12.37.4 Lubrication An external oil lubrication system shall be required. This system shall be either an oil circulating system or an automatic grease lubrication system. The bearings shall be designed for a minimum operation of 100,000 hours at the design speed for the centrifuge and under continuous service. The oil lubrication system shall be interlocked with the centrifuge motor such that issues with poor lubrication will inhibit or shutdown the operation of the motor and thus the centrifuge. The lubrication system shall be designed to operate independently and shall ensure that loss of power do not result in damage to the centrifuge bearings. 12.37.5 Covers Each centrifuge shall be installed with a removable cover and frame. These covers shall be acoustically appropriate for the installation and ensure that the noise levels are reduced to below the required levels identified for the equipment/operator interface. Inspection ports shall be included within the cover at appropriate locations and shall enable minor adjustments to be made with requiring removal. Vibration monitoring / isolators Vibration monitors shall be installed on each decanting centrifuge unit. A minimum 4 vibration mounts shall be provided under each centrifuge frame. A minimum 2 mounts shall be provided under the drive motor bracket (if separate). The number capacity and vibrator constant of each unit shall be as necessary to handle the load and impact of the centrifuge operations.
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12.37.6 Washwater Washwater system, using Treated Sewerage Effluent water, shall be provided to clean the Centrifuge during the shut down sequence. 12.37.7 Odor Control The Centrifuge shall be housed in a dedicated and ventilated building or room which shall be odor controlled. The Contractor shall undertake a review of the odor potential resulting from the sludge treatment facility, inclusive of the Decanting centrifuges. The Contractor shall ensure that the Decanting units and Centrate liquors are covered and connected to the main works odor control unit. The extract ventilation arrangements shall keep the unit enclosure(s) under a slightly negative pressure to minimize potential emissions of odorous air into the atmosphere and shall additionally take into account the maximum air additional into the unit for process purposes. Provision for access and process viewing shall be considered in the cover arrangement. The Contractor shall be aware of the potential for foaming in centrate liquors and shall design an odor extraction system accordingly. All odor control system fans and casing and plant exposed to untreated air shall be constructed from suitably corrosive-resistant materials for the contaminants likely to be present in the system. Proposed materials of construction shall be submitted to the Engineer for approval. Standby fans shall be provided to enable continuity of odor treatment in the event of the duty fan(s) failing. 12.37.8 Maintenance The manufacturer shall be required to certify that parts and service can be provided from a local base for the centrifuges in a timely manner as defined herein. The manufacturer shall be required to have a Philippine based service organization with a high level of stocked parts. The Manufacturer is required to have stocked locally and be able to deliver to site within 7 days the following: Gear reducers Backdrive components Lubrication system components and Control and Instrumentation components
All wearing parts shall be replaceable.

All components that require regular inspection and/or maintenance shall be safely accessible and replaceable and there shall be no obstruction to the removal of any components. Equipment shall be designed to avoid the need for the use of special tools for maintenance. Any required special tools shall be provided. The manufacturer shall supply all grease, oil and lubricants required for the start up and Guarantee period for the Contract.
12.37.9 Standards for Equipment Design The design and construction of the equipment shall comply with all statutory regulations and design standards associated with the type of plant offered and this Specification. 12.37.10 Weights and Lifting Arrangements
The weight of all major components and the heaviest component required for a maintenance lift shall be provided. Components weighing over 25kg that require removal for maintenance shall be provided with clearly labeled lifting points located to provide a balanced lift. 12.38 POLYMER PREPARATION AND DOSING SYSTEM
12.38.1 General The system shall be capable of dosing polyelectrolyte for the complete range of flows and sludge thicknesses produced by the treatment plant.
12.38.2 Granule Hopper The storage hopper shall be fabricated of grade 316 stainless steel and shall have a 250kg minimum capacity. The hopper shall be mounted on the polyelectrolyte feeder and shall be provided with supports. The hopper shall be provided with a low level alarm. The hopper shall be enclosed by a grade 316 stainless steel cabinet with a 40 Watt tubular heater fitted inside to prevent condensation and maintain polyelectrolyte in a dry condition. The transfer of granules into the hopper shall use a vacuum system designed to operate with either 25 kg bags or 1 tonne bulk bags.
12.38.3 Dry Granule Transfer The equipment for the transfer of dry polymer from the hopper to the wetting device shall include the following:
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A granule feeder with single screw discharge. The granule feeder outlet shall be fitted with a heater to prevent condensation. A stainless steel grade 316 funnel shall be provided to direct the granules from the screw discharge into the venturi. The funnel shall be fitted with a sieve. A centrifugal air blower to provide a high velocity air stream. The motor shall be totally enclosed with a degree of enclosure protection IP 55. An air dehumidifier. A venturi granule injector to feed the granules into the air stream. An anti-static connecting hose.
12.38.4 Wetting and Dispersing Device
Wetting and dispersing devices shall ensure that every granule of polyelectrolyte delivered by the air stream is wetted and dispersed into the make-up tank. The spray heads shall be of grade 316 stainless steel and shall be fitted with a water pressure gauge and a control pressure switch. Potable water shall be used. 12.38.5 Flocculent Make-Up Tank Make-up tanks shall be fabricated from glass reinforced plastic or steel reinforced glass fiber and shall include the following: Slow speed propeller or turbine mixer; Level electrodes to control solenoid valves, air blower, mixer, screw feeder and duty and standby transfer pump; Mounting for wetting and dispersing device; Final effluent inlet, outlet, drain and overflow connections; Removable covers; Sight glass.
12.38.6 Flocculent Storage Tank
Storage tanks shall be fabricated from glass reinforced plastic or steel reinforced glass fiber and shall include the following: Level electrodes to control transfer and dosing pumps, and to provide low level alarm; Flanged inlet, outlet and drain connections; Access openings; Tank contents gauge.
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12.38.7 Transfer Pump Transfer pumps shall be positive displacement helical rotor type. Rotor speed shall not exceed 500 rpm. Pumps shall be arranged as duty and standby units.
12.38.8 Metering Pump Metering pumps shall include the following equipment: An inlet metering and calibration cone for setting the unit output; A positive displacement helical rotor or piston metering pump with internal wetted parts suitable for contact with polyelectrolyte solution. The rotor speed of helical rotor pumps shall not exceed 500 rpm. Helical rotor pumps shall be fitted with a hydraulic speed variator between motor and pump; A pressure relief valve on the discharge side of the pump; A pressure gauge on the discharge side of the pump; Connections for in-line dilution water;
An in-line filter if final effluent is adopted for dilution; An in-line static mixer to mix polyelectrolyte solution with dilution water; A variable area rotameter; Control valves.
Pipework
Pipework for process and dilution water supply shall be uPVC.
12.38.9 Control Equipment Control of polyelectrolyte preparation and dosing shall be carried out both automatically and manually from a control centre mounted on or adjacent to the polyelectrolyte mixing unit. 12.39 SODIUM HYPO-CHLORITE SYSTEM Chlorine in the form of sodium hypochlorite shall be dosed to the treated sewage effluent. The basic design premise for the disinfection shall be as follows: Description Disinfection design range (as Cl) Expected dose (as Cl)
unit mg/l mg/l

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value 0.2 to 2 1
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The dose shall be optimized based on the residual free chlorine level indicated by online chlorine analyzers. Dosing shall be into a high energy mixing zone.. 12.39.1 Sodium Hypochlorite System 2 No. hypochlorite storage tanks, each having a capacity of 10 days supply at maximum dose rate and made from GRP shall be provided. Solution strength shall be about 12 %. The tank shall be shielded from direct sunlight. Each tank shall be replenished by tanker deliveries, connected using a cam-lock coupling for the tanker hose connection from the adjacent tanker parking bay and turning area. Each storage tank shall be provided with level sensors, linked to the SCADA system. The storage tanks shall have inlet/outlet ports, overflow, drainage, manhole, pipework for filling of tanks, and an air vent covered with insect screen prevent the entry of any rainwater. The tank shall be installed in bund of not less than 110% of the tank volume. Positive displacement dosing pumps to dose sodium hypochlorite solution into the final effluent stream shall be provided. The pumps shall be mounted on prepared concrete plinths. The pumps shall have a stainless steel casing and heads suitable for the chemical to be dosed. The gaskets used shall be made from EPDM. The dosing system shall be linked to the SCADA system to show the on/off situation of each dosing pump. All pipework shall be resistant to hypochlorite solution.
Chlorine Residual Analyzers Free residual chlorine values shall be continuously monitored by duty and standby analyzers with a minimum accuracy of plus or minus 4% of span. The operating range of the analyzer shall correspond to the maximum chlorine residual with a capability to withstand chlorine concentrations up to 10 times its maximum range and a recovery time of less than 5 minutes following out of range excursions. The chlorine residual indicator/transmitter shall incorporate local indication with high and low level alarm initiation adjustable either side of the set point anywhere within the range of the instrument. Panel mounted adjustable electronic timers shall inhibit short term variations not constituting a true alarm. The transmitter shall provide a fully isolated signal for remote control and indication. The sample water inlet to the measuring cell shall incorporate isolating and pressure reducing valves, a flow controller, and flow rate indicator to ensure the sample water enters the cell at the correct flow rate and pressure. In addition, the sample water inlet arrangement shall incorporate a strainer to prevent foreign particles entering the measuring cell. Where necessary, pH buffer facilities in accordance with the manufacturer's instructions shall be provided. A chlorine residual chart recorder shall be provided for final treated water at the pumping main leaving the site. This shall have the same residual range and reading as the analyzer indicator.
12.40 STANDBY GENERATOR 12.40.1 General

The engine and generator shall be primary rated for the full site load at the maximum ambient temperature. The generator set together with its auxiliary systems shall be installed within the standby generator building. The set shall be designed, manufactured, tested and certified to be compliant with the relevant BS, ISO and IEC standards. 12.40.2 General Arrangement The engine, radiator and generator shall be mounted on a common baseframe, via antivibration mountings. 12.40.3 Noise Level The noise level as measured 2 meters in any direction from the exterior of the standby generator building at 1 meter above ground level shall not exceed 80 dBA when the engine is running at full load. The Contractor shall carry out a test on Site to demonstrate compliance with this requirement. 12.40.4 Generator Controls The controls for the generator set shall be fitted in a set mounted control panel. The panel shall be mounted on the set via anti-vibration mountings. The panel shall provide the following controls and instrumentation: The set shall have three modes of control. a) Automatic in automatic mode the generator shall start automatically when a mains failure is detected on the live side of the Motor Control Centre mains incoming circuit breaker. If the mains failure lasts for more than 5 seconds the Motor Control Centre mains supply breaker shall trip and a start signal shall be sent to the standby generator system. The generator shall start and when the output volts have stabilized the Motor Control Centre panel incoming standby generator supply breaker shall close. The generator shall continue to supply the Motor Control Centre loads until the mains supply is restored and remains stable for more than 30 seconds. After this time the Motor Control Centre incoming standby generator supply breaker shall open and the incoming mains supply breaker shall close. The generator shall continue to run for 10 minutes on no load before shutting down automatically. b) Test when test mode is manually selected a mains failure is automatically simulated and the generator runs on load for an hour before automatically changing back to standby mode.
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c) Manual in manual mode the generator is started and stopped manually, there is no automatic changeover or switching of circuit breakers. The following controls shall be provided: Key operated four position, AUTO OFF - MANUAL TEST engine control switch. The set protection shut downs shall operate in all modes of operation. Key-operated START STOP switch, this shall be operable only when the control selector switch is in the MANUAL position. Fault reset pushbutton. Emergency STOP pushbutton mushroom head, twist-to-release type. Engine lubricating oil pressure gauge and low pressure warning light. Alternatively the oil pressure gauge may be mounted on the engine. Water temperature gauge. Engine hours run indicator. Battery charging ammeter. Battery voltmeter, selected by pushbutton. Engine speed trimming control and tachometer. Triple pole circuit breaker, with thermal and magnetic overload protection set up as appropriate to the rating of the set, and fitted with a 300-mA residual ground leakage current trip unit and tripping circuit. Ammeter and selector switch permitting display of the three phase currents. Voltmeter and selector switch permitting display of line to line & line to neutral voltages from alternator. Digital output voltage frequency meter. Output voltage trimmer. Control and instrument circuit breakers as appropriate. Shutdown facilities and alarm lamps as specified.
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Instruments and controls shall be identified by means of appropriate labels. In addition to markings on the ammeter scales, a label shall be fixed to the panel adjacent to the ammeters stating the full load current. 12.40.5 Alternator The alternator shall be the brushless, self-exciting type with salient rotating poles, damping windings and single end shield bearings. Radio interference suppression to BS EN 550141:2001or equivalent shall be provided. Protection shall be built in to the alternator to prevent damage in the event of sustained low speed operation due to an engine control fault. The winding insulation shall be a minimum of Class F. The output voltage shall be maintained to +or - 2.5% from no load to full load. The alternator and engine shall be suitable for continuous operation at a power factor between unity and 0.8 lagging at full load. The alternator shall be dust and moisture protected to IP23, or above. The alternator shall be fitted with an anti-condensation heater, which shall be provided with a manual operation switch. The alternator shall be capable of running at 110% full load for 1 hour every 6 hours in the maximum ambient temperature. It shall be supplied with thermistors in each phase winding, which shall give early warning of the temperature rising above the normal full load operating temperature. The full load temperature rise of the windings shall be limited to a maximum of 80 The C. thermistor relay shall trip the alternator output circuit breaker. The set shall then be shut down after the preset cooling period has elapsed. The output from the alternator shall be connected to outgoing terminals via a suitably rated manually operated molded case circuit breaker. The outgoing terminals shall be located within a separate enclosure. This enclosure shall be fitted with a suitably sized removable gland plate arranged for bottom entry cabling. A separate enclosure with its own gland plate shall be provided for control cables. 12.40.6 Diesel Engine The engine shall be of the diesel fuel powered internal combustion type, continuously rated, with the engine flexibly coupled to the alternator. The engine shall be governed within the following limits during running: -SO 3046 equivalent The engine speed shall not exceed 1800 rpm. Automatic shutdown facilities shall be provided to operate in the event of low lubricating oil pressure, high cooling water temperatures or high engine speed. In addition a fusible link emergency fire shut down system shall be provided within the generator enclosure, complete with wires, pulleys and fusible link. An emergency stop button shall also be provided on the exterior of the enclosure.
The engine shall be provided with fuel and lubricating oil filters, air cleaner and exhaust silencer. The set shall be supplied with the correct quantity and grade of lubricating oil. 12.40.7 Fuel tanks 12.40.7.1 General The fuel tank shall be constructed in accordance with BS 799 Part 5 with seams fillet welded both internally and externally. Welding personnel shall be qualified to the required British Standard. Prior to dispatch from works the tank shall be cleaned internally and externally. 12.40.7.2 Daily Service Tank A day tank with a storage capacity for 8 hours of operation at full load shall be provided. The pipework between the day tank and the diesel engine shall be copper. When deriving the usable fuel capacity of the tank, allowance shall be made for usage and for collection of debris in the bottom of the tank. The tank shall be provided with the following fittings and connection points: Filling point pipe Drain Cock Access point for dip tape.
100mm diameter level gauge graduated empty, full, full, full and full, adjacent to the filling point. A fuel oil tank low level switch shall be provided to give a low level alarm on the engine control panel. Once this low level is indicated the provisions shall be made to trip the engine. Hand operated pumps shall be provided to transfer the fuel from the bulk storage tank to the day tank. 12.40.7.3 Bulk Storage Tank A bulk storage tank shall be designed for a storage capacity for five days running at full load or 10,000 liters (whichever is the greater), or as otherwise stated in the particular specifications. The tanks shall be complete with the inlet pipe work, outlet pipe work, drain valves, vent pipes, lifting eyes, support feet, earthing boss and local level indicator with local audible high level alarm and alarm accept button. The level indication shall be transmitted to the instrument panel and shall be available for the connection to telemetry outside. The tank shall be bunded.
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The pipework from the bulk storage tank and the day tank shall be carbon steel as per BS EN 10217 or equivalent with a minimum wall thickness of 2.9mm.The joints in the pipework shall be minimum and flanged to PN 10 specification. Each tank shall be located within a tank bund with capacity equivalent to 100% of the storage tank capacity. 12.40.8 Engine Protection The engine shall be provided with suitable engine protection systems which will shut the engine down automatically in the event of a fault or abnormal operating conditions. The engine shall be fitted with an over speed trip which shall cut off the fuel supply when the engine speed rises above 120% of the normal running speed. In the event of a shutdown occurring due to a fault condition arising, the relevant fault lamp shall remain illuminated and restarting shall be inhibited until some reset action has been taken. 12.40.9 Starting An electric starting system utilizing heavy-duty lead acid batteries shall be supplied. An engine driven alternator and control unit shall be fitted for automatically recharging the starting batteries when the set is running. A minimum of three sequential attempts to start from cold over a six minute period and a maximum of 6 starts per day shall be possible without the assistance of a supply of mains electricity. The starting system shall be fully recharged within 12 hours of continuous engine operation following the most arduous of the above starting sequences. If the engine fails to start after three sequential attempts the start sequence shall be locked out and a Failed to Start alarm condition indicated. 12.40.10 Exhaust and Silencer System
The engine shall be fitted with an exhaust and silencer system. The exhaust shall terminate outside of the building above roof level. Within the building the exhaust shall be suitably lagged and finished with polished stainless steel cladding. Exhaust pipes shall be supported on rollers or pipe hangers. The exhaust pipework shall be connected to the engine via a bellows type expansion joint on the manifold flange. The exhaust pipework shall be fabricated from a minimum of 3/16 thick 316 grade stainless steel. Insulation shall be fitted to those parts of the exhaust system within the generator enclosure or elsewhere, that are likely to come into contact with operatives. 12.40.11 Cooling System
The engine cooling system shall consist of a forced air cooled radiator utilizing an engine driven cooling fan. The exhaust air shall be discharged directly to the outside of the
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building via ductwork. The incoming air will be taken from outside of the building and first pass over the alternator before passing over the engine and radiator. The Contractor shall be responsible for the design and provision of adequate cooling facilities for the alternator, engine and radiator, taking into account the high ambient temperatures of the location. This shall include the provision of a noise attenuated intake and exhaust baffles and corrosion resistant ducting required within or external to the enclosure. The Contractor shall submit calculations to demonstrate that adequate cooling of the generating set shall be achieved under all conditions up to the maximum ambient temperature. The Contractor shall ensure that hot air produced by the engine running continuously at full load shall be satisfactorily dissipated with no risk of short circuit to the cooling air inlet. PART 3 12.41 EXECUTION HEALTH AND SAFETY The Contractor shall observe all Health and Safety Regulations of the Philippines throughout the course of his works. The Contractor shall ensure that prior to the commencement of site installation a method statement of installation of all plant noting specific health and safety issues shall be submitted in writing to MWC. Work may not start on site until approval of the same is attained in writing. 12.42 TESTING OF PLANT BEFORE DELIVER All equipment supplied under this Contract shall be tested for quality of workmanship at the manufacturers premises. On delivery to site, MWC shall inspect all said plant and any equipment not complying with the specification shall be immediately rejected. The replacement costs of the same shall be the responsibility of the Contractor. Pump-sets shall be tested to ISO 2548, class C. The Contractor/Manufacturer shall conduct tests and furnish three (3) original certified copies of reports describing the procedures and results of tests in accordance to AWWA C504 and ISO 10631-1994 prior to delivery to the site.
12.43
INSTALLATION The Contractor shall install all the plant detailed herein and shall install the equipment as indicated in the manufacturers drawings. All written instructions from the equipment supplier shall also be observed. Distance between wall and equipment shall not be less than 1000mm. The fixing of all frames and brackets shall be with stainless steel expanding bolts and washers, unless otherwise noted. The Contractor shall be required to fabricate any piping and supports required to install the pumps, motors, and associated plant.
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The Contractor shall also be responsible for all electrical works in accordance with SES 14. The Contractor shall be responsible for providing all power requirements and special tools required to undertake the installation of the plant detailed herein.
12.43.1 Signage The Contractor shall be responsible for the provision of the following signs on the equipment to be used on the system: All items of equipment shall be identified by permanent labels giving the item designation. All labels shall be in English, engraved black lettering on white background. All necessary warning labels to be engraved on approved material with white letter on a red background. Provide signage arrow for the piping system. Example: Chlorine Tank Engraved CHLORINE TANK & CT 1 12.44 Plant Operation and Maintenance Manuals The Contractor shall furnish to MWC, at least fifty (50) days prior to the commencement of commissioning and testing of the equipment, five (5) sets of technical manuals for all equipment supplied or installed. Each set shall consist of one or more volumes, each of which shall be bound in a standard size, lever arch file hard cover binder suitable for bookshelf storage. Binder ring shall not exceed 75 mm. The manuals supplied shall cover the complete works and must be relevant to the actual equipment installed. The operation instruction manual shall be comprehensive and sufficiently detailed to ensure that the equipment can be competently and efficiently operated by MWC staff after commissioning and testing of the equipment have been completed. The maintenance manual shall be in sufficient detail to enable the overhaul and maintenance of all equipment to be effectively carried out by MWC maintenance staff. All manuals shall be supplied with detailed indices which will enable any specific item to be quickly and accurately located. The operating instruction manual shall be prepared separately from the maintenance instruction manual and compiled such that reference to the maintenance instruction manual is not necessary for the implementation of the operating instruction manual. Where manufacturers standard manuals are supplied for any equipment, they shall be those applicable to the equipment installed and the relevant sections shall be clearly marked. Trouble shooting manuals of the manufacturers equipment should also be furnished for future maintenance purposes. The manuals shall include the following: (1) (2) (3) (4) A concise description of the equipment and the proposed method of control and operation. A detailed description of each piece of equipment complete with performance specification and mode of operation. Procedure to be followed for equipment start-up, operation and shut down. Procedures to be followed for installation, testing, maintenance and repair.
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(5) (6) (7) (8)
(9) (10) (11) (12) (13) (14)
Fault-finding procedures for all equipment in the form of charts listing fault, possible causes, and remedy. Instructions of dismantling, repair, re-assembly and adjustment of all equipment. Lubrication chart for all installed equipment, including lubrication schedules, lubricant SAE grade and type, including frequency of required lubrication. Complete list of equipment installed showing the manufacturers name, manufacturers nearest representatives address, telephone and telex or fax numbers. A comprehensive index of manuals supplied by equipment manufacturers, indicating the equipment type, number and manufacturers name. A comprehensive routine maintenance schedule for all the equipment installed. Complete details of earthing system installed. Sufficient information to enable parts for any piece of equipment to be ordered from the manufacturer. Other manuals mentioned in each Section. Drawings comprising of: a. General Arrangement b. Sectional Arrangement c. Parts List d. Performance Curves
All manuals submitted to MWC, which do not meet the requirement of this Section, will be returned to the Contractor for improvement and resubmission within fourteen (14) days. 12.45 Tools A full set of any special tools required for the operation, maintenance, or repair work on mechanical equipment shall be supplied.
12.46 Spares A comprehensive set of spares is to be provided to maintain the mechanical equipment for a period of not less than 12 months in operation. 12.47 Guarantees The Contractor shall guarantee that the mechanical systems are free from all ground and from all defective workmanship and materials and will remain so for a period of one (1) year from date of acceptance of the work. Any defects appearing within the aforesaid period shall be remedied by him at his own expense.
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SECTION 13 ELECTRICAL SPECIFICATION PART 1 GENERAL SPECIFICATIONS
13.1
SPECIFIC CONDITIONS The performance of the equipment and materials installed shall be as specified and the quality of the installation is in accordance with the specification and good trade practice. The works shall be carried out in accordance with the requirements of all authorities having jurisdiction over the works and/or approval required therefrom. Such notice shall be provided and the application shall be prepared accompanied by such plans and information as may be called for and /or obtain such approvals. Reference Codes and Standards listed in the prefaces to those Standards and Codes are applicable in respect of all materials and workmanship except where in conflict with the provisions of this specification. Where this specification expressly requires standards higher than or different from those applicable under the relevant standard or documents, this specification will take precedence. Where special conditions exist which would make compliance with these specification unusually difficult, then details should be submitted in writing to the Engineer, who may grant an exemption, Any such exemption granted shall be obtained in writing from the Engineer by the party seeking the exemption. Any items of equipment offered and not listed under Preferred Equipment must be approved by the Engineer. Any such exemption granted shall be obtained in writing from the Engineer by the party supplying the equipment. All wiring and tests shall be carried out in strict accordance with the current edition of PEC Part 1 and 2 including amendments and rulings. If there is any conflict between Philippines Electrical Code Part 1 and 2 and other standards, the most stringent rule shall apply. All permit and electrical fees required for this work shall be obtained by and at the expense of the Contractor. The Contractor shall furnish and transmit to MWC, copies of Certificates of Inspection and Approval after completion of the work. The Contractor shall prepare all as-built plans and all other paper works required by the approving authorities. The contractor during the design of the plant shall carry out a risk assessment to determine the classification of any hazardous areas within the plant in accordance with BS EN 6007910. The classification shall be reviewed by the Engineer and the design and specification
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of all electrical equipment installed in the plant shall be in accordance with any hazardous area classifications determined by the risk assessment. 13.1.1 Codes and References
This specification shall be read in conjunction with the following documentation: a) Contract Documents and Standard References PEC IPCEA NEC NEMA IEEE std 141-1976 IEEE Pub. No. 142 IEEE IEC NFPA UL : Philippine Electrical Code : Insulated Power Cable Engineering Association : National Electrical Code : National Electrical Manufacturers Association : Protection and Coordination : Grounding of Industrial Power System : Institute of Electrical and Electronic Engineers : Institute of Electromechanical Commission : National Fire Protection Association : Underwriters Laboratories, Inc.
All electrical equipment shall be listed by and shall bear the label of Underwriters' Laboratories, Inc. (UL) or an independent testing laboratory acceptable to the local code enforcement agency having jurisdiction. The installation of electrical equipment and materials shall comply with the local and national safety and health regulations as applicable, including the specific requirements of the Building Code and Standards. Where the requirements of the Specifications conflict with UL, NEMA, NFPA, or other applicable standards, the more stringent requirements shall govern. 13.1.2 Definitions ACB MCCB PFC MCC MCB FLC O/L RSC uPVC ELCB : Air Circuit Breaker : Molded Case Circuit Breaker : Power Factor Capacitor : Motor Control Center : Miniature Circuit Breaker : Full Load Current : Overload : Rigid Steel Conduit : Unplasticized Polyvinyl Chloride : Earth leakage circuit breaker
13.1.3 Technical Specification The following supply conditions apply: Voltage Frequency
2.3 kV, 460V, 220V 60 Hz

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Phases Neutral Control Voltage
3, 4 Wire Earth Neutral Link at the star point of transformer 110 VAC
No other control voltage shall be used unless approved in writing by the Engineer.
13.1.4 Climatic Conditions Temperature Humidity 13.1.5 Degree of Protection General Electrical works shall comply with the requirements of the respective section to which it is included. Other electrical works not included above shall comply with the requirements summarized in Table 3. Highest Maximum 45 degrees C Average annual range 72-95% RH non-condensing
Table 3: Enclosure Classifications Area/ Location Enclosure Classification Basement Level (Indoor) Ground Level (Indoor) Outdoor Areas NEMA 6 or 4X as required NEMA 12 or 4X as required NEMA 3R or 4X as required
Refer to NEMA standard for other Enclosure classification for electrical works not included in Table 2. Material Requirements Where applicable, in chlorine and hydrofluosilicic (HFS) acid areas, sealing fittings shall be provided. NEMA 4X enclosures shall be 304 stainless steel except in chlorine and HFS areas where non-metallic enclosures shall be provided. NEMA 7 enclosures shall be cast aluminum where used with aluminum conduit; cast iron when used with galvanized steel conduit. NEMA 1, 2, 3R, and 12 enclosures shall be 2mm mild steel, Zinc Chromate primed and passivated, undercoated, two topcoats of high gloss enamel paint wrinkle beige exterior and interior. NEMA 4X, 7 and 9 shall not be coated.
13.1.6 Protection from water All outdoor equipment shall be fitted with a cover to provide effective protection against rain.
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All enclosures housing electrical equipment must be capable of preventing water penetrating to live parts. Design must take into account the likelihood of deliberate hosing in some locations. Enclosures having doors or removable panels exceeding 0.4 m2 in area should, where possible, be located indoors. No electrical component is to be located where it will be permanently wet without authority from the Engineer. Thermostatically controlled low surface temperature heaters shall be provided where necessary to prevent condensation of water. 13.1.7 Corrosion Protection Conduits, ducting, cable ladders, unistrut, brackets, etc shall be hot-dipped galvanized. Where exposed to sewer or other environment that may cause corrosion, suitable noncorrodible materials shall be utilized to prevent corrosion. All fixings such as screws, rivets, nuts, bolts, and washers shall be stainless steel 304. Cubicles and enclosures must be manufactured out of mild steel. Carbon steel or glass filled polyester construction is permissible where indicated by the Engineer. 13.1.8 Spare Parts and Special Tools Where a machine is fitted with components of a specialized nature, such as electronic components, etc. for which spares are not already held at or are not held elsewhere Manila (ex stock), or which cannot be replaced by other components dimensionally and functionally identical, which are held or available in Manila (ex stock), then such spares shall be provided as part of the original equipment. A full set of any special tools required for the operation, maintenance, or repair work on electrical or instrumentation equipment shall be supplied.
13.2 COLOR AND IDENTIFICATION 13.2.1 Color coding The colors shall be: Logical states of devises monitored and controlled by the control system shall be differentiated with colors as follows: Red danger, stop, emergency stop. Measures required in emergency situations Yellow caution, take action to avoid danger, avoid changes.
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Green Black, white, gray
safe start, on.
neutral, can be used for all purposes except those covered by red, e.g. reset, inching.
Blue
special, must not be used for purposes covered by red, yellow, or green, e.g. Thermal O/L light.
Wires color
460 V , 3 phase 220 V , single phase Earth Neutral 24 VDC - Green - Black
- Red, White, Blue - Phasor color, when switched red
+ VE Brown (Yellow) - VE Violet (Black)
Multicore cables and their cores do not have to be colored as above but must be uniquely identified at both ends. Label Colors
Labels shall be engraved black lettering on a white background. Warning labels shall be white lettering on a red background. 13.2.2 Wiring and Terminal Identification All single cores including individual cores of multicore cable to be identified at each end with approved markers. The only exception to this requirements are short lengths not exceeding 100 mm which are used to connect between CBs and contactors, or loops from one terminal on terminal strips or contact blocks provide these short lengths are not loomed up or otherwise covered, one end only be numbered. Cable cores shall be identified at the rail terminals only. All terminals should be clearly marked on outgoing side of terminal and common type circuits shall be grouped logically i.e. power, control etc. MCC/Panel wiring
At every termination the wire shall have a crimped connection. No soldered or bare wires shall be used as terminations. The joining of any wire in the duct is expressly prohibited. All external connections (with the exception of the supply and local submains) shall be via terminals mounted on the mounting plate. All terminals shall be grouped in a logical order. Panel and Cubicle Wiring Wiring within the panels and cubicles shall be installed in an approved PVC wiring duct and any conductors not installed in these ducts shall be laced with PVC ties or strips in an approved manner. The total cross sectional area of wiring within ducts shall not be greater than 40% of the total cross sectional area of duct. All wiring shall be stranded with minimum size of: 1.0 mm for Electronics/Instrumentation signals 2 1.5 mm for control circuits 2 2.5 mm for Power and CT circuits
2
All ducts shall be terminated with suitable crimp lugs. No soldered or bare wires shall be used as terminations. All wiring shall be rigidly supported and where against metal, protective insulation shall be provided. Wiring between hinged panels and fixed portions shall be secured by insulating shelves at each side of the hinge and shall hinge freely without undo flexing of the cables and in such a manner that the bunched cables or equipment on the hinged panel cannot foul other parts. 13.2.3 Cables Identification All circuits are to be uniquely identified by an alphanumerical cable numbers as listed in the cable list, and cable cores shall be identified at the rail terminals only. All sheathed cables shall be uniquely identified at each end by means of engraved or embossed labels firmly attached to the cable. For bottom entry this label should be attached just after it enters the enclosure in which it is terminated. For top entry this label should be attached just before it enters the enclosures. All power, control and instrumentation cabling shall be identified at all terminations by use of a durable type tag and approved by Engineer. 13.2.4 Item Identification and Equipment Labeling All electrical components shall have all terminals clearly and permanently marked. All items of equipment shall be identified by permanent labels giving the item designation.
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All labels shall be in English, engraved black lettering on white background. All necessary warning labels to be engraved on approved material with white letters on a red background. Characters shall be minimum height of 15mm for equipment label and 6mm for electrical component, uppercase print type font, mechanically engraved. Labels mounted inside electrical enclosures and switchboards may be mounted using approved double-sided adhesive tape, and shall not be attached to removable ducting tops. Labels mounted outside electrical enclosures to be fixed with at least two screws, rivets or drive parts on the permanent structure to which the component is mounted, adjacent to the component and readily visible from in-front of the component. Where ready access is not available in front of a component then additional labeling that is visible from a readily accessible position will be required, e.g. Solenoids, limit switches etc. positioned behind panels, under machinery etc. are to be identified also by labels mounted on external surfaces of the machine. Instrumentation equipment may be identified by using cable the alphanumeric identification tag approved by the Engineer. 13.3 INSTALLATION 13.3.1 General All field wiring to motors, control stations, sensors and actuators shall be wired using cables. Single wires in conduit will not be accepted. Connections of series contacts such as emergency and motor stops, safety switches etc., are not to be looped in the field. All wiring is to be brought back to a common terminal rail. Indication of the devise being operated is to be provided both locally to the devise and at the approved area control station.
13.3.2 Electrical Raceway System General Conduit shall be one size larger than is required by Regulation for the number of cables to be drawn in and not less than 20 mm. It shall be of the high impact, rigid, PVC pattern, resistant to ultra violet light. Where steel conduits are used, they shall not be utilized as the earth continuity conductor to plant and equipment. All steel conduits shall be bonded to earth. All conduit runs whether above ground or below shall utilize inspection boxes/drawpits at every change in direction or/and every 50 meters, to enable the cables to be routed through the conduits.
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Where space allows, every conduit run shall include for a nylon draw rope to aid the pulling in of additional cables at a later date. Installation Raceways shall be installed between equipment as indicated. Raceway systems shall be electrically and mechanically complete before conductors are installed. Bends and offsets shall be smooth and symmetrical, and shall be accomplished with tools designed for this purpose. Factory elbows shall be utilized wherever possible. Where raceway routings are indicated on plan views, the Contractor shall follow those routings to the extent possible. Where raceways are indicated but routing is not shown, such as home runs or on conduit developments and schedules, raceway routings shall be the Contractors choice and in strict accordance with the PEC Chapter 3 - Wiring Methods and Materials, customary installation practice. Raceway shall be encased, exposed, concealed, or under floor as indicated. Routings shall be adjusted to avoid obstructions. The Contractor shall coordinate with all other trades prior to installation of raceways. Lack of such coordination shall not be justification for extra compensation, and removal and re-installation to resolve conflicts shall be at no extra cost to Manila Water. Support rod attachment for ceiling-hung trapeze and cable tray installations shall meet the seismic requirements relevant to the site of works. Exposed raceways shall be installed parallel or perpendicular to structural beams. Install expansion fittings with bonding jumpers wherever raceways cross building expansion joints. All exposed raceways shall be installed at least 15 mm from walls or ceilings except that at locations above finished grade where damp conditions do not prevail, exposed raceways shall be installed 7.5 mm minimum from the face of walls or ceilings by the use of clamp backs or struts. Wherever contact with concrete or dissimilar metals can produce galvanic corrosion of equipment, suitable insulating means shall be provided to prevent such corrosion. Conduits All exposed conduits shall be rigid steel, unless otherwise indicated. All conduits concealed, buried, or encased in concrete shall be Schedule 40 PVC . Where conduit emerges from concrete encasement, PVC coated RSC elbow shall be utilized for transition from the concrete. Conduit shall emerge from the concrete perpendicular to the surface whenever possible. Exposed conduit shall be 20 mm minimum trade size. Encased conduit shall be 25 mm diameter, minimum trade size. Supports shall be installed at distances conforming to the requirements of PEC Chapter 3 - Wiring Methods and Materials.
Conduit shall not be encased in the bottom floor slab below grade. Encased conduit shall have outer diameters not exceeding 8mm of the concrete slab thickness; and shall be routed between reinforcing bars. All threads shall be coated with a conductive lubricant before assembly. Joints shall be tight, thoroughly grounded, secure, and free of obstructions in the pipe. All conduits shall be adequately reamed to prevent damage to the wires and cables inside. Strap wrenches and vises shall be used to install conduits to prevent wrench marks. Conduits with wrench marks shall be replaced, at no additional cost to Manila Water. Wherever possible, conduit runs shall slope to drain at one or both ends of run. Wherever conduit enters substructures below grade, the conduit shall be sloped to drain water away from the structure. Extreme care shall be taken to avoid pockets or depressions in conduit. Connections to lay-in type grid lighting fixtures shall be made using flexible metal conduit not exceeding 1.2 meters in length. Connections to motors and other equipment subject to vibration shall be made with liquid-tight flexible conduit not exceeding 0.9 meters in length. Equipment subject to vibration, which is normally provided with wiring leads shall be provided with a cast junction box for the make-up of connections. Conduit passing through walls or floors shall have appropriate PVC sleeves. Core drilling shall be performed in accordance with the relevant Sections of the Specification. Fittings and Boxes All fittings and boxes shall have neoprene gaskets and non-magnetic stainless steel screws. All covers shall be attached by means of holes tapped into the body of the fitting. Covers for fittings attached by means of clips or clamps will not be acceptable. Boxes larger than standard cast or malleable types shall be 304 stainless steel, NEMA 4X or as indicated in 14.1.7. In outdoor areas, conduit shall be terminated in rain-tight hubs. In other than outdoor areas, sealed locknuts and bushings shall be used. Cable Support System Cable ladder racking, trays and ducting shall have a minimum of 20 percent spare capacity at the end of the contract. All fixings to concrete or masonry shall be of the expansion type set in holes. Explosive powder-charged fixings shall not be used. Fixings to structural steelwork shall be by clamping, not welding or drilling, except with the specific prior approval of the Engineer.
Cable support systems shall be installed in accordance with the manufacturer recommendations to give a maximum between support deflections of 10 mm when carrying the final number of cables to be installed. All steel supports, frames, hangers and the like shall be electroplated and in most areas hot dip galvanized. All exposed threads on support systems, conduit and other places where the galvanizing finish has been removed shall be painted with galvanized paint. (Dont use sprays cans type of paint.) All lengths of the cable support system shall be bonded to earth. The Contractor shall submit to the Principal a layout of his proposed method of reticulation throughout the Plant showing positions of all cable ladder, tray or ducting system. Cable Ladder Cable ladders shall be manufactured from non-corrodible material. They shall be completed with accessories including hangers, brackets and cable clips. The contractor shall supply and erect all cable ladders and all brackets and fabricated steelwork necessary to support the cable ladder and shall ensure that they are adequate in all respects for the loading imposed. All changes in direction shall be made using purpose made slow radius bends and cranks as manufactured for this purpose. Cable ladders installed outside the building shall be provided with cover. Cable Trays Cable trays shall be provided in strict accordance with the manufacturer's printed instructions. Allowable cable fill areas shall meet the requirements of PEC Article 3.18 Cable Trays. Prior to installation, cable tray fills shall be verified based on cables and trays actually provided. Continuous grounding of cable trays including bonding jumpers shall be maintained in accordance with PEC Article 2.50 - Grounding Requirements. Cable trays shall be installed using hangers and supports on 2.4 metre centres, maximum. Cable Segregation The following groups of cables shall be segregated from each other by continuous insulated barriers when installed in common tray/ladder systems, or by using separate raceways or conduits and marked with individual voltage.
34.5 kV Primary Feeders 460 V Feeders 230 V Feeders and Branch Circuits Control and Instrumentation Cables Signal and Communication Cables DC Circuits/Wirings (When Required)
The arrangement of cables on ladder trays or brackets shall be such that where cables join or leave the ladder or brackets there is not unnecessary crossing or tangling of cables. Where cables are liable to mechanical or environmental damage they shall be protected in a suitable manner. All instrumentation/data cables shall be segregated from power cables by a minimum of 300mm and from control cables by a minimum of 50mm. Segregation of cables in trenches, on cable trays, in conduit, in trunking, or in ducts shall be in accordance with PEC. Particular attention shall be taken to ensure the correct segregation of intrinsically safe circuits.
13.3.3 Underground Electrical Works General The Contractor shall provide all underground electrical works, complete and in place in accordance with Contract requirements. Works shall include the underground service conductors, HV pedestal, equipment pads/foundations, and its associated trench and conduits; which shall be continuous from the service entrance equipment to the outdoor power system connection. Submittals The Contractor shall submit, for Manila Waters approval, technical brochures and manuals, and shop drawings indicating information on the following components. Conduits Power, Control, Signal and Telephone Cables and Splices High/Medium Voltage Cables and Termination Kits Insulating Tape Cable Lubricants Sealing Materials for Manhole/Handhole Joints
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Installation
Poured in Place Manholes/Handholes Cable Trench Manufacturers Instructions Manufacturers directions for use of ground megger with proposed method. Termination kit Manufacturers installation instruction.
Installation of underground cables shall be performed in accordance with the requirements of the Philippine Electrical Code. Associated earthworks including excavation, backfilling, and pavement restoration shall be in accordance with relevant provisions described elsewhere in the Contract. Associated concreting works for electrical requirements shall be at least 21 MPa with 2.54 cm maximum aggregate. 13.3.4 Underground Duct with Concrete Encasement
Underground duct lines shall be constructed with concrete encasement. The concrete encasement shall be rectangular in cross section and shall provide at least 75 mm concrete cover for ducts. Conduits shall be separated at least 50 mm apart. The kind of conduits used in any one-duct bank shall not be mixed. The top of the concrete envelope shall not be less than 460 mm below grade except those under roads and pavement, which shall be not less than 610 mm. Duct lines shall have a continuous slope towards handholes with a pitch of 75 mm in 30 meters. Except at conduit risers, changes in direction of runs exceeding a total of 10 degrees, either vertical or horizontal, shall be accomplished by long sweep bends having a minimum radius of curvature of 7.62 meters. Sweep bends may be made up of one or more curved or straight sections or combinations thereof. Manufactured bends shall have the following minimum radii corresponding to the given conduit diameters, as shown in Table 4. Table 4: Minimum Radius Requirements Conduit Diameter Minimum Bend Radius < 75 mm 75 mm 457 mm 914 mm
Conduits shall be terminated in end-bells where duct lines enter handholes or cable trenches. Separators shall be of pre-cast concrete, high impact polystyrene, steel or any combination thereof.
The joints of conduits shall be staggered by rows and layers so as to provide maximum strength for the duct line. During construction, partially completed duct lines shall be protected from entry of debris by means of suitable plugs. As each section of a duct line is completed from handhole to handhole, a brush thorough having a diameter of the duct, shall be drawn until the conduit is clear of all particles of earth, sand and gravel; then immediately install conduit plugs. Where required, cast-in-place handholes/manholes shall be provided complete with all accessories, drain facilities and strength indicated. Concrete handholes/manholes shall have a smooth trowel finish for floors and horizontal surfaces. Walls shall be constructed on a footing of cast-in-place concrete. Walls and bottoms shall be of monolithic concrete construction. Duct entrances and windows shall be located near the corners of structures to facilitate cable racking. Covers shall fit the frames without undue play. Steel and iron shall be formed to shape and size with sharp lines and angles. Casting shall be free from warps and blowholes that may impair their strength and appearance. Exposed metal shall have a smooth finish and sharp lines. All necessary lugs and brackets shall be provided. Pulling irons and other built-in items shall be set in place before depositing the concrete. A pulling-in iron shall be installed in the wall opposite each duct entrance. Drainage pipes and fittings shall be cast iron, extra strength. Drain shall be cast-iron, coated or uncoated, plain pattern, bottom outlet with perforated or slotted hinged cover. Ground rods for handholes shall be installed in electrical distribution will be 20 mm diameter by 3000 mm long copper-clad steel, which shall be connected to the cable shielding, metallic sheath at each joint or splice by means of a 22 mm2 braided tinned copper wire. Ground rods shall be protected with a double wrapping of pressure sensitive plastic tape for a distance of 150 mm above and 150 mm below concrete penetrations. Ground wires shall be neatly and firmly attached to handhole/manhole walls and the amount of exposed bare wire shall be held to a minimum. Cable Installation Single core power cables to be clamped in Trefoil Arrangement. Cables shall be securely braced with cable clamps or ties as required. Vertical rises of cables shall be secured at intervals no less than 1 meter, to allow for cable expansion. Where cables pass through fire rated walls or floors a fire barrier or fire rated sealing compound shall be used to seal the space after installation of the cables.
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Cable route markers shall be installed at all changes of direction and at road crossings, and shall have their positions marked and identified by co-ordinates on the 'as installed' cable route drawings. Each marker shall be a block of concrete approximately 300 mm square by 150 mm, permanently marked 'ELECTRIC CABLES', with arrows showing the directions of the cable route. Cables laid under or through roadways, footpaths, structures or buildings shall be installed in ducts. 50% spare duct capacity shall be provided subject to a minimum of one spare duct, and a maximum of 5 spare ducts at each duct installation. Cables shall not be cast directly into concrete. Cable Design Cables are to be sized to take account of volt drop, grouping, protection and environmental conditions in accordance with PEC. The applicable de-rating factors for ambient temperature and method of installation shall be applied when selecting cable sizes. Cable routes and cable lengths shall be determined by the Contractor subject to the Engineers approval. Cable sizing calculations shall be submitted to the Engineer for approval. Cables shall be selected such that the voltage drop does not exceed the maximum value defined in PEC. Wherever the installation is specified as being flameproof, conduit runs entering these areas shall have a barrier box inserted in the run immediately before the conduit passes into the flameproof area. All conduit work inside the flameproof area shall be carried out with solid drawn galvanized conduit and all conduit fittings, sockets and accessories shall be galvanized and certified suitable for the hazard as specified. At the completion of wiring all machined faces of the accessories shall be thoroughly cleaned and greased prior to the screwing or bolting of all accessory cover plates into their final flameproof secured position. Cable Protection Cables shall be fully protected from mechanical damage. The protection shall not allow liquids to enter or accumulate within the protection. All cables are to be protected where they pass through any openings, gaps, holes, or over edges of metalwork, ladders etc. The contractor shall ensure that surrounding surfaces are smooth and free of sharp edges etc., and that holes are bushed with close fitting plastic bushes. Cable Entrances
All cable entrances to equipment and buildings shall be firmly sealed to prevent ingress of weather and water. Cable Glands Where cables terminate in cubicles or auxiliary equipment boxes, the cables shall be fitted with suitable cable glands. These cable glands shall grip the cable securely, seal on the outer sheath of cable and be complete with locknuts. They shall for armoured cable include provision for securely bonding the earth.
Cable Pulling Ducts shall be thoroughly cleaned out to remove foreign material before the cable pulling. Cables shall be pulled downgrade with the feed-in point at the handhole/manhole of the highest elevation. Flexible cable feeds shall be used to convey cables through the handhole/manhole opening where space permits by training the cable around the interior to form one complete loop. Minimum allowable bending radii shall be maintained in forming such loops. Cable pulling tensions shall not exceed the maximum pulling tension recommended by the cable manufacturer. Lubricants for assisting in the pulling of jacketed cables shall be specifically recommended by the cable manufacturer. Cable lubricants shall not be deleterious to the cable sheath, jacket or outer covering. Cable Terminations Terminations of insulated power cables shall be protected from accidental contact, deterioration of coverings and moisture by the use of terminating devices and materials. All terminations shall comply completely with the manufacturers recommendation instructions. Cables joints shall be made only in approved junction boxes. All terminations of field cable cores shall be to individual terminal blocks mounted in a group adjacent to each other. Only one wire shall be connected to each side of a terminal. Terminals which may be live, when a section is isolated by its own isolator, shall be shrouded using clear plastic with warning notices marked 'Danger live terminals, isolate
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elsewhere' and with the voltage clearly marked on the shroud. The shrouds shall be secured by screws and sufficient to cover terminal lugs Connection of power cables shall be with crimp type lugs of the correct size for each size conductor together with electroplated bolts, nuts and lock nuts. Connection of control and signals cables, except thermocouples, shall be with appropriate crimp pins or lugs. All motor cables shall terminate at a local isolator for the motor. The isolator shall be rated to AC23. Cabling between the isolator and the motor terminal box shall be enclosed in flexible conduit. Cable or core termination shall under no circumstances be under mechanical stress due to lack of support of the cable or vibration. The connection of cable screens shall fan out from the signals power supply, with the remote ends being insulated from earth. (Star connection) Screens on screened cables shall be insulated or sleeved and brought out as appropriate. Heat shrink sleeving shall then be fitted over the end of cable sheath. All field sensors with molded in leads shall be held by compression glands at the terminal boxes. Where leads are subject to mechanical damage, suitable sized loose flexible or rigid conduit shall be fitted over this lead and fixed to support in an appropriate manner. The Contractor may be required to demonstrate his jointing technique, and, if in the opinion of the Engineer, the termination is faulty, the Contractor shall replace all other terminations so jointed at no extra cost. Cables, conduits or ducting entering cubicles, junction boxes, motor terminal boxes or like, shall be from the bottom. (Unless otherwise specified or approved by the Engineer). High/medium voltage splices and terminations shall be made using a kit method, which shall be a product of one manufacturer and shall have the approval in writing of the manufacturer of the cable, which is to be spliced or terminated. When required, splices shall be made only in manholes. High/Medium Voltage Cables After installation, and before placing in service, a DC High Potential Test shall be performed on all cables rated above 600 V AC. All precautions and limits as specified in the applicable standards shall be adhered to during the test.
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Current sensing circuits in testing equipment shall measure only the leakage current associated with the cable under test, and shall not include internal leakage of the test equipment. Test procedures shall be as follows and the results for each cable shall be recorded. Record temperature and relative humidity. Do not perform tests unless weather is clear and relative humidity is below 7%. Each conductor shall be individually tested with all other conductors grounded. All shields shall be grounded.
Terminations shall be properly corona suppressed by guard ring, field reduction sphere, or other suitable methods. Perform megger and continuity test prior to high pot testing. A DC high potential shall be applied at least 5 equal increments until maximum test voltage is reached. DC leakage current shall be recorded at each step after a constant stabilization time consistent with system charging current decay. 100% voltage shall be reached in a maximum of 60 seconds. A graphic plot shall be made of the leakage current (X-axis) versus voltage (Y-axis) at each increment. The test conductor shall be raised to a maximum test voltage and held for a total of 15 minutes. Readings of leakage current (Y-axis) versus time (X-axis) shall be recorded and plotted. The conductor test potential shall be reduced to zero and grounds applied for at least 10 minutes. Grounding Non-current carrying metallic parts associated with electrical equipment shall have a maximum resistance to solid earth ground not exceeding the values below in Table 5. Table 5: Grounding Requirements Description Ground rods for power transformer Ground rods for pad-mounted transformers
Requirements 3 ohms 5 ohms
Description Grounded secondary distribution system neutral and non-current carrying metal parts associated with distribution systems and grounds not otherwise covered
Requirements 5 ohms
The Contractor shall provide additional ground rods/cables in order to attain the above grounding resistance values at no additional cost to Manila Water. Grounding electrodes shall be cone pointed driven ground rods driven full depth plus 152 mm, installed when indicated to provide an earth ground of 5 ohms or less. Grounding connections that are buried or otherwise normally inaccessible, and except those specific connections for which access for periodic testing is required, shall be by exothermic type weld process. Thermic welds shall be made strictly in accordance with manufacturers written recommendations. Welds that have puffed up or show convex surfaces indicating improper cleaning shall not be accepted. In lieu of an exothermic type process, a compression ground grid connector of a type, which uses hydraulic compression tool to provide the correct circumferential pressure may be used. Tools and dies shall be as recommended by the manufacturer. An embossing die code or other standard method shall provide visible indication that a connector has been adequately compressed on the ground wire. Grounding conductors shall be bare soft-drawn copper wire with size as indicated in the drawings. Exposed or above grade grounding cables shall be green PVC or type TW insulated. Connect copper-clad steel ground rods only to copper ground conductor and weld the connection. Insulate the entire area of the rod in the vicinity of the weld and the connecting wire and seal against moisture penetration.
13.3.5 Power Transformer The transformers shall be mounted on concrete pad/foundation as shown on the drawings. The top of concrete slab shall be at least 100 mm above the finished grade for outdoor installations, unless otherwise indicated. The slab shall project at least 300 mm beyond all edges of the transformer. Conduit turn-ups and cable entrance space shall be provided as required by the transformer to be installed. Installation of the equipment shall be in accordance with the manufacturers instructions. Such instructions shall be supplied with the complete assembly. The manufacturer shall have a qualified representative to be present on site at all times to supervise installation and testings.
Grounding shall be provided as specified in Section 13.3.4 Table 5. For transformer 2 grounding, a bare copper cable not smaller than 100 mm not less than 600 mm below grade shall be likewise provided and connected to the indicated ground rods. 2 Transformer neutral connections shall not be smaller than 50 mm . Where the rated secondary current exceeds 400 amperes, the size of the transformer neutral ground connection shall be increased to not less than one-half the cross-section area of the secondary-phase conductors. The measured ground resistance shall not exceed 3 ohms. Additional ground rods/cables shall be provided in order to attain this value, at no additional cost to Manila Water.
13.3.6 Interior Wirings Electrical installations shall conform to the requirements of Philippine Electrical Code and to the requirements specified herein. Wiring Method Wiring method shall involve insulated conductors installed in conduit, except where specifically indicated or specified otherwise, or as required by PEC Article 3.0 - Wiring Methods, which will be installed otherwise. An insulated equipment-grounding conductor shall be provided in all feeder and branch circuits, including lighting circuits unless otherwise shown on the drawings. Insulated green-colored conductor shall be provided for grounding conductors installed in conduit or raceways. Mounting Heights Panelboards, circuit breakers, and disconnecting switches shall be mounted so the height of the operating handle at its highest position will not exceed 2 meters from the floor. Lighting switches shall be mounted 1.4 meters above finished floor, receptacles 450 mm above finished floor, and other devices as indicated. Mounting heights for wiring devices and outlets shall be measured from finish floor up to the centre of device or outlet. Mounting heights for special purpose outlets shall be as required by equipment served. Conductor Identification Conductor identification shall be provided within each enclosure where a tap, splice or termination is made. For conductors 14 mm2 and smaller, color coding shall be by factory-applied color-impregnated insulation. For conductors 22 mm2 and larger, color coding shall be by plastic-coated self-sticking markers, colored nylon cable ties and plates, or heat-shrink type sleeves. Identify control circuit terminations. Splices
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Splices shall be made in accessible locations. Splices in conductors 5.5 mm2 and smaller shall be achieved with an insulated pressure type connector, or twist-lock wire nuts. Splices for conductors 8 mm2 and larger shall be achieved with a solderless connector, and covered with an insulation material equivalent to the conductor insulation. Grounding and Bonding Grounding and bonding shall be installed in accordance with the prescribed codes and standards. All exposed non-current-carrying metallic part of electrical equipment, metallic raceway systems, grounding conductor in non-metallic raceways, and neutral conductor of wiring systems shall be grounded. Ground connection shall be made to driven ground rods on the exterior of the building. Where ground fault protection is employed, care shall be taken to ensure that the connection of ground and neutral does not interfere with the correct operation of the fault protection. Grounding Conductor An insulated, green-colored, equipment-grounding conductor shall be provided in all feeder and branch circuits. This conductor shall be separated from the electrical system neutral conductor. Electronic Equipment Special attention shall be paid to the electronic system earthing, if required for computers and control systems. Computer systems and instrumentation equipment shall be earthed separately from the electrical earth system, which can be an independent earth system depending on manufacturers requirements. Resistance The maximum resistance to ground of the grounding system shall not exceed 5 ohms under normal dry conditions. Where the resistance obtained exceeds 5 ohms, additional ground rods/cables shall be provided in order to attain this value; at no additional cost to Manila Water.
13.3.7 Instrumentation Installations for instrumentation and control systems shall conform to the applicable requirements of the latest approved edition of the Philippine Electrical Code, NEC (NFPA 70), IEEE and ISA Standards. The instrumentation and accessory equipment shall be installed in accordance with the manufacturers instructions and location as shown on the drawings. Ideal electrical
shutoffs for power supplies to field instrumentation shall be provided by the Contractor. All piping, including to and from field instruments, shall be provided with test tees, shutoffs and disconnecting units as necessary or as required by Manila Water. The Contractor shall be responsible in checking the drawings to ensure that the actual installations are in accordance the size and number of wires required on the shop drawings. If cable size and number are found to be insufficient, the Contractor shall provide the proper size and additional cables at no additional cost to Manila Water. The Contractor shall furnish the services of the manufacturers servicemen as necessary or when required by Manila Water. Such provisions shall include all special tools, test manometers, calibration weights, temporary materials, and labor to perform the tests at no additional cost to Manila Water. Certified copies of the tests shall be furnished in duplicate to Manila Water for reference. 13.3.8 Lighting Fixtures Lighting fixtures shall be installed plumb and square with building and wall intersections. Ball hangers shall suspend pendant-mounted fixtures, which are mounted from sloping ceilings. Fixtures installed in machine rooms shall be located after machines have been installed. All fixture locations shall be coordinated with works of other trades to prevent obstruction of light from the fixtures. Mounting heights specified or indicated shall be to the bottom of fixture for ceilingmounted fixtures and to centre of fixture for wall-mounted fixtures. Approval for the exact mounting for lighting fixtures in the permanent works shall be obtained before installation is commenced and where applicable, after coordinating with the style, pattern of the ceiling installed. Recessed fixtures shall be installed light-tight to the ceiling and shall be provided with auxiliary safety supports attached directly to the building structure. Said safety supports shall consist of no. 12 AWG soft drawn galvanized wire or no. 10 AWG aluminum wire. Emergency lights shall be wired ahead of the light switch to the normal lighting circuit located in the same room or area. Fixture Poles Anchor bases shall have galvanized steel anchor bolts, threaded at the top end and bent 90 at the bottom end. Galvanized nuts, washers, and covers for anchor bolts, including concrete for anchor bases, PVC conduits/end-bells, and ground rods. Design and details for concrete footings/foundations shall be subject to Manila Waters approval. Backfill shall be thoroughly compacted and arranged so as to prevent any pressure between conductor, jacket or sheath and the conduit end-bell. Poles shall be adjusted as necessary to provide permanent vertical position with the bracket arm in the proper position
for luminare location. After installation, exposed surfaces of steel poles shall be coated with two coats of exterior aluminum paint. Grounding Noncurrent-carrying part of equipment shall be grounded. Where the copper-grounding conductor is to be connected to metal other than copper, specially treated or lined connectors suitable for this purpose shall be provided. Grounding conductors and wires shall be green insulated with PVC or type TW rated 600 VAC. 13.3.9 Outdoor Load Interrupter Switchgear The equipment shall be mounted on concrete pad/foundation or above cable trenches as shown on the drawings. Conduit turn-ups and cable entrance space shall be likewise provided as required by the equipment to be mounted. Installation of the equipment shall be in accordance with the manufacturers instructions. Such instructions shall be supplied with the complete assembly. The manufacturer shall have a qualified representative to be present on site at all times to supervise installation and testings.
13.3.10 Guarantees The Contractor shall guarantee that the electrical systems are free from all ground and from all defective workmanship and materials and will remain so for a period of one (1) year from date of acceptance of the work. Any defects appearing within the aforesaid period shall be remedied by him at his own expense. 13.4 ELECTRICAL DRAWINGS/SUBMITTALS 13.4.1 General The Contractor shall submit, for Manila Waters approval, the following calculation and documentations relevant to the electrical works, including but not limited to: Electrical drawings (A1 size) Instrumentation drawings (A1 size) Panel drawing (A3 size) Automation drawings(A3 size) Manufacturers Data Shop Drawings (A3 size) Technical brochures and manuals, and shop drawings shall provide the following information requirements:
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Shop drawings for all grounding work not specifically indicated, including equipment grounding requirements; Switchboards, MCCs, panels (A3 size) Cover Index Legend
Single Line Diagram Plant layout showing location electrical equipment in relation to the plant. Equipment Layout Front, side, rear elevations, top views, cross section and internal device layout showing dimensional data, labeling, etc. , as well as front and rear access requirements. Bus bar ratings and arrangement shall also be shown on the layout. Location of conduit/tray entrances, access plates and support details; Types of materials and finish
Nameplates indicating HP, KW, voltage, current, phase and other relevant data; Schematic/Connection diagrams Drawings shall show in schematic form all wiring and electrical equipment supplied under this Contract, together with all other circuitry to which this equipment is interconnected (control panel, junction box, etc.). Any relevant reference data supplied by the Engineer shall be incorporated. Drawings shall be in Ladder diagram format showing terminal numbers, internal wiring diagrams, conductor size, and cable numbers. AC Distribution Diagram DC Distribution Diagram Control wiring Diagram PLC digital Input/Output diagram PLC Analog Input/Output diagram Termination Diagram/Connection diagrams shall include all control panel and junction box connection diagrams and also interconnection diagrams. Cable Schedule/routing diagrams shall be supplied and shall show all cables involved in the contract together with cable identification number, cable type, length and connection positions. Cable lists may also be used.
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Parts List/ Complete material lists stating quantity, description, manufacturer and brand name of each item or class of material, order number and installed location Method of anchoring, seismic requirements and weights; Temperature limitations, as applicable; Equipment, fixture and panel mounting details; Test reports or Certificate of Compliance and Test Reports
Catalogue cuts or photocopies of applicable pages of bulletins or brochures for mass produced, non-custom manufactured material. Catalogue data sheets shall be stamped/marked to indicate the project name, applicable section and paragraph, model number, and options. This information shall be marked in spaces designated for such data, to facilitate submittal monitoring, evaluation and approval. Shop drawings shall be custom prepared. Drawings or data indicating "optional" or "as required" equipment are not acceptable. Options not proposed shall be crossed out or deleted from shop drawings. All drawings shall be created using AutoCAD, preferably Release 2009. Graphical symbols used on drawings shall comply with the symbols contained in the current version of the appropriate standard. (PEC, NEC or IEC) Cross-references shall be marked on all schematic diagrams to show where a coil has its contacts and where contacts have their coils. This referencing shall apply to all types of equipment shown on more than one drawing. 13.4.2 Drawing Sheets and Scales All drawings shall be on sheet with sizes and borders complying with the Preferred series of sheets, with filling margins. All electrical wiring and circuit diagrams shall be A3 size and all electrical layouts shall be on A1 size. 13.4.3 CAD Standards Set-Up Drawings shall be created in model tab with ACAD.DWG as the prototype drawing. Titleblock shall be a block containing attributes for the Titleblock Information. Titleblock must not be exploded. Drawing origin shall be set to 0,0.
Border and Titleblock origins shall be set at the lower left-hand corner. Border and Titleblock shall be inserted at location 0,0 in Layer Titleblock. Limits shall be the Sheet size or the Border extremity. Colors Pen Number 1 2 3 4 5 6 7 Linetypes All line types shall be selected from the AutoCAD Standard Linetypes. Text Styles All font style shall be Roman Simplex with the following text heights. Application Titles, Drawing Numbers Sub-titles General Notes, Material Lists Dimensions, others A1 Size Thickness 0.6 0.40 0.2 A3 Size Height Thickness 4 3 2 0.40 0.30 0.2 Pen Color Red Yellow Green Cyan Blue Magenta White Pen Thickness 0.20 0.50 0.40 0.05 0.30 0.10 0.60
Height 6 4 2.5
Line Number All drawings for MCCs, Switchgear and Control Panel shall have the following line number allocation. AC Distribution DC Distribution Control Wiring Diagram Digital input/output diagram Analog input/ouput diagram Termination Diagram 1001 2000 2001 3000 3001 5000 5001 6000 6001 7000 7001 9000
Line number shall be used for wiring and terminal identification. 13.5 POST CONTRACT DRAWINGS AND DOCUMENTATION 13.5.1 General The drawings shall be supplied in loose-leaf binders with index to simplify location of a particular drawing.
No site work, other than standard equipment or controls, will proceed until such drawings or specifications have been reviewed and marked as satisfactory or released for construction. Three reproducible copies of the drawings, specifications or documentation shall be shipped with the equipment or immediately after the plant commissioning and personnel training unless otherwise specified. The electrical drawings and submittals mentioned in Section 13.4 shall likewise be submitted as part of post contract documentation. 13.5.2 Document List A document list shall be produce to show all documents being supplied under this Contract. This list shall show the document name, document number, paper size, latest revision number and highest sheet number used. 13.5.3 Single Line and Block Diagrams These are to describe the process control in simple terms using single line diagrams for instrumentation, controls, protection and control sequence. 13.5.4 Plant Layout Drawings shall show the location of all electrical equipment in relation to the plant. 13.5.5 Equipment Layout Drawings Cross section and other drawings shall show clearly the location, device layout, labeling of the equipment mounted in switchgear, control boxes etc. and the location of cables supporting routing. 13.5.6 Schematic Diagram Drawings shall show in schematic form all wiring and electrical equipment supplied under this Contract, together with all other circuitry to which this equipment is interconnected. Any relevant reference data supplied by the Engineer shall be incorporated. Drawings shall be in Ladder diagram format. 13.5.7 Connection Diagrams/Termination Diagram Connection diagrams shall include all control panel and junction box connection diagrams and also interconnection diagrams. 13.5.8 Bill of Materials/Parts List All apparatus shall be listed in the Bill of Materials showing quantity, description, manufacturer and type, order number, installed location. 13.5.9 Cable Routing Diagrams or Cabling Lists Cable routing block diagram shall be supplied and shall show all cables involved in the contract together with cable identification number, cable type, length and connection positions. Cable lists may also be used.
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13.5.10 Operation and Maintenance Manuals The Contractor shall send direct to the MWC, three (3) copies of the approved Operations and Maintenance Manuals. These manuals shall be in separate folders and shall provide all information needed for the safe efficient commissioning, operation, adjustment and maintenance of the plant. The Contractor shall collate all the information relating to the enclosure(s) and its associated equipment. Two (2) draft copies of each manual shall be supplied prior to the dispatch of the enclosure(s). Operation Manual Manufacturers data and Shop Drawings Technical brochures and manuals, and shop drawings shall comply with the requirements summarized in previous section. Equipment manuals for various items necessary for the operator setting up and adjustment of process variables in accordance with the control philosophy. A detailed written description of the control philosophy including descriptions of the action to be taken by operators, with respect to operator controlled devices, together with operator adjustable variables. The Operation Manual shall provide the Plant Operator with the information required for successful start-up and Shut-Down Procedures, Operation of Manual Interface, Operation of Local Interface, Plant Considerations, Associated Document References.
Maintenance Manual The Maintenance manual shall include: Index and reference to enable the user to quickly find the relevant information. Schedule of drawings, showing title, revision, manufacturers reference and purchasers reference. Plant and parts list giving manufacturers name, address, catalogue number or reordering reference, and serial numbers of individual items. Setup, calibration, commissioning instructions for all items of plant, including operating characteristics of all protective devices. Commissioning data for all settings and tests performed. Fault finding and rectification instructions.
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Results of all tests before delivery. Results of all tests on site. The Maintenance Manual will provide the Maintenance Technician with the information and references for Preventive, Corrective and Condition-Based Maintenance, Associated Documentation References, Preventive Maintenance Procedures, Condition-Based Maintenance Procedures, Corrective Maintenance Procedures and Fault Finding Techniques. List of abnormal operating conditions, their cause and remedy. Recommended routine maintenance procedures Recommended list of spares
13.5.11 Tools
A full set of any special tools required for the operation, maintenance, or repair work on electrical or instrumentation equipment shall be supplied. 13.5.12 Spares A comprehensive set of spares is to be provided to maintain the electrical or instrumentation equipment for a period of not less than 24 months in operation. 13.5.13 Exemptions Where special conditions exist which would make compliance with these Specifications unusually difficult, then details should be submitted in writing to the Engineer, who may grant an exemption. Any such exemption granted shall be obtained in writing from the Engineer by the party seeking the exemption. 13.5.14 Preferred Equipment Any items of equipment offered and not listed under Preferred Equipment must be approved by the Engineer. Any such exemption granted shall be obtained in writing from the Engineer by the party supplying the equipment. 13.5.15 Location of Equipment The location of all electrical equipment shall be such that it will allow both convenient and safe access for service, testing, calibration etc., without the use of temporary staging, ladders, the dismantling of other equipment or the removal of the component itself. No apparatus or terminal block shall be mounted within 250 mm vertically from the internal floor level. 13.6 TESTING 13.6.1 General Tests are to be pre-planned, scheduled, and carried in a safe and efficient manner. Notification will be given at least five (5) days in advance to carrying out any tests of the
panels and field wiring so that a representative is able to plan witnessing of each test at the following stages: Equipment and cables support mounted within panel/in the field, but not wired. Fully wired and ready for test.
All test required by Statutory Authorities are to be carried out to proved that the systems operate in accordance with appropriate codes and regulations. A functional test and check of all electrical components shall be performed prior to the conduct of sub-system testing and commissioning. Compartments and equipment shall be cleaned as required before commencement of functional testing. Functional testing shall involve the following activities: Visual and physical check of cables, bus work, circuit breakers, transformers and connections associated with all new and modified equipment; Setting of protective relays to assure tripping at the current value and time required by the system Where features for adjustable time or pick-up settings for ground current, instantaneous over-current, short-time over-current, or long-time over-current are available, circuit breakers shall be field adjusted by manufacturers representative to the recommended time and pick up settings. Setting shall be tabulated and proven for each circuit breaker in its installed position. Seven copies of test results duly certified by the tester shall be submitted to Manila Water. Works and field testing shall be witnessed by a company representative or the Engineer and all testing and results shall be recorded. The checklist (record sheets) shall be obtained from the Electrical Engineer. 13.6.2 Field inspection and Testing All plants provided under this contract shall be available for inspection and testing as required by the Engineer or his inspector, during manufacture. The costs of the tests including the provision of all necessary test equipment at the manufacturers works shall be deemed included in the Contract Price. Prior to starting any test the Contractor is required to check that the installation, electrical devices and instrumentation are strictly in accordance with the Specification, electrical and instrumentation drawings. All AC test instruments shall have a minimum accuracy of 0.5%; all DC test instruments shall have a minimum accuracy of 0.1%.
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All other test instrument (pneumatic and electronic calibrators, temperature calibrators etc.) shall have a minimum accuracy of 0.1%. Each test instruments shall be calibrated in accordance with acceptable international standards. The calibration certificates shall not be more than 3 month old and shall be presented to the Electrical Engineer prior commencing work. Following completion of works and before the delivery, testing shall be performed by the contractor to the Engineers satisfaction. Distribution Conductors 600 Volt Class All 600 Volt class distribution conductors shall be tested to verify that no short circuits or accidental grounds exist. Tests shall be performed using a megger test set that applies a voltage of approximately 1 kV DC to provide a direct reading in resistance. High/Medium Voltage Cables High and medium voltage cables shall be tested after the installation in accordance with the requirements of NEMA. Grounding Ground testing of all grounding electrodes shall be performed before operating the equipment. Subsystem testing shall occur after Manila Water has accepted the proper operation of alarm and status contacts, and after process control devices have been adjusted as accurately as possible. The Contractor shall adjust limit switches and level switches to their operating points prior to testing and will set pressure switches, flow switches, and timing relays as may be dictated by operating results. After initial settings have been completed, each subsystem shall be operated in the manual mode and tested to demonstrate that operation complies with Contract requirements. Once the manual mode of operation has been proven, automatic operation shall be likewise tested to verify such items as proper start and stop sequence of pumps, proper operation of valves, proper speed control, etc. Motor operated valves shall be tested after having been phased and tested for correct motor rotation and the travel and torque limit switches adjusted by the manufacturer. Tests shall verify status indication, proper valve travel, and correct command control from local and remote devices. Ground resistance tests shall be performed in the presence of Manila Water. Tests results shall be submitted at the time and manner described elsewhere in the Contract. A ground resistance megger Earth tester with a maximum of 0-50 scale shall be used during
testing. The full of potential method or the three terminal methods as described by BIDDLE or NETA shall be employed. Subsystems shall be defined as individual and groups of pumps, control systems, air conditioning units, ventilation fans, etc. Ground Rods Ground rods shall be tested for ground resistance value before any wire is connected. A portable ground testing megger shall be used to test each ground or group of grounds. The instrument shall be equipped with a meter reading directly in ohms or fractions thereof to indicate the ground value of the ground electrode under test. A copy of the megger Manufacturers directions for use of the ground megger shall be provided to determine the method to be used. Upon completion, test reports, including the following information requirements, shall be submitted: 13.6.3 Lighting Lighting tests shall be performed to verify proper operations of switching and, where applicable, remote controls. The tests shall also demonstrate that the circuitry was installed in accordance to panel schedules. Inspections and Testings The Contractor shall give at least 5-days notice so that Manila Water can witness the conduct of the following tests and inspections. The Contractor shall be responsible for providing power and testing instruments, and personnel required for all field tests. Operating Test Upon completion of the installations, an operating test shall be conducted to demonstrate that the lighting system operates in accordance with the requirements of the Contract. Insulation Resistance Test Insulation resistance tests shall be performed as specified in Section 13.6.5 before and after connection of fixtures and equipment.
Low voltage 600 V AC cables - identify each cable & test result High/medium voltage cables - identify each cable and test results Grounding Electrodes & Systems - identify electrodes and systems, each test
Ground Resistance Test Ground resistance tests shall be performed as required in Section 13.6.2. Test on devices subject to Manual Operation. Each device subject to manual operation shall be operated at least three times, demonstrating satisfactory operation each time. Acceptance Checks, Settings and Tests Acceptance checks, settings and tests shall be performed in accordance with the manufacturers recommendations and the latest IEEE Standards. Work shall be performed in careful and safe manner so as not to endanger personnel or equipment. Lighting demonstrations shall be likewise conducted on the lighting fixtures to demonstrate compliance to Contract requirements. Unless otherwise directed by Manila Water, such exercises shall be performed at least 2 weeks before final acceptance. The operations of the installed exterior lighting systems shall be demonstrated during the evening to ensure that the fixtures are properly focused, photocell operation is correct, and that fixture switching functions as intended. Similar requirements shall apply to interior lighting. Through demonstration, the Contractor shall also verify that panel schedules properly indicate the lighting outlets connected to each circuit.
13.6.4 MCC and Switchgear Test Tests shall include but not limited to: Cubicles shall be inspected to ensure that the quality of finish is to standard. The correct apparatus and labeling have been installed and the wiring has been carried out in a neat and correct manner. The equipment shall be carefully inspected to ensure that all electrical connections are tight, particular attention should be paid to busbar connections and all clearances should be adequate. All wiring shall be checked against the schematic layout and all control switches relay contacts, timers, etc. checked for correct polarities and mode of operation.
Operational tests of control, protection, relays and alarms equipment with all items of auxiliary equipment for mounting remote, temporarily wire-in for the tests.
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Where certain control interfaces are not available, simulated signals shall be used to test individual systems. Checking phase sequence and voltage levels. Sequential operational tests of all control circuits including interlocks. Insulation Test (Phase to phase, Phase to neutral and Phase to earth) Checking the individual operation of all motors without load for rotation, bearing lubrication, noise, vibration and temperature rise. Recording the operating load current of all motors. Measure and balance full load currents in each phase when the system is fully loaded.
Power Instrumentation Tests shall be performed to demonstrate that voltmeter and ammeter switches are functional, and that kilowatt meters are within catalogue accuracy. Safety Interlocks Tests shall be performed by attempting to subvert the intended sequence to demonstrate that the mechanical and/or electrical interlocking is functioning. Ground Fault Protection Ground fault tripping shall be activated by operating test features provided with ground current protective systems and injecting a known and reasonable current in the ground current sensor circuit. In general, ground fault tripping occurs at a ground current equivalent to 20 percent of phase current. Current injection shall not be required to circuits 400 amperes or less. 13.6.5 Cable Test Test shall include but not limited to: Every cable shall be tested for insulation (Megger), continuity compliance and earth loop impedance. The results of all tests shall be detailed on a signed test certificate prior to submittal for review. The energization of each circuit shall not be allowed until the test certification has been reviewed by the Engineer.
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Cable Insulation Resistance Testing 460/230-volt circuits with 600 VAC rated wires/cables shall be tested for insulation resistance with a 1,000-volt megohm meter. Testing shall be done after the equipment feeder/branch circuit terminations are completed. Phase-to-phase (A to B, B to C and A to C) and phase-to-ground insulation resistance tests shall be performed on each cable prior to 34.5-kV cable termination at equipment but subsequent to stress cone makeup. Equipment damaged during the tests shall be disconnected. Tests shall be performed with all other equipment connected to the circuit. In order to be acceptable, the cable must withstand the test high voltage without breakdown, have steady or decreasing leakage current during the high potential test, and have satisfactory comparable megger readings in each megger test. Cables operating at more than 2,000 volts shall be tested in accordance with ICEA publications S-68-61, S-61-402, S-19-81, and S-68-516. Cable testing and report submittal shall be performed by an organization sanctioned by the Manufacturer of the cable to be tested. Testing shall verify the quality of cable terminations. All test results shall be submitted to Manila Water for review at least 30 days prior to plant operation, any system testing or equipment energisation. The results shall state the equipment tested and time of test. 13.6.6 Transformer Test All tests shall be in accordance with latest version of ANSI and NEMA standards. The following standard factory tests shall be performed but not limited to: Resistance measurements of all windings on the rated voltage connection Ratio test on the rated voltage connection and all tap connections Polarity and phase- relation test on the rated voltage connections No-load test at rated voltage on the rated voltage connection Exciting current at rated voltage on the rated voltage connection Impedance and load loss at rated current Applied potential test Induced potential test
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Interior Wiring Systems Devices Subject to Manual Operation Each device subject to manual operation shall be operated at least five times, demonstrating satisfactory operation each time. 600-Volt Wiring All 600 V AC wiring shall be tested to verify that no short circuits or accidental grounds exist. Insulation resistance tests shall be performed on all wiring sized 14 mm2 and larger using a megger test set which applies a voltage of approximately 1 kV DC to provide a direct reading of resistance; minimum resistance shall be 250,000 ohms. Grounding System The grounding system shall be tested to assure continuity and that the resistance to ground is not excessive. Each ground rod shall be tested for resistance to ground before making any connections to the rod; then tie entire grounding system together and test for resistance to ground. Resistance measurements in normally dry weather shall be taken not less than 48 hours after rainfall. Written results of each test shall be submitted to Manila Water. Information of test results shall include location of the rods, and the resistance and soil conditions at the time of testing. 13.6.7 Instrument Checkout Each instrument, including transmitter, shall be identified and compared with the process diagrams to verify its function and operation. Transmitting instruments containing or provided with protecting walls shall be verified to have compatible components suitable for the service and application intended. Analytical instruments shall be verified to the service intended. Solutions and/or source elements shall not be installed until instrumentation is ready for re-wire operation in final calibration. Spare parts furnished with instruments shall be checked, identified and stored with identification tags attached. Spare parts shall not be used to complete initial installation and start-up without re-ordering to insure complete spare parts complements. Damaged spare parts shall be returned immediately to vendor with corrective action requested.
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13.6.8 Instrument Inspection, Cleaning & Testing All instruments must be disconnected from the process piping and vessels during hydrostatic testing of the process lines. Instrument process piping shall be hydrostatically tested together with process piping and vessels. All interconnecting wires from panel to field mounted devices shall be tested by ringing out. Wiring pairs shall be disconnected at the transmitter and the panel terminal blocks, joined in pairs at the transmitter, and tested from the panel termination. Individual leads shall be tested using ground return, or common, to verify continuity and identification. If any changes in connections are necessary, wires shall be retag accordingly. Signal wire polarities shall be verified by simulation of transmission signals. Ground connections and shielding terminations shall be checked against drawings or manufacturers instructions. All control cable shielding shall be grounded at one end only, with reference at the receiver station (control panel). Equipment (case) grounds shall be in accordance with drawings and manufacturers instructions. Indicator scales on all transmitters and receivers shall be checked for correct range and legend. Especially calibrated flowmeters shall be verified as to scale range and information data sheets supplied. 13.7 CALIBRATION 13.7.1 General Electrical instrument calibration shall be performed on an individual instrument or combination of instruments as required to complete the measurement or to prove the loop functional. Factory tested elements are not to be calibrated unless it is required for critical service and facility is available. Functional checks shall be performed in a manner to ascertain operational capability. 13.7.2 Calibration Data Sheets Calibration data sheets shall be prepared and submitted for file reference for all critical measurements. 13.8 INSTRUMENT ENVIRONMENTAL PROTECTION Environmental protection shall be provided for all instrument equipment against damage upon receipt, storage and during installation. Instruments located outdoors, and subject to severe ambient conditions including moisture and corrosion shall be protected by installation in a weatherproof housing or similar protective enclosure or shield.
The installation of protective housings, or enclosures shall not inhibit the functioning of the instrument or in any way detracted from the ability to perform routing service as required. 13.9 COMMISSIONING The contractor shall provide sufficient skilled staff, during the commissioning phase, to carry out necessary adjustments as they are identified. All settings and adjustments to equipment are to be recorded. Commissioning shall only be attempted as a function of normal plant operation in which plant process flows and levels are routine and equipment operates automatically in response to flow and level parameters or computer command, as applicable. Simulation of process parameters shall be considered only, upon receipt of a written request from the Contractor. The motor current tabulation should reflect the values occurring during commissioning. The indications of all switchboard ammeters and kilowatt-meters shall be recorded every half-hour during commissioning. All tests must be witnessed by the Engineer or Company Representative and carried out to the Engineers Company Representative satisfaction. 13.10 TRAINING The contractor shall provide training as per prepared (specified) training program for the maintenance electricians so that they can efficiently maintain and fault find on the equipment. As the plant works shift the training shall be repeated so all personnel will be trained. Commissioning shall not be completed until all training has been provided to the Engineers satisfaction. PART 2 PRODUCTS SPECIFICATIONS
13.11 LOW VOLTAGE SWITCHBOARD General All equipment shall be designed, in accordance with IEC EN 60439 comply with Form 4 Type 7 segregation, The design of the switchboard shall provide limited arc fault containment and be rated to the fault levels specified in the Equipment Specification. The switchboard shall be designed to operate on 460 volt, 3 phase, 4 wire 60Hz AC with neutral solidly earthed The switchboard shall be free standing, totally enclosed metal clad switchboards incorporating withdrawable air circuit breakers.
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All electrical cubicles and boxes shall be suitable for bottom cable entry and front access unless otherwise specified. Non magnetic gland plated shall be supplied for all non stainless steel enclosures. All enclosures mounted directly onto floors shall be supplied with a welded 75 mm RHS hot dip galvanized plinth. In wet process areas hot dip galvanized steel stands or legs shall be supplied. The heat generated within the cubicle shall not cause the air temperature around the equipment to rise above the rating of this equipment. Air to air heat exchanges may be used if required but not with refrigeration units. All control items shall be DIN rail mounted where possible. No inflammable or hygroscopic materials shall be used. In all cases, equipment shall be designed, rated, tested and shall perform in accordance with the latest edition of the applicable Standards. It will be permissible to obtain access to live parts through a door or cover while the equipment is alive by defeating mechanical interlock or using special tools. Such interlock must be automatically restored on refastening the door or cover. All doors shall swing about a vertical axis. Any item of apparatus must be capable of being removed for replacement without requiring any other item to be removed first. Captive nuts or threaded steel shall be used so all apparatus can be replaced without removing the gearplates or other parts of the cubicle. Self tapping screws are not acceptable. No equipment shall be mounted on the sides, top or bottom of the cubicle (internal light exempted). All field wiring shall terminate via terminal rail blocks, not connected directly to control devices. A minimum distance of 50 mm shall be allowed between cable ducting and equipment for the terminating of wires. Conduit or cable entry shall not be made from the top. Construction Main switchboards to be fabricated from 2mm mild steel. Control panels to be fabricated from 1.6 mm thick. All panels or doors supporting equipment in which large cutouts are required shall be constructed of at least 2.0 mm sheet steel.
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All joints shall be continuously welded and ground to be smooth finish. All doors and covers shall be provided with compressible Neoprene gaskets. Switchboard doors will be fitted with key lockable handles. Doors over 1500 mm high will be fitted with two door handles at top and bottom. A single handle and locking rods will not be accepted. Drawing pockets will be provided for each switchboard, mounted on the inside of the cabinet door. Doors are to be effectively earthed by 6 mm2 insulated flexible copper bonding straps. Painting mild steel metalwork shall be as follows: After construction and all cut outs completed, the sheet metalwork shall be thoroughly rubbed down to a smooth blemish free surface free of all defects and rush. All metalwork shall be Zinc Chromate primed and passivated, undercoated, two topcoats of high gloss enamel paint wrinkle beidge exterior and interior. The switchboard shall be so arranged that it may be readily extended in either direction. Each shipping section shall have provision for top lifting and lifting eyes or beams shall be provided. The manufacturer shall provide the internal fixings within the equipment necessary for the holding down bolts. Workmanship shall be of a high standard in all cases and the finished equipment shall present a neat and attractive appearance. All bolts, nuts, washers and spring washers used in the assembly of components and cubicles shall be of adequate size for the duty required and shall be Zinc plated to prevent corrosion. Cadmium plated components shall not be used. Cable ducting shall be so sized and arranged that the cables in the duct do not exert pressure on the lid or cause deformation of the duct. Cable ducts are to be dedicated to electrical cables only. Under no circumstances are pneumatic lines to run in these ducts. Any cables entering through the top of sides of an envelope shall pass through cable glands. Where circuits or sub mains exceeds 100 Amps and are single cored and gland plates shall be designed to prevent currents in the plates.
Main Switchboards
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All main switchboards shall be design as defined in and of comparative type construction. Main switchboards supplied directly from transformers shall have: One voltmeter with selector switch for phase and line voltage selection. One multi function relay with the following minimum features: Phase failure relay Over/Undervoltage relay Phase unbalance relay Ground fault relay Under load current relay Overload relay Bus Bars
Phase Bars Bus Bars shall be hard drawn, high conductivity copper supported on approved insulation. The Bus Bar Assembly shall be rated based on short circuit calculation for 1 second minimum and have type tested certificates for an approved testing station. Main busbars shall be rated for minimum of 25 % greater than the total loading on them. Connections for demountable or withdrawable switchgear shall be so arranged as to permit easy disconnection without disturbing the working condition of the busbar or cable connections. The busbar are to be pre-drilled to permit easy extension in either direction. Main connections and busbars shall be arranged and identified in either by painting, PVC sleeving or other approved means.
Earth Bar This shall be installed in line with the standards.
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A suitable sized earth bar shall extend the length of the switchboard.
13.12 MEDIUM VOLTAGE SWITCHGEAR General The Contractor shall furnish, install and commission medium voltage switchgear and all its related appurtenances, complete and operable, in accordance with Contract requirements. Works shall include installation of the appropriate concrete pad/foundation and other mounting accessories. The switchgear and its components shall be designed, manufactured and tested in accordance with the latest applicable standards of NEMA and IEEE. Product Requirements The switchgear shall be free-standing, indoor type, designed for operation on a 35 kV, 3Phase, 3-wire and 60 hertz system. The switchgear assembly shall consist of individual vertical sections housing various combinations of vacuum circuit breaker/or fusible load interrupter, switches and other auxiliaries, bolted to form a rigid metal-clad, dead front switchgear assembly. Metal side sheets shall provide grounded barriers between adjacent structures and solid removable metal barriers shall isolate the major primary sections of each circuit. The stationary primary contacts for circuit breaker shall be silver-plated and recessed within insulating tubes. A steel shutter shall automatically cover the stationary primary disconnecting contacts when the breaker is disconnected or out of the cell. Rails shall be provided to allow withdrawal of each 2.3 kV circuit breaker for inspection and maintenance without the use of a separate lifting device. Each vertical section containing a switch shall have a single, full-length flanged front door and equipped with two rotary latch type handles that can be padlocked. Provision shall be made for operating the switch and storing the removable handle without opening the full-length door. The manufacturer shall furnish accessories for installation, inspection, testing, operation and maintenance of the medium voltage switchgear. Standard factory tests shall be performed on the switchgear assembly to be supplied under this Contract. All tests shall be in accordance with the applicable requirements of the latest approved edition of ANSI and NEMA Standards. Specifications for particular switchgear components and other requirements shall be as follows:
Bus The main bus shall be copper and have fluidized bed epoxy flame retardant and track resistant insulation. The bus supports in between units shall be flame-retardant and trackresistant. The switchgear shall be constructed so as all buses, bus supports and connections shall withstand stresses that would be produced by currents equal to the momentary rating of the circuit breakers. A set of 2,000-ampere insulated copper main bus shall be provided and shall have provisions for future extensions. All bus joints shall be plated, bolted and insulated with easily installed boots. The bus shall be braced to withstand fault current equal to the close and latch rating of the breakers. The temperature rise of the bus and connections shall be in accordance with ANSI standards and documented by design tests. A copper ground bus shall extend the entire length of the switchgear. When required, a bare, fully rated neutral bus shall extend the entire length of the switchgear. Main Circuit Breaker The main circuit breaker of the switchgear shall be of the vacuum and horizontal draw-out types, capable of being withdrawn on rails. The breaker shall be opened by a motorcharged energy spring mechanism, charged normally by a universal electric motor and in an emergency by a manual handle. The primary disconnecting contacts shall be silverplated copper. Requirements for main circuit breaker ratings shall be as follows in Table 6 Table 6: Main Circuit Breaker Ratings for Switchgears Description Number of poles Frequency Voltage Rating Nominal Maximum Design BIL Rated Continuous Current Short Circuit Current at Rated Maximum kV
Requirements 3 poles 60 Hertz 34.5 kV 35 kV
60 kV 500 A 15 kA
Description Closing and Latching Capability Three-Second Rating Rated Interrupting Time
Requirements 97 kA crest 30 kA 5 cycles
The circuit breaker shall contain three vacuum interrupters separately mounted in a selfcontained, self-aligning pole unit, which can be removed easily. The vacuum interrupter pole unit shall be mounted on supports for 5 kV class. A contact wear gap indicator for each vacuum interrupter, which requires no tools to indicate available contact life, shall be easily visible when the breaker is removed from its compartment. The current transfer from the vacuum interrupter, moving stem to the breaker main conductor shall be of non-sliding design. The breaker front panel shall be removable when the breaker is withdrawn for ease of inspection and maintenance. The secondary contacts shall be silver-plated and shall automatically engage in the breaker operating position, which can be manually engaged in the breaker test position. Interlocks shall be provided to prevent closing of a breaker between operating and test positions, to trip breakers upon insertion or removal from housing and to discharge stored energy mechanisms upon insertion or removal from the housing. The breaker shall be secured positively in the housing between and including the operating and test positions. The breakers shall have 110 VAC control voltage. The control voltage source shall be 110 V AC. Trip units shall be provided in accordance with the following requirements. Where indicated on the drawings, the switchgear manufacturer shall furnish and install, in the metal-clad switchgear, the quantity, type and rating of protection relays and as described in the Contract. The devices shall be solid-state microprocessor based and multi-function type that operates from the secondary output of current transformers. Devices for phase time over-current, instantaneous over-current, and ground fault protection prescribed by ANSI 50/51, 50/51G, or 50/51N, shall be incorporated into a single device. The device shall provide ANSI 50/51 protective functions for each of the three phases, and ANSI 50/51N or 50/51G ground fault protection functions as shown on the plans or as determined by the coordination study. The device shall be true rms sensing of each phase and ground. Ground element shall be capable of being utilized in residual, zero sequence, or ground source connection schemes, or deactivated.
The primary current transformer rating being used for phase and ground protection feeding the device shall be programmable by means of dipswitch settings for current transformers with primary current ratings from 50 to 4000 amperes. The protection curves shall be field programmable and similar to those on low-voltage breaker trip units for close coordination with downstream devices. The time over-current protection curves for phase and ground shall have field selectable FLAT, IT, I2T, and I4T long delay slopes as well as selectable short delay pick up and short delay time settings to coordinate with existing over-current relays and power fuses. The phase instantaneous over-current trip shall have field programmable pick-up points from 1.0 to 25 times current transformer primary rating or NONE. In addition, discriminator circuit shall protect against current exceeding 11 times current transformer primary rating, only when the breaker is being closed. The device shall have independent time over-current (ANSI 51) and instantaneous (ANSI 50) over-current trip contacts. When required, differential pilot wire relays shall be Sukkor RF or similar utilizing copper pilot wires. The device shall have a built-in alphanumeric display capable of displaying the following information with metering accuracy of 1% of primary current transformer rating or full scale. Individual phase currents Ground current Cause of trip Magnitude and phase of current causing trip Peak current demand for each phase and ground since last reset Current transformer primary rating Programmed phase and ground set-points Device shall have the following features: Integral manual testing capability for both phase and ground. Zone-selective interlocking capability for short time and ground fault protection Continuous self-testing of internal circuitry. Unit failure alarm contact for customer use. Programmable lockout/self-reset after trip function. Programmable set-points for device curve selection.
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Programmable inputs such as current transformer ratios.
Access to program and test modes shall be via sealable hinged cover for security. Device shall be suitable for operating temperatures up to 55C. Device shall be suitable for operating with humidity from 0 to 95% relative humidity (non-condensing). Device alarm and/or trip contacts shall not change state if power is lost or an under-voltage occurs. These contacts shall only cause a trip upon detection of an over-current or fault condition based upon programmed settings. The device shall be suitable for operating on control power with a normal input voltage of 110 volts, 60 Hz. When AC control power schemes are shown on the drawings, a single phase uninterruptible power supply shall be included to supply control power to protective devices in addition to the control power transformer or remote control power shown or herein specified. Ring type current transformers shall be furnished as required. The thermal and mechanical ratings of the current transformers shall be coordinated with the circuit breakers. Their accuracy rating shall be equal to or higher than ANSI standard requirements. The standard location for the current transformer on the bus side and line side of the 2.3 kV breaker unit shall be front accessible to permit adding or changing current transformers without removing high voltage insulation connections. Shorting terminal blocks shall be furnished on the secondary of all the current transformers. Voltage and control power transformers of the quantity and required ratings shall be supplied. Voltage transformer shall be mounted in draw-out drawers contained in an enclosed auxiliary compartment. Control power transformers shall be mounted in draw-out drawers. Rails shall be provided for the drawer to facilitate inspections, testings and fuse replacement. Shutters shall isolate primary bus stabs when drawers are withdrawn. Accessories shall include 2.3 kV surge arresters. These shall be provided at the outgoing terminations (load side) and securely grounded to the metal structure as shown in the drawings. A panel mounted SQUARE D Powerlogic Circuit Monitor Type CM-2450 or approved equivalent shall be provided for metering purposes. The supply shall include the required instrument transformers (PTs and CTs). Branch Circuit Breakers Branch circuit breakers shall be of the vacuum and horizontal draw-out types, capable of being withdrawn on rails. The breakers shall be of similar type, make and features as that of the main circuit breaker. Current ratings and other devices shall be as shown on the drawings.
Fuses rated as shown on the drawings shall be provided for fault protection. Motor Protection Relay Motor protection relay of make and model G.E. Multilin 269 Plus shall be installed in the works. An alternative brand providing the following functions maybe offered for Manila Waters approval: Enclosures The enclosure for the switchgear assembly shall be NEMA 12 gasketed (neoprene gasket), dead front and freestanding indoor construction. Engraved nameplates, mounted on the face of the assembly, shall be furnished for all main and feeder circuits as indicated on the drawings. Nameplates shall be laminated plastic, having black characters on white background, and secured with screws. Characters shall be at least 5 mm high. A master nameplate giving switchgear designation, voltage/ampere rating, short-circuit rating, manufacturers name, general order number and item number shall be likewise furnished. All components and devices mounted within the assembly, such as fuse blocks, relays, push buttons, switches, etc., shall be suitably marked for identification corresponding to appropriate designations on the manufacturers wiring diagrams. Surface finish shall consist of a coat of gray (ANSI-61), thermosetting, polyester powder paint applied electrostatically to pre-cleaned and phosphatized steel and aluminum for internal and external parts. The coating shall have corrosion resistance of 600 hours to 5% salt spray. Prior to shipment, the complete assemblies, indoor as well as outdoor, shall be given 1.5 to 2.0 mil thick exterior finish spray coat or air drying high gloss gray enamel. Installation Motor overload Unbalance supply voltage Motor under current Ground fault Rapid trip for mechanical jam Motor stator over-temperature Motor and pump bearing over-temperature.
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The equipment shall be mounted on concrete pad/foundation or above cable trenches as shown on the drawings. Conduit turn-ups and cable entrance space shall be likewise provided as required by the equipment to be mounted. Installation of the equipment shall be in accordance with the manufacturers instructions. Such instructions shall be supplied with the complete assembly. The manufacturer shall have a qualified representative to be present on site at all times to supervise installation and testings.
13.13 OUTDOOR LOAD INTERRUPTER SWITCHGEAR General The Contractor shall furnish, install, and commission the outdoor type load interrupter switchgear and all its related appurtenances, complete and operable, in accordance with the Contract requirements. This includes the appropriate concrete pad and foundation and other mounting accessories. The switchgear and its components shall be designed, manufactured and tested in accordance with the latest applicable requirements of NEMA, IEEE and but not limited to ANSI Standards Ground Rod The ground rods shall not be connected until they have been tested for ground resistance value. A portable ground testing megger shall be used to test each ground or group of grounds. The directions provided by the Manufacturer shall be carefully followed to ensure proper use of the ground testing equipment. A copy of the directions shall be provided to Manila Water in advance to be used as reference during test witnessing. Device Subject to Manual Operation Each device subject to manual operation shall be operated at least three times, demonstrating satisfactory operation each time. Acceptance Checks, Settings and Tests Acceptance checks, settings and tests shall be performed in accordance with the manufacturers recommendations and the latest IEEE Standards. Work shall be performed in careful and safe manner so as not to endanger personnel or equipment. Product Requirements
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The medium voltage switchgear shall be an integrated assembly of vacuum circuit breaker that is coordinated electrically and mechanically for high voltage circuit protection. Medium voltage switchgear ratings are shown in Table 7Error! Reference source not found.. Table 7: Medium Voltage Switchgear Ratings Description Nominal System Voltage Maximum Design Voltage Basic Impulse Level Bus Continuous Current Momentary Current Two-Second Current Requirements 34.5 kV, 3-phase, 4-wire 38 kV 150 kV 600 A 30 kA Asym 25 kA Asym
Each switch shall have the following minimum ratings, as shown in Table 8: Table 8: Medium Voltage Vacuum Breaker Ratings Description Maximum Design Voltage Basic Impulse Level Continuous and Load Interrupting Current Momentary Current (Switch closed, 10 cycle) Fault Close Current Two-Second Current Requirements 38 kV 150 kV 600 A 30 kA Asym 30 kA Asym 25 kA Asym
The switch shall be operated by a manually charged spring stored energy mechanism that will simultaneously disconnect or connect all underground poles. The speed of opening and closing the switch shall be independent of the operator. It shall be ensured that it will be impossible to tease the switch into any intermediate position. The interrupter switch shall have separate main and make/break contact to provide maximum endurance for fault close and load interrupting duty. The switch, or switch and fuse assembly, shall have glass polyester insulating barriers between phases and between the outer phases and the enclosure. Fault protection shall be furnished by current limiting fuses; with ratings as indicated. Fuses shall have a minimum interrupting rating of 30,000 amperes asymmetrical at 35 kV.
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The manufacturer shall furnish accessories for installation, inspection, testing, operation and maintenance of the medium voltage switchgear. Standard factory tests shall be performed on the switchgear assembly to be supplied under this Contract. All tests shall be in accordance with the applicable requirements of the latest approved edition of ANSI and NEMA Standards. Enclosures The enclosure for the switchgear shall be dead front, free standing, pad-mounted. Engraved nameplates, mounted on the face of the assembly, shall be furnished for all main and feeder circuits as indicated on the drawings. A master nameplate giving switchgear designation, voltage/ampere rating, short-circuit rating, manufacturers name, general order number and item number shall be likewise furnished. All components and devices mounted within the assembly, such as fuse blocks, relays, push buttons, switches, etc., shall be suitably marked for identification corresponding to appropriate designations on the manufacturers wiring diagrams. Surface finish shall be thermosetting, polyester powder paint applied electrostatically to precleaned and phosphatized steel and aluminum for internal and external parts. The coating shall have corrosion resistance of 600 hours to 5% salt spray. Prior to shipment, the complete assemblies, indoor as well as outdoor, shall be given 1.5 to 2.0 mil thick exterior finish spray coat or air drying high gloss gray enamel. Installations The equipment shall be mounted on concrete pad/foundation or above cable trenches as shown on the drawings. Conduit turn-ups and cable entrance space shall be likewise provided as required by the equipment to be mounted. Installation of the equipment shall be in accordance with the manufacturers instructions. Such instructions shall be supplied with the complete assembly. The manufacturer shall have a qualified representative to be present on site at all times to supervise installation and testings. 13.14 MOTOR CONTROL CENTRES General The work covered by this Specification includes the design and manufacture of motor control centre (MCC) equipment completely assembled. The Manufacturer shall also provide technical assistance during the installation and placement in service of the equipment.
All equipment shall be designed, built, rated, tested and shall perform in accordance with the latest editions of the applicable standard. The standards and regulations of any body having jurisdiction over the equipment particularly Meralco shall apply. Where the stipulation of this Specifications, the data sheets and the drawings do not comply with the minimum requirements of the applicable regulations and standards; the latter shall prevail. Where the stipulations of this Specification, the data sheets and the drawings are more exacting than the minimum requirements, the former shall prevail. Service conditions The MCC and all components therein, shall function in a satisfactory manner within the rated capacity under the service conditions specified regardless of whether or not all necessary specific performances are set forth in this Specification or in the applicable standards. Design Construction Details General: The MCC within this Specification shall be compartmentalized and shall comply with IEC 439 Form 4 Type 7, and be rated to the levels specified in the Equipment Specification for operation on a 460 volt 3 phase 4 wire 60 Hz supply. Enclosure: The MCC shall be constructed with suitably folded and stiffened corners and edges with an integral supporting structure, and shall be manufactured as per section in low voltage switchboard. The MCC shall be free standing, front connected and front wired. The front of the MCC shall have doors supported with chrome plated pintle hinges. The door shall not extend more than 450 mm perpendicular to the MCC face. The door locking shall be designed to prevent opening when subjected to forces caused by an internal fault. Master locking system on all doors. All openings shall be fitted with a suitable non distorting compressible seal, which shall engage onto the MCC panels stiffened return surround on one side and the doors rear face within the stiffened return on the other side. Each section of the MCC shall be supported on the identical 75 mm RHS hot dip galvanized plinth, fully braced and welded, turned outwards. Gland plates shall be fitted to the top and the bottom of the MCC and at the incoming supply cable entry, this gland plate shall be 3.5 mm aluminum, and all other gland plates shall be made out of the MCC construction material. All gland plates shall be gasketed and bolted.
A minimum of 150 mm clear space shall be available above and below the gland plate for access to the glands. Air duct shall be provided for every VFD compartment to eliminate hot air circulation inside MCC. Wiring diagram pockets shall be provided. Provision for 25% spare for future expansion shall be provided. Component Arrangement The MCC shall be 600 mm deep, 2200 mm high with plinth, width of a modular panel shall be 1000 mm with door size of twin 450 mm. All electrical equipment shall wherever possible be mounted on DIN rails on metal mountings. If equipment has to be attached directly onto the mounting plate, they shall be secured by screws in the pretapped holes, self-tapping screws are not permitted. Terminals shall be of a type providing a positive mechanical clamp on connection, fully shrouded and suitable for mounting on DIN standard rail. Double banked terminals in one composite molding shall not be used. No apparatus or terminal block shall be mounted within 300 mm vertically from the internal floor level. All wiring shall wherever possible be wired in ducts. Cable ducting shall be so sized and arranged that the total number of cables and wires to be installed in the duct do not exert pressure on the lid or cause deformation of the duct. Signal wiring where possible be segregated from other wiring. The minimum clearance between panel mounted equipment, cable looms, ducting, terminals and MCC framework or panels shall be 50 mm. Shipping The MCC shall be delivered on site in sections not longer than 4M. Each section shall be suitable braced and have lifting points so that during a crane lift no distortion will take place. Assembly instruction shall accompany the equipment. Bus Bars Grounding Bar shall be provided.
Busbars shall be of tinned, hard drawn, high conductivity copper. They shall be insulated throughout their lengths by means of phase color sleeving. The busbar assemblies and joints shall be in accordance with the manufacturers/suppliers recommendations. The rating, supports and bracing of all main connections between all main circuit switching mechanisms and busbars shall be designed for operation at the same short-time withstand current rating as that specified for the busbars. Live connections to and from busbars shall be either fully insulated or suitably screened and all covers screening the busbars and connections shall be provided with adequate warning labels Current transformers shall be bar type, to BS 3938 accuracy and output mounted on the cabling side of the ACB or MCCB. MCCs shall be provided with a hard drawn, tinned, copper earth bar located clear of any gland plate or cable access. The earth bar shall have a minimum cross-sectional area of 120 mm2. The earth bar shall be the full length of the panel and split only at sections used for transport and installation purposes. Where splits occur, the bar shall be joined by a minimum of two bolted connections. Provision shall be made at each end of the earth bar for connection to a main earthing system The sectional area of the neutral bar shall be equal to the sectional area of the phase bar. Other Identification, test and inspections, drawings, wiring and approvals of MCCs shall agree with the relevant sections within this Specification. Instrument cubicles shall be separate; the layout shall be approved by the Engineer. All fields wiring to remote control panels or instrument shall be terminated into a terminal rail, not wired directly to devices.
13.15 DISTRIBUTION BOARDS/CONTROL PANEL Construction The enclosure shall be constructed as per section on Low Voltage switchboards. The door seal shall be of high quality and a pressured catch handle shall be employed. Exterior cables (power source cables as well as feeding cables) shall be directly connected to the MCCB or isolator. Adequate space for exterior wiring shall be provided.
A permanent connection diagram identifying the feeders shall be provided in holder fitted with a transparent cover inside the door on completion of construction. Provision for 25% spare for future expansion shall be provided. Bus Bars Busbars shall be of tinned, hard drawn, high conductivity copper. They shall be insulated throughout their lengths by means of phase color sleeving. The busbar assemblies and joints shall be in accordance with the manufacturers/suppliers recommendations. Live connections to and from busbars shall be either fully insulated or suitably screened and all covers screening the busbars and connections shall be provided with adequate warning labels Grounding Bar shall be provided. The sectional area of the neutral bar shall be equal to the sectional area of the phase bar.
13.16 COMPONENTS General All switches shall be of the fault make load break suitably derated for their enclosure. Power switches and Isolators Switches are to be rated for AC3. They are to be lockable and have operating indication of OFF and ON. Main cubicle switches shall be rated for at least the same fault level as the busbars and shall be able to break the full load current or make onto a fault. Circuit Breakers The main incoming terminals of the main switch shall be extended by copper take offs. The unit shall be lockable in the service, test and isolated position and when the CB is Open/Off. Circuit-breakers as installed shall be capable of carrying the maximum rated current continuously Circuit-breakers shall comply with BS EN 60947-2 category P2, and be capable of withstanding the fault level of the system as specified. ACBs shall be of the withdrawable type and equipped for manual stored energy operation. They shall have shunt release coils. ACBs shall have at least two normally open and two
normally closed spare auxiliary contacts over and above those required for operation of the scheme as detailed on the drawings. All main CBs shall have thermal, instantaneous overcurrent and earth fault protection with provision for single phasing, and delayed under voltage if required. Branch Circuit protective devices shall be molded case circuit breakers providing complete circuit overcurrent protection by having inverse time and instantaneous tripping characteristics. Circuit breaker for general purpose convenience outlet shall be ELCB type rated at 30mA. Circuit breakers shall be operated by a toggle-type handle and shall have a quick-make, quick-break over-center switching mechanism that is mechanically trip free. Automatic tripping of the breaker shall be clearly indicated by the handle position. Contacts shall be non-welding alloy. A push-to-trip button on the front of circuit breaker shall be provided local manual means to exercise the trip mechanism. Each molded case circuit breaker microprocessor-based tripping system shall consist of three current sensors, a trip unit, and a shunt trip. All main CB and motor CB shall be provided with handle to be interlock with enclosure door, to ensure that the door cannot be opened or closed with the isolator in the on position. Feeder Protection Relay Protection Relays with the following minimum protections: Instantaneous overcurrent relay Ground fault overcurrent with time delay Thermal overload relay Load unbalance, phase sequence overcurrent relay
Motor Protection Relay Motor protection shall be provided as specified in Soft Stater Section. Metering Three phase digital incoming metering shall be provided by a power quality meter. Metering shall include A, V, W, Wh, var, VA, Hz, and PF.
Four switch inputs shall be provided which can be programmed for relay activation, counters, logic, reset and alarms. Four output relays shall be provided which can be programmed to activate on alarms, setpoints, switch inputs, kWh pulse or communications control. These output relays shall also be able to use demand metering values of A, var, W and VA to control load shedding. PLC interface shall be provided via four isolated 4-20 mA outputs programmable from measured parameters. Local user interface shall include a keypad and display for entering all setpoints and reading all measured values, and LED indicators for output relays, communication status and alarm status. An RS232 computer interface port shall be located on the front panel. All metering shall be Solid state digital metering. Metering shall be panel mounted type. Ammeter, Voltage and run hour meter shall be provided to all motors and linked to SCADA for local and remote monitoring and can be linked to MCCs. Pushbuttons Pushbuttons shall have a heavy duty oil tight rating, be of the 22.5 mm diameter mounting hole type and follow the colors, these being: Pushbuttons should be of oil tight (hoseproof) type. Pushbuttons shall be shrouded to minimize the possibility of accidental operation. All buttons shall be clearly labeled. Pushbutton shall comply with the following color coding: Start pushbutton Stop pushbutton Emergency Pushbutton Reset pushbutton Indication Indicator lights shall be of similar design as the pushbuttons with a 22.5 mm diameter mounting hole, and should also be hoseproof. The lights shall be LED type or transformer type. Indicating lights shall comply with t he following: Off or De-energised Run or Energised Trip or Fault Ready or Permissive Starters
Coloured Green Coloured Red Coloured Red Coloured Amber
Coloured Green Coloured Red Coloured Amber Coloured White
Each starter is to have isolation, overcurrent and thermal protection, a contactor, control voltage C/B and terminals for output power and control cables. The power wiring shall be red, white and blue. The minimum size of all power wiring shall be 3.5 mm2.The overcurrent and thermal protection shall be coordinated so that both motor and starter equipment is protected. Process display of every Soft Starter and Variable Speed Drive shall be located in front of each compartment. Each starter shall comply with BS EN 60947 and unless otherwise specified shall be class 12 utilization category AC3 Motor starters shall include the following: Suitably rated lockable MCCB and bolted neutral link, with magnetic and thermal overload, interlocked with the section door closed in both the ON and the padlocked OFF positions Door mounted control selector switch Thermistor protection unit; only required for motors rated at or above 15 kW. Door mounted indicating lamps for Running, Stopped and Tripped Poor mounted push buttons to read Start, Stop, Reset and Lamp Test
Preferred Starter Below 7.5 KW 7.5 and above DOL/VFD if it requires automation Soft Starter/ Variable Speed Drive if it requires automation or Soft Starter for normal controller.
Thermal Protection The setting of the relay or starter will refer to the motor full load current. Overload elements are required in all three phases. The overload shall be temperature compensated, and have differential single phasing protection. Thermal overloads shall be fitted with two pairs of electrically separated auxiliary contacts for indication and tripping purposes. (2 x NO., 2 x NC) Contactors
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Contactors shall be triple pole, air break with inherent no volt release to BS EN 60947 class 12, utilization category AC3, and be complete with a minimum of one set of spare auxiliary changeover contacts Motor starting contactors for reversing, star/delta, auto transformer, etc., shall be mechanically and electrically interlocked Contactors for power factor capacitor shall be provided with on delay relay. Control Relays All control relays shall be of the plug-in type held by retaining clips. All contacts shall be rated for at least 5 amps. All relays shall be in sealed enclosures with means for manual operation from the front. An indication to show relay operation is required. DC Power Supplies Dc power supplies shall have isolated outputs, have regulation to control the voltage within 0.5 % of the rated value over the full load range. The output ripple shall be within 0.2% peak to peak or less than 0.05% RMS. The output shall be protected against short circuits. The gear plate shall have a perforated steel cover mounted such that the cover can be removed while the unit is alive without the possibility of the cover touching live parts. The input and output terminals shall be of the type described under Terminals and shall be rated for clamping on the outgoing side, two cables each rated for the full current of the power supply. The power supplies shall not exceed the nominal voltage at power up more than 1.5 V. Timers All timers shall have electronic timing. They shall be multi voltage and shall accept 12 to 240 volts AC or DC without any wiring or switch changes. They shall be multi function giving delayed on and true delayed off as selected from a function switch. The time range shall be adjustable between 0.6 seconds and 60 hours. A visible indication shall be given when the timer has timed out. The timer shall have an 11 pin circular plug in base. The output shall be voltage free contacts rate for a minimum of 5 amps inductive. Terminals External wiring shall be terminated at terminal blocks within motor control centers and control panels. Terminal shall be Klippon or Polyamide spring assisted type or approved equivalent. Terminal blocks shall be rail mounted.
Terminal blocks shall be segregated in groups by barriers of blank space to separate extra low voltage terminals from those of higher voltage. It is preferred that both terminals and cables be colored to indicate voltages. This will improved safety and make fault finding easier. No more than 2 wires may be terminated in any tunnel or clamp type terminal. Approved insulated crimp lugs must be used to terminate multi-strand flexible cables. One cord only in each lug. The use of plug in type strip terminals is not permitted. Control Circuits The standard control voltage is 110V. Contactor coils shall operate on 110 volts (phase to neutral) 60 Hz. Any other voltages shall not be used unless approved by the Engineer. One leg of any coil, solenoid, relay, contactor, lamp or current consuming device, must be connected directly the earth or neutral side of the supply. Where control circuits are not isolated automatically when the phase supplies are isolated or when multiple source supplies are used then prominent warning signs shall be displayed together with instructions for de-engaging these circuits. Capacitor Capacitor shall be properly selected to attain 98% power factor. Group of motors fed in motor control center shall be provided with capacitor bank with automatic switching of controller for power factor correction. Standard Type: Frequency Degree of protection Execution Discharge Resistor IEC 831 or Approved Equal Dry type Design 60Hz IP42 Indoor Permanently connected built-in discharge resistors are sized to ensure safe discharge of the capacitor to less than 50V in 1 min. after switch off. 0.5 W/kvar +50o C -25o C
Losses Max. ambient temperature Min. ambient temperature 13.17 SOFT STARTER
A. Standard Operating Conditions

The SS shall be capable of withstanding any combination of the following environmental conditions in which it must operate without causing electrical/mechanical damage or degradation of performance:
Ambient temperature range Atmosphere
0 to 40 degrees C Non-condensing relative humidity up to 90%
B. Enclosure Minimum degree of protection of all SS shall be IP 21. All components shall be factory mounted and wired on a dead front, grounded, NEMA-13/IP 54 enclosure. If a free-standing enclosure is provided, it shall be suitable for wall mounting.
C. Electrical Characteristics
The SS shall have the following electrical characteristics: Input Power Voltage Frequency Output Power Voltage Efficiency 460V (+/- 10%) 95% 460V (+/- 10%) 60 Hz (+/- 2%)
D. Soft Start/Stop Characteristics 1. The controller shall provide a soft start with selectable kick start and a soft stop option. 2. The SS shall be selected to provide a successful start of the relevant connected load by being able to provide sufficient current so that the motor is able to develop the level of torque required.
E. Ventilation The SS shall have built in cooling fans so that the SS can be forced air cooled to operate within the above rated environmental conditions. The SS shall be housed in a motor starter
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panel. Adequate ventilation must be allowed to ensure the internal temperature of the enclosure does not exceed 40 degrees C.
F. Transient Protection The SS shall be equipped with Transient protection so that it will not cause damage to power components upon absorbing an electrical transient. By-pass internal run shall be available to prevent excessive heat built up within the enclosure. Motor protection shall not be lost during the by-pass mode.
G. Power factor The SS shall be equipped with Capacitor to improve the power factor to 98%.
H. Control Switch The SS shall be equipped with Auto/Off/Manual control switch. In the manual mode the SS will be controlled by local stop/start buttons. In the Auto mode the SS will be controlled by remote 2 wire system.
I.
Monitoring 1. Digital parameter adjustment shall be provided through a built-in keypad. A built-in alphanumeric, backlit LCD display shall be provided for controller set-up, diagnostics, status, and monitoring. Analog potentiometer adjustment is not acceptable. 2. The controller shall provide the following monitoring functions indicated through the builtin LCD display: Three phase line current Phase-to-phase supply voltage Power in kW kWh Elapsed time Power Factor Motor Thermal capacity SS status
3. The SS must make available the following output signals for the external controller in addition to summary alarm voltage free contact: Run
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Start/Run Motor Current (4-20 mA) Motor Thermal Model (4-20 mA) Fault indication
J. Protection and diagnostics 1. The SS shall incorporate, as standard the following protection features: Over voltage Under voltage Stall/Jam Overload Underload Phase Unbalance Phase Sequence Under current Motor Thermistor Starter Overtemperature Line Fault Power loss Ground Fault
2. Fault diagnostics shall be indicated in descriptive text on the built-in LCD display. The exclusive use of fault codes shall be unacceptable. An auxiliary contact that is programmable for fault indication shall be provided.
K. User Adjustments 1. The acceleration ramp time shall be adjustable from 0-30 seconds. 2. The initial torque setting shall be adjustable from 0-90% of locked rotor torque. 3. Current limit starting shall be adjustable from 50-600% of the motors full load current. 4. A selectable kickstart feature shall be available to provide a current pulse at 550% of the motor full load current rating. The time period shall be adjustable from 0.0 to 2.0 seconds.
L. Communications The SS shall have RS485 or RS232 port as standard allowing the starter to be used in conjunction with the external control system. Through this link, the SS must be able to be controlled and monitored.
13.18 VARIABLE FREQUENCY DRIVE
A. Standard operating condition All VFDs shall conform to the following standard operating conditions: Ambient temperature range Elevation Atmosphere AC line Frequency Variation 0 to 40 degrees C up to 3300ft Non-condensing relative humidity up to 95% +/- 3%
B. Ingress Protection/Enclosure VFDs shall have a minimum IP 21 degree of protection. All VFD components shall be factory mounted and wired on a dead front, grounded, NEMA-13/IP 54 enclosure. If a free-standing enclosure is provided, it shall be suitable for wall mounting. C. Power Input Unless otherwise specified, power input to the unit shall be 480 Vac ( 10%), 3-phase, 60 Hz. D. Efficiency and Power factor 1. The VFD shall have an efficiency of 97%. The efficiency shall exceed 90% at 50% speed and load. 2. The VFD shall maintain the line power factor at no less than 0.95, regardless of speed and load. E. Harmonic Distortion Compliance 1. Total harmonic distortion shall be calculated under worst condition in accordance with IEEE standard 519-1992. The VFD shall comply with the total harmonic distortion of line voltage and the line current limits as defined in IEEE 519-1992. 2. Harmonics compliance shall be verified with onsite field measurements of both voltage and current harmonic distortion at the drive input terminals with and without the VFDs operating. A recording type Fluke or equivalent harmonic analyzer and total harmonic currents and voltages must be utilized. F. Motor Application/Compatibility
1. The VFD shall be capable of operating existing motor induction motor, regardless of manufacturer, with a horsepower and current rating as indicated. 2. The VFD shall be able to start into a spinning motor. The VFD shall be able to determine the motor speed and resume operation without tripping. G. Monitoring, displays and communications
1. The VFDs display shall be LCD type capable of displaying three (3) lines of text and indicators. LCD process display shall be located in front of MCC panel. The following are to be available for monitoring at minimum. Output frequency Output Speed Motor current Motor power in KW Motor voltage or output voltage Input voltage Elapse time meter Digital input/output status Kilowatt hour meter
2. VFD shall have integral Modbus/Profibus communication capability. 3. VFD parameters, fault log and diagnostic log shall be downloadable 4. Process display of every Soft Starter and Variable Speed Drive shall be located in front of each compartment H. Input/Output Features The VFD shall have the following features: Two programmable analog inputs (0-20mA/0-10V). One programmable analog outputs (0-20mA ). Five programmable digital inputs (24VDC). Two programmable digital outputs (form C, dry contact relays). All programmable digital outputs can be programmed to give start and stop signal to other motor. Autochange features capability of changing the starting order of other drives shall be available. System program providing built-in drive control or application specific configuration capability.
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I.
Protective Functions The VFD shall include the following protective features at minimum: Overcurrent Overvoltage Undervoltage Ground/Earth fault Inverter fault Phase loss Output phase loss Undertemperature/Overtemperature Motor overload/underload
J. Control Functions 1. The standard operator interface shall consist of an LCD keypad located on the front of the VFD. 2. The operator shall be able to scroll through the keypad menu to choose between the following: Monitor Operate Parameter setup Actual parameter values Active faults Fault history
3. The following setups and adjustments, at a minimum, are to be available: Start command from keypad, remote or communication port. Speed command from keypad, remote or communication port. Motor direction selection Maximum and minimum speed limits Acceleration and deceleration times, two settable ranges. Multiple preset speeds adjustments
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Catch a spinning motor start or normal start selection
K. Diagnostic Features and Fault Handling 1. The VFD shall include a comprehensive microprocessor based digital diagnostic system which monitors its own control functions and displays faults and operating conditions. 2. The Fault Log shall record, store, display and output to a serial port upon demand, the following for the most recent events: Date and time of day Type of fault
3. A historic log shall record, store and output to a RS-232, RS-422, or RS- 485 serial link port upon demand.
L. Drive Options The following drive options shall be provided: 1. All special features shall be factory mounted and wired within the VFD enclosure unless otherwise specified. 2. Pressure transducer in the VFD to convert a 0-100psi pneumatic signal to an electrical signal for automatic speed control. 3. The VFD shall be provided with circuit breaker for disconnecting power supply. This will provide the ability to isolate the VFD for maintenance and service. All switches include handle operators, door interlocking and could be locked (preferably by a padlock). M. Other features and requirements 1. VFD Automatic Control 2. PID utilization on internal or external setpoint. 3. Auto start functions: On/Off, Operable from a 4-20mA signal or from the PID output, command, or feedback signal. 4. Programmable digital outputs (form C, dry contact relays). Digital outputs can be programmed to give start and stop signal to other motor. Autochange features capability of changing the starting order of other drives shall be available. 5. All drive setting adjustments and operation parameters shall be stored in a parameter log which lists allowable maximum and minimum points as well as the present set values 6. The drive shall preferably be compliant to standards on electromagnetic compatibility (EMC). The drive shall be compatible with existing or new monitoring instruments and equipment that shall be used with the drive. The MWCI Project Proponent, as well as the Manager, shall verify this requirement for drives that would be supplied separately from monitoring instruments/equipment
13.19 DRY TYPE TRANSFORMER General Furnish and install, single phase dry-type transformer of two-winding type, self-cooled, with rating and voltages as indicated on the drawings. Transformer shall be designed, manufactured, and tested in accordance with all the latest applicable ANSI, NEMA and IEEE standard and shall be UL listed. Transformer shall be designed for continuous operation at rated kVA, for 24 hours a day, 365 days a year operation, with normal life expectancy as defined in ANSI. Insulation System Transformer shall be insulated at 220 oC insulation system. Required performance shall be obtained without exceeding the above indicated temperature rise in a 40 oC maximum ambient, with 30 oC average over 24 hours. All insulation materials shall be flame-retardant and shall not support combustion as defined in ASTM Standard Test Method. Core and Coil Assemblies All transformer cores shall be constructed of low loss, high quality, electrical grade laminated steel. By design, the flux density is to be kept well below the saturation level to reduce audible sound level and minimize core losses. The core volume shall allow operation at 10% above rated primary voltage at no load without exceeding the temperature rise of the unit. Coil conductors shall be either aluminum or copper and must be continuous. The entire core and coil assembly shall be impregnated with thermal setting varnish and cured to reduce hot spots in the coils and seal out moisture. Coils with exposed magnet wire will not be acceptable. Transformers shall have common core construction. Transformer shall be provided with six, 2.5% full capacity taps two above and four below. Enclosure Transformer enclosure shall be constructed of heavy gauge sheet metal and coated with a gray powder paint finish. The enclosure construction shall be ventilated, NEMA 2, drip-proof, with lifting holes. All ventilation openings shall be protected against falling dirt. On outdoor units, provide
suitable weathershields over ventilation openings. To assure proper ventilation, locate the unit at least 150 mm from the adjacent wall or structure. Sound Levels Transformer average sound levels shall not exceed 40 db based on ANSI and NEMA levels for self-cooled ratings. Tests The following tests shall be made on all transformers: 13.20 EARTHING The installation of copper earthing rods 3.0 meters long and a minimum of 15 mm in diameter with the required number to achieve a ground resistance of 5.0 Ohms or less. The earthing rods shall be arranged, driven into the ground and connected together etc to the manufacturer instructions. The earthing rods shall be connected together and wired to a new main earth bar via suitably sized copper cable(s). For the earthing of electrical systems, equipment and structures, each installation shall have one common earth bar connected to at least two groups of earth electrodes. All metallic conduits, cabinets and equipment shall be properly grounded and bonded by means of copper straps. The conduits of each system shall be grounded by connecting to the metallic water service pipe. All ground connections shall have clean contract surfaces and shall be tinned and seated while bolting. Unless otherwise specified, exposed ground cables shall be installed in conduit and connections made readily accessible for inspection. Connections shall not be made underground or concealed in floors and walls. All ground connection shall be clamped and brazed or cad welded. The following equipment shall be grounded: Motors, Secondary main distribution panel, Panels,
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Ratio tests at the rated voltage connection and all tap connection. Polarity and phase relation tests on the rated voltage connection. Applied potential tests. Induced potential tests. No-load and excitation current at rated voltage on the rated voltage connection.
All other equipment as required by the National or Philippine Electrical Code, All grounding type receptacle outlets.
The resistance of the combined grounding system shall not exceed 5 ohms and shall be in accordance with the standards of the National Electrical Code, Philippine Electrical Code and all governing authorities having jurisdiction. All earthing cables shall where possible include for green and yellow PVC sheaths. The entire installation shall be free from improper grounds and from short circuits. Insulation and earth loop impedance tests shall be made in the presence of the Engineer. Each panel shall be tested with mains connected to the feeder, branches connected and switches closed, all equipment in place and permanently connected. Each individual power feeders shall be tested with the power equipment connected for proper and intended operation. In no case shall the insulation resistance be less than that allowed by the Regulation for Electrical Equipment of Buildings; failures shall be corrected in a manner satisfactory to the Engineer.
13.21 POWER TRANSFORMERS General Transformer shall be designed, manufactured, and tested in accordance with all the latest applicable IEC 76, B.S. 171 or any other equivalent international standard and shall be UL listed. The specification provides for design, manufacture, test at Manufacturer's Works in the presence of the contactors representatives, suitable packing, transportation and off-loading at site of works or stores in satisfactory condition. Type Transformer shall be installed outdoors, pad-mounted, dead front, radial feed, two-winding and designed for continuous operation at rated kVA, for 24 hours a day, 365 days a year operation, with a temperature rise not exceeding 45oC measured by thermometer and of the winding temperature rise not excepting 50oC as measured by resistance. The transformers shall be of the naturally cooled, outdoor, oil immersed, hermetically sealed type. The normal voltage ratio of the transformers at normal tapping and on full load and the transformers vector reference and percentage impedance voltage shall comply with IEC 76 or BS171 or equivalent standard and with local utility company requirements. Taps
The windings of the transformers shall have tappings at "2.5%, "5% and "7.5% i.e. Seven tapping positions operated by an off-circuit tapping switch with clearly marked position indicator. Locking facilities shall be provided and such lock can be inserted only when the switch is on a definite tap. Lock with two keys shall be supplied for each transformer. Duty Under Fault The transformers shall be capable of sustaining a three phase symmetrical short circuit on the LV side with the fault power maintained on the H.V. side without damage or distress for a duration of three seconds. Core The core shall be constructed of the best quality low loss cold rolled grain oriented steel lamination. The fluse density in any part of the core shall not exceed 1.6 Tesla (16000 lines per sq.mm) at normal voltage and frequency. Typical loss curve (iron loss v/s magnetic flux density) at 60Hz for proposed lamination along with steel manufacture's name, type and compositions of the offer. The core plates shall be insulated from one another to reduce the core loss to a minimum and the core shall be held together by bolts and damping plates all of which shall be adequately insulated. The completed core shall be provided with lifting eyes to facilitate its removal from the transformer tank and shall be adequately braced and supported to prevent movement during transit or in service. It shall not be mechanically connected to the cover. Windings All transformers windings should be manufactured from electrolytic copper having a minimum conductivity of 99.9% and as per relevant international standards. The maximum current density in both H.V. and LV. windings shall not exceed 2 Amps per sq.mm at normal operating conditions. All windings shall be fully insulated to IEC.76 for standard insulation level and for the specified system voltage. Basic Insulation Level The basic insulation of transformer shall be according to the latest relevant lEC specification and shall be designed to withstand the rms power frequency test voltage and peak Kv for the impulse test voltage as detailed in Particular Electrical Specification. Cable Boxes / Termination The transformer shall have H.V .and LV. cable boxes. The H.V cable box shall be with brass wiping gland and sockets suitable for 3 core PILC SWA and XLPE/SWA/PVC stranded cable up to 185 sq.mm. The L.V cable boxes with glands shall be suitable for the following sizes of cable and / or Busbar system:
11- single core 630 sq.mm PVC/PVC or XLPE/PVC copper cables for 1500KVA transformers 7-single core 630 sq.mm PVC/PVC or XLPE/PVC copper cable for 1000 KV transformers 4-single core 630 sq.mm PVC/PVC or XLPE/PVC copper cable for 500 KVA transformers
The cable boxes shall be suitable for approved type of heat shrinkable terminations. H.V. and L.V bushings shall be replaceable with out difficulty. Replacement of bushings shall not require the removal of top cover which means manhole should be provided on top cover to facilitate replacement of bushings. Bracing The transformer shall be braced to withstand the mechanical forces that will result from a bolted fault on the transformer secondary terminals. The forces shall be based on an infinite bus on the primary unless otherwise indicated. Earthing Terminal Each transformer shall have two separate earth terminals for connection to the substation earthing system. Fittings The transformer shall be completely assembled with all its fittings and supplied with first fill of oil. Fitting on the transformer shall be according to the type of transformer offered and the following shall be considered as minimum requirements: For Hermatically sealed Type: Oil level gauge. Dial type thermometer with maximum reading pointer for measuring oil temperature. Thermometer pocket with thermometer for measuring oil temperature. Rating and diagram plates as per the latest relevant IEC requirements. Main tank drain valve and plug. Tank earthing terminals.
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Tank Finish
Lifting eyes for lifting of core. Over pressure relief device/vent/valve. Lifting lugs for lifting of whole transformer. Oil filling hole and cap. Cable box and support for H.T& L.T side or bushing as applicable. Core earthing Terminals Oil sampling bottles Stainless steel name plates.
The process of painting of mild steel parts shall ensure that no corrosion takes place under the prevailing climatic conditions. All the metal parts of the transformer shall be sand blasted to class SA 2.5 or blast cleaned. Then the tank shall be degreased with an alkalic spray wash and zinc phosphatised. The first coat shall be zinc epoxy primer. The second shall be an undercoat of epoxy high build and final top coat shall be epoxy. The final color shall be light grey in shade. Gaskets All the gaskets used for sealing the tanks and connected external parts shall be made from suitable materials that totally prevent the leakage of oil and ingress of humidity and air to the oil and winding under all operating conditions. The manufacturer should present sufficient information and details about the type, thickness, materials etc. of the gaskets with his offer. Relays and Instruments The protection and metering devices shall transmit their action to the control panel at medium voltage switchgear. The action may include the following: Measurement; Alarm signal; and
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Trip (de-energizing the transformer by opening the proper circuit breaker).
Signaling and tripping shall be transmitted by means of a direct or alternating current. The contacts shall have adequate interrupting capacity. Relays and instruments shall include the following components. Winding Temperature Indicator (Thermometer)
The transformer shall be provided with a device for indicating the winding temperature. The device shall have a dial type indicator in addition to a pointer to register the highest temperature measured. Two separate sets of make and brake contacts, one to operate on alarm and the other to trip the main circuit breakers shall be provided. Additional contacts shall also be provided for control of fans and pumps and for alarm indication. The tripping contacts shall be designed to close at temperatures between 60C and 120C whilst temperature and alarm contacts at temperature between 50 C and 100 C temperature. Both shall reopen when the temperature has fallen by 10 C below the preset level. All contacts shall be adjustable and readily accessible. It shall be possible to move the pointers by hand in order to test the alarm, tripping and cooling circuits. A setting scale shall be provided. Alarm and trip contacts shall be designed for making or breaking the necessary loads. Three thermometers will be required for the transformer. Indicating Thermometer for Oil Temperature
The thermometer shall be of the dial type mounted approximately 1,500 mm above ground level. The dial shall have an indicating pointer with manual reset feature, and a set of ungrounded normally-open contacts for operating an annunciator. The temperature element shall be located in the path of the hottest oil. A well shall be provided so that the thermometer bulb can be removed without lowering the oil in the transformer. Pressure Relief Device
The relief device installed at the main tank and the OLTC shall automatically relieve excessive pressures caused by internal disturbances. Ungrounded normally-open contact shall be provided for the relief device to indicate operation of the device. Tests All transformers shall be subject to routine tests including oil leakage according to the relevant specifications. The transformers shall be tested under a pressure of oil above normal oil level for a period not less than 48 hours. Certified copies of the type and special test certificates shall be supplied along with offer. If approved type and special test
certificates pertaining to identical transformers are not enclosed with the offer, the engineer reserves its rights to ask for short circuit withstand test, impulse withstand test and temperature rise test to be carried out in presence of the engineer at the manufacturer's works. The supplier shall make provision in his offer to bear all costs that incurred in carrying out these tests. However cost towards travel accommodation and miscellaneous costs of the engineer shall be included in the quoted price. Manufacturer to provide the stage wise inspection and production schedule. Routine tests would comprise the following: a) b) c) d) e) f) g) h) i) k) Measurement of winding resistance Ratio, polarity, and phase relationship Impedance voltage Measurement of load losses Measurement of no-load losses Measurement of no-load current Insulation resistance Oil leakage test, Voltage test Heat run test for transformer of each rating
Rejection Offers without guaranteed particulars filled in will be rejected. Transformers for which the actual losses at the time of testing exceed 15% of individual losses and 10% of total loss will be rejected. Noise Level Every care shall be taken to ensure that the design and manufacture of all transformers with their accessories shall be such as to reduce noise and vibration to acceptable level.
The transformer shall be subjected to noise measurement as per IEC 551. The Contractor is required to submit noise measurement test certificate along with the offer. Guaranteed Particulars Contractor is to give the following details for transformer: Sr. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Description Continuous rating under the ambient conditions Equivalent BSS Continuous rating approx. Supply of voltage System highest voltage Normal voltage ratio at normal tapping Method of cooling BSS Vector Group Maximum temp. rise at normal loading a. Top oil b. Winding Impedance Voltage % Impulse Level Iron loss at normal voltage x tapping Copper loss at normal full load at 75 C Magnetizing current at normal voltage as percentage of full load current Efficiency 125% load at 0.8 P.F. 100% load at 0.8 P.F. 75% load at 0.8 P.F. 50% load at 0.8 P.F. Regulation at 0.8 P.F. lagging Regulation at 1.00 P.F. Resistance of winding at 75 C a. HV winding Ohms/phase approx. b. LV winding Ohms/phase approx. Thickness of tank plate a. Sides b. Bottom c. Top d. Fins Total oil required approx. Oil grade Weight a. Core winding approx. b. Complete transformer including oil Overall dimensions (approx.) a. Height b. Length
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14.
15. 16. 17.
18.
19. 20. 21.
22.
c. Warning Signs
Width
The supply shall also include warning signs for the enclosure of transformers having a nominal rating of 500 volts and above; except when such equipment is guarded by a fence then the signs shall be mounted on the fence. Metal signs shall have the legend DANGER HIGH VOLTAGE in two lines of letters of nominal 75 mm height. The Contractor shall provide the number of signs required so that it will be readable from each accessible side of transformer enclosure or fence. Warning signs shall conform to the requirements of PEC and the Local Utility Company. 13.22 MOTORS
LOW-VOLTAGE MOTORS A. General Specifications
1. Motor type Unless otherwise specified, the electric motor shall be Squirrel Cage, Totally Enclosed FanCooled (TEFC).
2. Voltage Rating All motors up to 750 horsepower shall operate on a 460 Volts, 3 phase, 60 Hz power.
3. Enclosure and Ingress Protection All motors shall be TEFC and waterproof. Ingress protection rating shall be IP 56/NEMA 4/4X. For applications where motors may become submerged, rating shall be IP 68.
4. Noise All motors shall operate at a noise level less than 85 decibels A-weighted mean sound pressure level (dBA). The specified noise limit applies for a reference distance of one meter (for all conditions). 5. Duty Cycle Low voltage motors shall be rated for continuous duty running at full rated load. 6. Motor fans Motor fans shall be bi-directional, corrosion-resistant and non-sparking.
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B. Electrical Specifications
1. Starting Squirrel cage motors shall be suitable for direct on line starting. All winding ends however, shall be brought out. Each motor shall be rated for the maximum frequency of starting. Starting or stall current shall not be greater than 7 times the motor full load current. Any requirement for soft starters or variable frequency drives for motor starting however, shall be properly verified.
2. Power Connections For motors above 5.0 kW, both ends of each motor winding shall be brought out to the terminal box such that the motor is suitable for Star/Delta starting. Terminal boxes to be of adequate size and shall be easily accessible in the installed position. Cable entry to the terminal box shall be from at least two directions and terminating shall be into suitably robust terminals or studs.
3. Thermistor A PTC type Thermistor shall be fitted to all motors rated above 22 kW (30 Hp). Thermistors may be fitted to motors with variable speed drives (frequency converters).
4. Motor Protection The motor protection circuit shall employ an auto resetting overload.
5. Service Factor For water supply pumping stations, the motor shall have a service factor of 125%. For all other applications, a service factor of 115% shall be used.
C. Mechanical Specifications
1. Motor Frame and Nameplate Frame shall be Cast Iron. Only corrosion-resistant stainless steel 316, rigid heavy-duty nameplate shall be affixed on the frame. The plate shall not be locally fabricated and shall come with the motor package. Motor nameplate shall conform to NEMA and NFPA requirements.
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2. Bearing Bearing shall be heavy-duty, sealed and can provide L10 rating life of 100,000 hours minimum at continuous duty. If bearings are oil lubricated, a visual oil level indicator shall be provided.
3. Temperature Rise and Winding Insulation Class All motors supplied shall be insulation class F for B temperature rise. Entire wound and insulated stator shall have a coating of epoxy paint on all air gap surfaces to protect against moisture and corrosion. Motors shall be suitable for 10 starts per hour.
4. Winding Material Winding shall be copper material only.
5. Lifting Low Voltage Motors may be required to have a means of lifting (as applicable), preferably built into the frame.
D. Energy Efficiency The following criteria shall be followed for all electric motors: 1. The latest issue of the NEMA Premium Energy Efficiency Motor standards shall be the preferred energy efficiency reference for low voltage motors up to 500 HP rating (refer to the NEMA Premium Efficiency Table for each HP rating-TEFC motors). LV Motors above 500 HP shall have an efficiency of at least 93% at the specified operating point. 2. US EPAct and CEMEP energy efficiency standards (EFF1 motor efficiency class) may also be used. In no case, however, shall an EFF2 and EFF3 class motor be supplied/installed in any project. 3. For optimum efficiency, the motor/s should operate in a range within 90% to 100% of its rated power (over sizing motors shall be avoided since efficiency and power factor drop in motors running below load rating).
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Nominal Efficiencies For "NEMA Premium" Induction Motors Rated 600 Volts Or Less (Random Wound) HP 1 1.5 2 3 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 200 250 300 350 400 450 500 Totally Enclosed Fan-Cooled 6-pole 4-pole 82.5 85.5 87.5 86.5 88.5 86.5 89.5 89.5 89.5 89.5 91.0 91.7 91.0 91.7 91.7 92.4 91.7 93.0 93.0 93.6 93.0 93.6 94.1 94.1 94.1 94.5 94.5 95.0 94.5 95.4 95.0 95.4 95.0 95.4 95.8 95.8 95.8 96.2 95.8 96.2 95.8 96.2 95.8 96.2 95.8 96.2 95.8 96.2 95.8 96.2 2-pole 77.0 84.0 85.5 86.5 88.5 89.5 90.2 91.0 91.0 91.7 91.7 92.4 93.0 93.6 93.6 94.1 95.0 95.0 95.4 95.8 95.8 95.8 95.8 95.8 95.8
MEDIUM-VOLTAGE MOTORS A. General Specifications
1. Motor type Unless otherwise specified, all medium voltage electric motors shall be Squirrel Cage, Totally Enclosed Fan-Cooled (TEFC).
2. Voltage Rating Unless otherwise specified, all motors beyond 750 HP shall be classified as medium-voltage motors and shall operate on a 2,300 Volts, 3 phase, 60 Hz power.
3. Enclosure and Ingress Protection
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All motors shall be TEFC and waterproof. Ingress protection rating shall be IP 56/NEMA 4/4X. For applications where motors may become submerged, rating shall be IP 68.
4. Noise All motors shall operate at a noise level less than 85 decibels A-weighted mean sound pressure level (dBA). The specified noise limit applies for a reference distance of one meter (for all conditions). 5. Duty Cycle Unless otherwise specified, medium voltage motors shall be rated for continuous duty running at full rated load. 6. Motor fans Motor fans shall be bi-directional, corrosion-resistant and non-sparking. B. Electrical Specifications
1. Starting All medium voltage motors shall be provided with a soft starter or a variable frequency drive with by-pass option for RVAT control in case of soft starter or VFD failure. Each starter is to have isolation, over current and thermal protection, a contactor, control voltage C/B and terminals for output power and control cables. The power wiring shall be red, white and 2 blue. The minimum size of all control wiring shall be 2.0 mm . The over current and thermal protection shall be coordinated so that both motor and starter equipment is protected. Starting or stall current shall not be greater than 7 times the motor full load current. Process display of every Soft Starter/Variable Frequency Drive shall be located in front of each compartment.
2. Thermistor/Temperature Sensors A PTC type Thermistor shall be fitted to all medium voltage motors. Thermistors may be fitted to motors with variable speed drives (frequency converters). Temperature sensors may also be fitted.
3. Motor Protection The motor protection circuit shall employ an auto resetting overload.
4. Service Factor For water supply pumping stations, medium voltage motors shall have a service factor of 125%. For all other applications, the service factor of 115% shall be used.
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C. Mechanical Specifications
1. Motor Frame and Nameplate Frame shall be Cast Iron. Only corrosion-resistant stainless steel 316, rigid heavy-duty nameplate shall be affixed on the frame. The plate shall not be locally fabricated and shall come with the motor package. Motor nameplate shall conform to NEMA and NFPA requirements.
2. Bearing Unless otherwise specified, bearings for medium voltage motors shall be heavy-duty, sealed and can provide L10 rating life of 100,000 hours minimum at continuous duty. If bearings are oil lubricated, a visual oil level indicator shall be provided. Resistance-type detectors shall also be fitted for bearing and stator temperature protection.
3. Temperature Rise and Winding Insulation Class All motors supplied shall be insulation class F for B temperature rise. Entire wound and insulated stator shall have a coating of epoxy paint on all air gap surfaces to protect against moisture and corrosion. Unless otherwise specified, medium voltage motors shall be suitable for 10 starts per hour.
4. Winding Material Winding shall be copper material only.
5. Lifting Low Voltage Motors may be required to have a means of lifting (as applicable)., preferably built into the frame.
D. Energy Efficiency The following energy efficiency criteria shall be followed for all medium voltage electric motors: 1. Efficiency shall be at least 93% at the specified operating point. 2. For optimum efficiency, the motor/s should operate in a range within 90% to 100% of its rated power (over sizing motors shall be avoided since efficiency and power factor drop in motors running below load rating).
Electric Motor data The following data shall be submitted by the supplier/vendor for each type of motor: 1. Manufacturer 2. Rated full load horsepower and Rated volts
3. Number of Phases and Frequency in Hertz 4. Full load amperes (FLA) 5. Locked rotor amperes (LRA) at rated voltage or NEMA code letter. 6. Nominal speed at full load (rpm) 7. Service factor 8. NEMA design letter and machine type (TEFC) 9. Electric Motor test report for energy performance from the manufacturer 10. Operations and Maintenance Manual Overall Efficiency test compliance All motors shall comply with the IEC/EN 60034-2-1 Efficiency Test method standard. Warranty B. A minimum one-year manufacturers warranty shall be provided for all motors. Warranty shall
commence from the date of acceptance.
13.23 WIRES AND CABLES Low Voltage Wires and Cables Wire and cable conductor sizes are designated by square millimeters (mm2). Conductors shall be copper. Insulated conductors shall indicate the date of manufacture imprinted on the wire insulation with other identification. Wire and cable manufactured more than 6 months before delivery to the job site shall not be used. Conductor identification shall be provided within each enclosure where a tap, a splice or a termination is made. Wires shall be insulated for 600 V AC type THHN, unless otherwise indicated. Only wires with W in the type designation shall be used in wet or damp locations. Ground wires shall be green insulated type THW or PVC. Unless otherwise indicted, conductors for 600 Volt wires and cables shall be at least 3.5 mm2. Mains/Power Cable
o
Mains cables shall be THHN single core stranded copper cables at 90 C temperature rating min. (unless otherwise specified or approved by the Engineer) Motor Cable
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Motor cables shall have a minimum cross section of 3.5 mm and shall be a multicore o or single core PVC insulated, PVC sheathed multi stranded copper cable at 75 C temperature rating minimum. (unless otherwise specified or approved by the Engineer) Control Cable
Control cables shall be PVC insulated multicore cables having multi stranded copper 2 conductors with a minimum cross section area of 1.5 mm min. All control cables shall o be rated for a minimum of 600/1000 V and 75 C. Signal Cable
General purpose signal cable 4-20 mA or any other signals for electronic devices shall be multicore, having stranded copper conductors with a minimum cross sectional area 2 of 1.5 mm (unless otherwise specified and approved by Engineer) and be PVC insulated, overall screened, PVC outer sheath construction with a maximum working voltage of 110 VAC/150VDC. Instrumentation cable shall be provided in accordance with the following requirements. Attenuation loss shall not be more than 1.2 dB/km at 10 KHz frequency Insulation resistance measured at 100V DC at 20C Among conductors shall not be less than 10,000 M ohm-km Between each conductor and earth shall not be less than 10,000 M ohm-km Conductor resistance measured at 20C shall not be more than 16.5 ohm/km
High/Medium Voltage Terminations Medium and high voltage terminations shall conform with IEEE 48 Class I, and shall be modular molded rubber type. The manufacturer shall provide all components, materials and complete instructions for service voltage 35 kV outdoor and indoor type. High/Medium Voltage Wires and Cables Copper conductors, 35 kV 133% insulation level, and shall be shielded. Insulation shall be cross-linked polyethylene XLPE, and shall be PVC jacketed. Wires and cables shall be obtained from any of the following brands or approved equivalent. Connectors and Terminals Wire connectors shall be for use with copper conductors. Tape
Plastic insulating tape shall be capable of performing in a continuous temperature environment of 80C. Pull Wire Pull wire shall be 2.0 mm2 hot-dipped galvanized steel or plastic having minimum tensile strength of 91 kgs, in every empty duct. Minimum slack shall be left at each end of pull wires. Mechanical Connectors Mechanical connector shall not be required at thermic weldments. 13.24 LIGHTING AND SMALL POWER General The Contractor shall furnish, install and commission the indoor and outdoor lighting systems and all its related appurtenances, complete and operable, in accordance with the Contract requirements. The works shall include lighting fixtures, mounting accessories, lighting poles and foundations, and other devices necessary for the complete operation of the lighting system. General area lighting is to be located to allow access for relamping without the use of temporary scaffolding. Suitable means of access are ladders not exceeding 2.1 M in height, mobile work platforms or extension handles and lamp changer heads. Lighting fixtures and its associated devices shall be manufactured and tested in accordance with the applicable standards of ANSI - and the standards of the Certified Ballast Manufacturers Association. Submittals The Contractor shall submit, for Manila Waters approval, technical brochures and manuals, and shop drawings for the following components including the required information. Shop drawings and catalogue data, including mounting support details. Catalogue literature for each fixture.
Materials of construction, type of diffusers, hardware, gasketing, reflector and chassis, finish, and ballast. Photometric data, including coefficient of utilization, average brightness, candlepower distribution curve, and lumen output chart.
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Pole-mounted fixtures, including complete data on the pole material, finish, handholes, anchoring, and fixture attachment; including concrete footing/foundation details. Ballast catalogue data indicating lamp wattage, input watts, sound rating, power factor, and type of ballast. Data for outdoor ballast shall be including low temperature starting characteristics. Photocell data submittal shall indicate switching capacity, the means of adjusting the lighting pickup level, and enclosure. Substitution for specified fixtures shall be subject to Manila Waters evaluation of the products construction quality, light distribution, appearance, and maintenance. Product Requirements All fixtures shall be factory assembled/tested, and shall be furnished as completed sets including mounting accessories ready for field installation. Fixtures shall be pre-wired with leads at least 2 mm2 for connection to building circuits. Lighting fixtures shall be maintained in their original cartons from the manufacturer until the time of installation. Fixtures poles shall be stored on blocks above grade until the time of installation. Fixture lenses, diffusers, and reflectors shall be cleaned before the system demonstrations. Where finishes in fixture trim including poles and brackets are damaged, it shall be refinished at no additional cost to Manila Water. Exterior Fixtures Exterior fixtures with its mounting pole and bracket shall be capable of withstanding 160 kph winds without damage. Exterior fixtures shall have corrosion-resistant hardware and hinged doors or lens retainer. Lighting for outdoor shall be high pressure sodium lamps mounted on steel structures or steel poles (hot dip galvanized). Automatic switching circuits shall be provided for outdoor lighting. Switching circuits shall have an automatic-manual changeover switch. Automatic sensors shall be of a solid state light sensitive type. Interior Fixtures Interior fluorescent fixtures without diffusers shall be furnished with end plates. Where diffusers are required, they shall be of high molecular strength acrylic. Minimum thickness of the acrylic shall be 3.2 mm for all diffusers, except those on 0.37 m2 fixtures that will be 4.7 mm thick. Fluorescent lamps shall be 220V, 60 Hz, T-5 with power factor 0.9 lagging or better.
Lighting for offices, control room, rest rooms, etc. shall be provided by fluorescent lamps T5 model, either directly mounted to the ceiling or by pendant suspension. For 6 meters above, high bay lighting or approved equivalent shall be used. Low bay and high bay lighting fixtures, which will be used with metal halide lamps in polymeric lamp containment barriers, shall be UL 1572 listed and CSA certified for indoor installation. Each fixture shall consist of the following: Die-cast aluminum ballast housing with electro-coat gray paint finish; Alzak finished reflector; Enclosed and gasketed optics; Mogul base socket; and Safety chain provision.
Battery-type self-powered emergency lights shall be provided where indicated. It shall be equipped with automatic power failure device, test switch pilot light and fully automatic high/low trickle charger in a self-contained power back. The batteries shall be sealed wet or gel electrolyte type, able to operate unattended, and require no maintenance including additional water for within a minimum period of 5 years. Photoelectric Cells Hermetically sealed cadmium sulphide cell rated 240 volts AC, 20 amperes, 2 pole with single throw contacts rated 1800 volts A. The switch shall be mounted in a cast weatherproof aluminum housing with swivel arm designed to mount on or beside each luminare. The switch shall turn on below 30 lux and off at 30 to 100 lux. Time delay shall prevent accidental switching from transient light sources. A directional lens shall be mounted in front of the cell to prevent fixed light sources from creating a turnoff condition. Switch shall be aimed according to manufacturers recommendations. Ballasts Ballasts for fluorescent fixtures in office areas shall have Class "A" sound rating. Such ballasts shall be of the low loss type. All ballasts shall be UL listed, with high power factor, thermally protected and Class P. Primary ballast voltage shall be suitable for use in the branch circuits required in the Contract. Ballasts for high intensity discharge (HID) luminaries shall be UL listed; thermally protected, with constant wattage auto-transformer (CWA) or regulator and high power factor type. Ballast shall be designed to operate on the voltage system to which they are connected. Single lamp ballast with a minimum starting temperature of 30C shall be provided. Ballast shall be constructed so that open circuit operation will not reduce their average life.
Poles Steel poles shall be designed for wind loading of at least 160 kph. Poles shall be pedestalbased type, complete with anchor bolts and designed for use with underground supply conductors. Steel poles shall be made from at least 5 mm thick steel with minimum yield/strength of 3,380 kg/cm2. The steel shall be hot-dipped galvanized as per ASTM A-123 factory finish. A pole shall be provided with grounding connection designed to prevent electrolysis when used with copper ground wire. Anchor Base Assemblies Anchor bolts shall be steel rods with minimum yield strength of 3,520 kg/cm2. The top 305 mm of the rod shall be galvanized as per ASTM A-153. Anchor base for steel poles shall be structural quality hot-rolled carbon steel plate with minimum yield strength of 2,530 kg/cm2. Distribution System The circuits for lighting and power outlets shall be from a 460/380/220V, 3-phase, 4-wire system with the neutral directly grounded. High pressure discharge lamps shall be 220V, 60 Hz. Illumination Levels The standard illumination levels shall be based on the latest edition of PEC. Emergency Lighting Emergency lighting shall be provided where necessary in order to secure the minimum lighting required with respect to equipment maintenance and personnel safety. For emergency lighting, fixtures with built-in batteries shall be used with sufficient battery power to give one hour continuous running during power failures. Emergency lighting shall be arranged so as to immediately switch on automatically in the event of power failure. Socket Outlets All outlets located outside the plant shall be rated to IP 56 except in offices.
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1-phase 220 V 2 flat pin + E Wall Switches Wall switch shall be of closed flush or surface mounting tumbler type, single pole 300v, 10A or 15A, and shall be fully recessed within boxes fitted with plates for covering. 13.25 INTERIOR WIRINGS General The Contractor shall provide all interior wiring systems, complete in place and operable, in accordance with Contract requirements. The works shall include supply and installation of all the necessary materials, equipment, devices, mounting supports and accessories. Submittals The Contractor shall submit, for Manila Waters approval, technical brochures and manuals, and shop drawings indicating information on the following components. Circuit breakers Panelboards Device plates Insulated conductors
Wiring and Cables Wires and cables shall meet the applicable requirements of Philippine Electrical Code for the type of insulation, jacket, and conductor specified or indicated. Wires and cables manufactured more than 12 months prior to date of delivery to the site shall not be used. Properties of the wires, cables and its components works shall be as follows: Conductors
Conductors shall be stranded. Unless indicated otherwise, conductor sizes shown are based on copper. Minimum conductor size for power and lighting branch circuits shall be 3.5 mm2 for Class 1 remote-control and signal circuits, 2.0 mm2 and for Class 2 low-energy remote-control and signal circuits, 2.0 mm2. Insulation
Unless specified or indicated otherwise, all power, lighting and control wires shall be rated 600 V AC, type THHN; except that grounding wire may be type THW or PVC insulated. All wires run through cable tray shall be double insulation as per specification in previous section.
Bonding Conductors
For sizes 8.0 mm2 and smaller, bonding conductors shall be solid bare copper wire as per ASTM B1. For sizes 14 mm2 and larger, bonding conductors shall be stranded bare copper wire as per ASTM B8, Class B. All exposed bonding wires/conductors shall be green insulated. Panelboards Panelboards for use as service disconnecting means shall be circuit breaker equipped. Design shall be such that any individual breaker can be removed without disturbing adjacent units or without loosening or removing supplemental insulation supplied as a means of obtaining clearances as required by UL. Where space only is indicated, provisions shall be included to allow future installations of breaker sized as indicated. All panelboard locks included in the project shall be keyed alike. Directories shall be typed to indicate load served by each circuit and mounted in a holder behind transparent protective covering. Requirements for panelboard components shall be as follows: Panelboard Buses
UL-listed bus current ratings shall be provided as indicated. Bus bars shall be supported on bases independent of the circuit breakers. Main buses and back pans shall be designed so that breakers may be changed without machining, drilling, or tapping. An isolated neutral bus shall be provided in each panel for connection of circuit neutral conductors. A separate ground bus marked with a green stripe along its front and bonded to the steel cabinet for connecting grounding conductors shall be likewise provided. Circuit Breakers
Thermal magnetic type with interrupting capacity shall be provided as indicated. Breaker terminal shall be UL listed as suitable for the type of conductor provided. Installation of plug-in circuit breakers shall not be permitted. Multiple breakers shall be common-trip type with a single operating handle. Breaker design shall be such that an overload in one pole automatically causes all poles to open. Phase sequence shall be maintained throughout each panel so that any three adjacent breaker poles are connected to Phases A, B, and C, respectively. Circuit breaker for general purpose convenience outlet shall be ELCB type rated at 30mA.
13.26 CONDUITS AND BOXES All conduits for power, control, instrumentation and lighting power circuits for exposed installations shall be rigid galvanized steel conduit with threaded fittings 20mm (3/4in) conduit shall be minimum size used for exposed work and 25mm (1 in0 conduit shall be minimum for embedded work. All conduits for power, control, instrumentation and lighting circuits for corrosive atmosphere installations shall be rigid and galvanized steel conduit PVC coated including threaded fittings as required. In general, power and control cables may be run in the same conduits provided the cable insulation voltage rating is identical. Rigid Steel (RSC) Conduit and Intermediate Metal (IMC) Conduit Rigid Steel (RSC) Conduit and Intermediate Metal (IMC) Conduit shall be mild steel, hot-dip galvanized inside and out. RSC and IMC to be supplied under this Contract shall be manufactured in accordance with ANSI C80.1 - Rigid Steel Conduit, Zinc Coated, and UL6. Rigid Non-Metallic Conduit Rigid non-metallic conduit shall be Schedule 40 PVC and sunlight resistant. Rigid PVC conduit to be supplied under this Contract shall be manufactured in accordance with NEMA TC-2 - Electrical Plastic Tubing and Conduit, and UL-651 - Standard for Rigid Non-metallic Conduit standards. Liquidtight Flexible Conduit Liquidtight flexible conduit shall be constructed of a flexible galvanized metal core with sunlight resistant thermoplastic outer jacket. Liquidtight flexible conduit shall be manufactured in accordance with UL-360 - Steel Conduits, Liquid-Tight Flexible. Liquidtight flexible conduits and fittings shall be AFC, BLISS brand or approved equal. PVC coated gray color flexible conduits shall be used for the final connection to removable field apparatus such as motors, RTD probes and the like. Conduit installed outside shall be stabilized against ultra violet light. Where mounted on moving parts of machinery or where subject to mechanical damage the conduit shall be flexible PVC covered galvanized steel.
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All flexible conduits shall be terminated in purpose built glands. Fittings and Boxes Boxes for equipment requiring more than 300 mm length of terminals shall be fitted with a door. Reference shall be made to the section on SWITCHBOARDS for details on manufacture, equipment, wiring, labeling etc. In wet processing areas boxes shall be made of stainless steel. They shall be mounted at a normal working height with a minimum floor clearance of 300 mm. Cast Metal Boxes and Malleable Iron Fittings All fittings and boxes for use with galvanized steel conduit shall be of malleable iron or cast gray-iron alloy with zinc plating threaded type with five full threads. PVC Fittings and Boxes All fittings for use with rigid non-metallic conduit shall be PVC, solvent welded type. Boxes shall be PVC or fiberglass reinforced polyester (FRP). Sheet Steel Boxes Steel boxes for outlets, switches and junction boxes shall be of pressed sheet steel, hotdipped galvanized, gauge #16 minimum. Cable Trays Cable tray systems shall be composed of straight sections, angle couplers, reducers, fittings, and accessories as defined in the latest NEMA Standards publication VE-1 Ventilated Cable Tray. The cable tray and fittings shall be hot-dipped galvanized steel. It shall be ladder type with 150 mm spacing with a minimum loading depth of 76 mm and nominal width as indicated. When required in corrosive locations, cable trays shall be stainless steel. Where exposed to sewer or other environment that may cause corrosion, suitable noncorrodible materials shall be utilized to prevent corrosion. All nuts, bolts, and washers shall be stainless steel 304.
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Loading capacities shall meet NEMA weight classification with a safety factor of 1.5.
13.27 INSTRUMENTATION AND CONTROLS General Instrumentation for controlling and monitoring the process shall be of a robust design and manufactured by recognized supplier. The manufacturer shall be represented in the Philippines having both spare parts and engineering support. All field instrumentation and junction boxes shall be rated to IP65. Analogue signals shall be 4-20mA dc for transmission on a 2 wire system. Digital signal s shall be of the 24V DC PNP type (unless otherwise specified or approved by the Engineer). Sensors installed to give signals for totalizing shall give digital output pulses. The generation of pulses shall be integral within the unit together with calibration and output signal pulse rate and width adjustment. Conversion of analogue signals to pulses by either remote devices or software will not be accepted. These sensors are usually required to give both analogue and digital signals such as flow and volume, kW and kWh. Submittals The Contractor shall submit, for Manila Waters approval, technical brochures and manuals, and shop drawings for the following components including the required accessories. Flow, Level and Pressure Measuring/Indicating Devices Flow, Level and Pressure Switches Transmitters and Transducers (Where Applicable) Panel Mounted and Miscellaneous Field Instruments Instrumentation Panel Programmable Logic Controller (PLC) Computers (PC) and Printers Marshalling and Junction Boxes Wires and Cables Instrument Loop and Wiring Termination Diagrams Tests and Calibration Certificates
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Mounting Supports. Manholes/Handholes Operating and Maintenance Manuals Start-up and Operating Spares
An Instrument List for each location giving tagging, application location and range of information shall be submitted to Manila Water for review and approval. The instrument and control systems shall be sourced from a manufacturer that has been producing similar equipment for at least 5 years. When requested by Manila Water, an acceptable list of installations with similar equipment shall be provided to demonstrate compliance with this requirement. Devices Subject to Manual Operation Each device subject to manual operation shall be operated at least five times, demonstrating satisfactory operation each time. Tests shall include operation of the emergency shutdown system and controls. All signals for manual operation must have proper indication. Wiring All instrumentation and control wirings and terminations shall be loop and continuity checked prior to termination. System functional testing and operation shall not be initiated unless all wirings have been fully checked and tested. The Contractor shall replace all defective wires and cables identified during testings at no additional cost to Manila Water. Product Requirements Unless otherwise specified, all instrumentation and control devices shall be designed according to the following requirements: Solid-state electronic type
Transmission signal shall be 4 to 20 mA DC and 1 to 5 volts. Zero based signal transmission shall not be permitted. The latest concept of the manufacturers design All necessary power supplies shall be furnish as required
Transmitters with indication, in engineering unit, on the equipment or near the transmitter Aspects of materials and painting to withstand the installation environment bushed
Ease of maintenance and inspection Interchangeability of common devices and parts Protection from induced surge by lightning, including:
Protective level that does not interfere with normal operation, and lower than instrument surge Free from maintenance and self-restoring Suitable housing with proper grounding Individual grounding installation for all surge protectors
The manufacturer shall furnish accessories for installation, inspection, testing, operation and maintenance of the instrumentation and control systems. Standard factory tests and calibration shall be performed on devices and equipment to be supplied under this Contract. All tests and calibrations shall be in accordance with the applicable requirements of the latest approved edition of ANSI, IEEE, ISA and NEMA Standards. Magnetic Flow Meters The flow meter shall comprise an electromagnetic detector, power supply and converter providing an overall system accuracy of 1%. The flow meter shall feature bi-polar pulse technology. The flow meter shall measure a flow range of 0 to 100 ML/d and feature an accumulator with a single digit count of 10 kL. The detector shall have a stainless steel metering tube suitably lined to resist wear and corrosion. The whole of the detector unit shall be suitable for continuous submerged operation. The converter shall incorporate all range settings, zero settings and necessary controls. It shall produce a linear 4-20 mA analogue signal. The converter shall have a digital display to show the flow and quantity. The digital display shall have instantaneous flow in the units of ML/d and accumulator volume in units of ML. The converter shall be housed outside and adjacent to the flow meter pit in a weather protected cubicle. The converter shall be capable of accurately rejecting quadrative signal components and line voltage variations of 6 to 10%. An instrument panel for the flow meter shall be supplied adjacent to the motor control centre. The instrument panel shall have a numerical display with units of ML/d for flow and ML for the accumulator volume. The indicator shall be an eight-digit, 12 mm high, fluorescent discharge flush mounted panel meter. Signal cables between the detector head and the converter shall be screened to suppress interference and the entry at the detector head shall maintain waterproof protection of the coil enclosure. Electricity supply shall be derived from a double pole circuit breaker within
the switchboard or panelboard as shown on the drawings. The Contractor shall provide transformers required for operation of equipment at voltages other than 240 VAC. The Contractor shall use a calibrated flow simulator to test the converter and meter. The Contractors proposed testing procedure shall be fully detailed in the Schedule of Guaranteed Technical Information. Pressure and Level Transducers When required, pressure and level transducers, shall be an ultrasonic type transducer industrial class. Transducers shall be factory tested and calibrated prior to site delivery and installation.
Instrumentation Panel Instrument panels and desktop (PC) computers shall be provided to monitor and display the incoming and discharge flow. Such equipment shall be located in the pump station control room. The front shall be fabricated of heavy gauge steel of not less than 3.2 mm thickness with suitable bracing and turnbuckles. Other parts shall be fabricated from heavy gauge steel of not less than 3.2 mm thickness with suitable bracing and turnbuckles. An indicator showing process variable shall be mounted on the panel. Other necessary equipment shall be installed inside the panel. Doors with keying device shall be installed on the rear side of the instrumentation panel as maintenance access. Where indicated, nameplates with white plastic plate and engraved in black filled lettering shall be mounted on the panels. The panel shall be painted per section in low voltage switchboard. Wires leaving the panel shall terminate at barrier type terminal strips. All terminals shall be identified. At least 50% additional terminals shall be provided. All exposed fastening devices shall be nickel plated brass or stainless steel. The panel shall be factory tested prior to shipment and manufacturers test certificates shall be submitted to Manila Water. Field installation by the Contractor shall consist of fixing and setting the panel in place and making all electrical connections. Control Sensors and Equipment All field sensors shall be of industrial quality and entirely suitable for their intended purpose. All field sensors shall be constructed of a high impact non corrosive material or encased in stainless steel. Digital signals from sensors shall switch the DC control voltage in either a positive current driving mode (PNP type) or via clean contacts. Sensors having outputs of the PNP type
shall be 3 wires, and have protection against short circuits, overloads and switching of inductive loads. All sensors are to have LED indication to show the operated state. Proximity switch or photocell shall have a terminal box attached to the body. All field sensor types to be approved by the Engineer. Online Analyzers Dissolved Oxygen Analyzer Dissolved oxygen monitoring systems shall comprise a transducer, transmitter and interconnecting cable. The transducer assembly shall comprise the sensor and mounting hardware. Mounting hardware shall be provided for either rigid wall mounting, freely swinging suspended wall mounting or a floating installation with the float suitably anchored to a fixed location, as required by the application. The sensor shall be membrane covered amperometric type suitable for constant immersion, giving high O2 selectivity and minimal maintenance requirements. The sensor shall also incorporate an integral temperature sensor. Cabling between the sensor and transmitter shall be easily disconnected from the sensor using a plug-in connector to allow quick and easy substitution of sensors in the event of a sensor failure. Also the sensor can be an optical sensor working on the fluorescence quenching principle suitable for constant immersion giving minimum maintenance and maximum availability. The sensor shall compensate for fluid temperature and air pressure. Cabling between the sensor and transmitter shall be easily disconnected from the sensor using a plug-in connector to allow quick and easy substitution of sensors in the event of a sensor failure. The transmitter shall be microprocessor based and shall include an integral display and a simple push button user interface. The display shall indicate oxygen content and provide the option of displaying temperature if desired. The display shall be capable of displaying all error codes, process variables, configuration data and other internal values. Calibration shall be a simple procedure, requiring minimal operator input. Input power required will be from a 220VAC or 24 VDC supply. An analogue output shall be provided along with a digital output to indicate fault status. The analogue output shall be by 4-20 mA current loop and shall be configurable to be proportional to the measured value or follow a user specified curve. Fault status shall be indicated by an open collector output, indicating system or sensor error. The instrument shall give measurements at an accuracy of 0.5% of the measured value and have quick response time. Drift shall be no greater than 1% of full scale per month, such that sensor recalibration shall not be a frequent requirement.
PH/ORP Analyzer PH/ORP monitoring systems interconnecting cable. shall comprise a transducer, transmitter and
The transducer assembly shall comprise the sensor and any mounting hardware required. The sensor shall use a glass membrane electrode, the outer layer of which shall give high H+ ion selectivity, to supply an electrochemical potential dependent upon the PH/ORP value of the process fluid. The sensor shall be suitable for constant immersion, with minimal maintenance requirements. The sensor shall also incorporate an integral temperature sensor. Cabling between the sensor and transmitter shall be easily disconnected from the sensor using a plug-in connector to allow quick and easy substitution of sensors in the event of a sensor failure. The transmitter shall be microprocessor based and shall include an integral display and a simple push button user interface. The display shall indicate PH/ORP and provide the option of displaying temperature if desired. The display shall be capable of displaying all error codes, process variables, configuration data and other internal values. Calibration shall be a simple procedure, requiring minimal operator input. Input power required will be from a 220 VAC or 24 VDC supply. An analogue output shall be provided along with a digital output to indicate fault status. The analogue output shall be by 4-20 mA current loop and shall be configurable to be proportional to the measured value or follow a user specified curve. Fault status shall be indicated by an open collector output, indicating system or sensor error. The instrument shall give measurements at an accuracy of 0.5% of the measured value and have quick response time. Drift shall be no greater than 1% of full scale per month, such that sensor recalibration shall not be a frequent requirement. Chlorine Analyzer Measurement of total free chlorine residual is important to allow chlorine dosing to be controlled to ensure that effluent is adequately dosed to ensure satisfactory disinfection but not excessively dosed which is wasteful of chemicals. Total free chlorine monitoring systems shall comprise a transducer, transmitter and interconnecting cable. The transducer assembly shall comprise the sensor and any mounting hardware required. The system shall not require chemical reagents to make measurements. The sensor shall measure the concentration of free chlorine by amperometric principles. Total free chlorine shall be in the form of hypochlorous acid contained in the medium, which shall diffuse through the sensor membrane. Once inside the sensor, the hypochlorous acid is reduced to chloride ions (Cl-) at the cathode, whilst at the anode, silver is oxidized to silver chloride. A current flow results from the electron release at the cathode and electron acceptance at the anode. The current flow is proportional to the total free chlorine concentration in the medium under constant
conditions. The concentration of hypochlorous acid in the medium depends on the pH value. Accordingly, the sensor shall incorporate a pH sensor and the transmitter shall adjust the free chlorine measurement to compensate for pH. Cabling between the sensor and transmitter shall be easily disconnected from the sensor using a plug-in connector to allow quick and easy substitution of sensors in the event of a sensor failure. The transmitter shall be microprocessor based and shall include an integral display and a simple push button user interface. The display shall indicate free chlorine residual and provide the option of displaying pH if desired. The display shall be capable of displaying all error codes, process variables, configuration data and other internal values. Calibration shall be a simple procedure, requiring minimal operator input. Input power required will be from a 220VAC, 110 VAC or 18-30 VDC supply. An analogue output shall be provided along with a digital output to indicate fault status. The analogue output shall be by 4-20 mA current loop and shall be configurable to be proportional to the measured value or follow a user specified curve. Fault status shall be indicated by an open collector output, indicating system or sensor error. The instrument shall give measurements at an accuracy of 0.5% of the measured value and have quick response time. Drift shall be no greater than 1% of full scale per month, such that sensor recalibration shall not be a frequent requirement.
13.28 PROGRAMMABLE CONTROLLERS (PLC) General This specification has been developed to establish minimum requirements for a solid-state programmable controller designed to provide high reliability in industrial applications. The controller shall be supplied with the CPU, input/output scanner, inputs, outputs, memory, power supply, and all power and interface cables necessary to function as a complete and operable programmable controller system. Service The supplier shall provide operating instruction manuals with adequate information pertaining to the following: System specifications Electrical power requirements Application considerations Assembly and installation procedures Power up procedures
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Troubleshooting procedures Programming procedures Explanation of internal fault diagnostics Shut down procedures Recommended spare parts list
In cases where the programming is done by the supplier, the supplier shall provide a copy of all working programs on CD as well as a printed program listing. The supplier shall provide a customer training program designed to teach the customer's personnel in the understanding and application of the programmable controller. The training program shall include training manuals and "hands-on" programming experience on a programmable controller of a type similar to that provided by the supplier. The supplier shall have the capability to conduct on-site training programs at a location provided by the customer. Within the enclosure all I/O racks, processor racks, and power supplies shall be grounded to meet the manufacturer's specifications. Design Description Programmable controller system shall be its modular, field expandable design allowing the system to be tailored to the customer's machine and/or process control application. The capability shall exist to allow for expansion of the system by the addition of hardware and/or user software. The logic processor, power supply, I/O scanner, and communication interface as well as input and output circuitry shall be of a modular design with interchangeability provided for all similar modules. The programmable controller system shall be designed and tested to operate in the high electrical noise environment of an industrial plant. Each input and output module shall be a self-contained unit housed within an enclosure. These input/output enclosures with their respective modules shall be field expandable . System Hardware and Software SCADA Software Specifications:
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Siemens WinCC SCADA Software ServicePack4 With SQL Server 2000 Programmable Logic Controller Siemens S7-300 CPU 315-2P Communication Available: Ethernet (TCP/IP), Profibus, MPI With Power Supply Module The SCADA system shall run on a PC with the following minimum specification: Pentium Processor (latest model) 3.0 GHz Clock speed 1 GB On board RAM 80GB 7200 rpm Hard disk drive SVGA video card with 64MB video RAM DVD ROM and CD Writer (minimum 32x read speed,16x write speed) 2 no. USB Ports 2 no. Parallel ports (for printers but USB acceptable) 2 no. Serial ports 1 no. PLC communications port 20 inch Colored LCD monitor Keyboard Mouse and mouse mat The SCADA system shall also comprise the following printers: 1 no. color printer (screen dumps, alarms and events) 1 no. laser printer (daily reports)
The system shall be supported by an on-line Uninterruptible Power Supply (UPS) for the purpose of providing a controlled shutdown of the system only. The UPS shall provide a back-up mains supply for a minimum of 3 hours. The PC and UPS shall be linked. All instruments (i.e. DO meter, pH meter, COD analyzer), should utilize Profibus within the plant.
Power supply and process instruments parameters in the substation, auxiliary supply, motors and other equipment shall be integrated in the SCADA system.
Operating System The operating system used on all WinCC installations shall be Windows XP professional. The version of Windows XP used shall be the latest version recommended by Siemens Software. The operating system shall have security built into it.
System Set-up The system shall be set such that it is capable of auto recovery in the event of a power failure. The system set-up shall include the disabling of the auto run facility for CD-ROM. The SCADA system shall be implemented on the required controls, indications and alarms for the plants power supply and process equipment, instrumentations and devices. All necessary information from the switchgears, switchboard/control panels shall be wired to terminal blocks in order to be connected to the PLC or SCADA system. All digital inputs and outputs shall be wired to terminal blocks. Remote/Local Automatic/Manual Power supply protection control, Motor Control Centers and other similar control panels shall be remotely or locally operated with two position control switch: (1) Manual mode, identified "Local/Manual" In "manual" position, on/off or opening/closing controls shall be done by local push buttons mounted on the control panels. All control panels shall include push buttons for circuit breakers, pumps, valves, fans, and associated equipment. In local/manual mode the equipment shall only operate from the local pushbuttons, remote operation via the PLC or SCADA system shall be inhibited. (2) Automatic mode, that is remotely controlled by the PLC and/or SCADA equipment, identified "Remote/Auto". In "automatic" position, on/off or opening/closing controls shall be done remotely to the panel from the PLC or SCADA equipment. Operation of the local push buttons mounted on the control panels while in this mode shall have no effect.
Reset push buttons shall be provided on control panels making it possible to start again, in automatic mode, a faulty piece of equipment after it has been checked and repaired.
Software License Where application software is licensed, then all associated licenses shall be made out in favor of: Manila Water Company Inc. 489 Katipunan Road, Diliman, Quezon City 13.29 CCTV PTZ type camera Signal Format Input Voltage Panning range Tilt Range Horizontal resolution Fixed Type camera Signal Format Input Voltage Horizontal resolution Digital Video Recorder Recording mode Camera display Signal cable Type: : Fiber Optic Type : Continuous : 16 channel : NTSC : 12/24V : 550TV lines : NTSC : 12/24V : 0-360degrees : 0-90degrees : 480TV lines
13.30 LIGHTNING PROTECTION General The lightning protection system shall include components as follows: air termination(s), mechanical support(s), low impedance insulated down conductor(s), performance recording equipment, and a low impedance grounding system. The lightning protection system shall employ an air terminal of the type designed to minimize corona emissions and optimize streamer inception when optimum pre-determined conditions are meet.
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The lightning protection system shall be mounted adequately rated for wind shear loading. Guying kits shall be provided as appropriate to local environmental conditions, or based on mast arrangement selected. The design of the components shall be traceable to long-term practical field studies, laboratory testing, fundamental scientific principles, and statistical levels of the lightning event as documented in international standard. The lightning protection shall be designed by a company engaged in the manufacture and development of lightning system components, of types, sizes and ratings as shown, who can show evidence or support that their products have been in satisfactory service for not less than 10years. The lightning protection system shall be installed strictly to the manufacturers instructions. Air Termination The air termination shall respond dynamically to the appearance of a lightning down-leader, shall be designed to trigger in relation to the optimum pre-determined conditions for upward leader inception, the triggering conditions must dynamically adjust to reflect the down leader intensity, building height above ground and the other factors that effect the electric field intensification above the air terminal. The air terminal shall incorporate a curved conductive surface spaced from a permanently grounded central finial. During triggering of the air terminal the curved conductive surface shall be temporarily grounded, thereby producing a snap increase in electric field directly above the air terminal. The air termination shall be designed with a range of optimal finial tip radii to match the different electric field conditions the terminal will be subjected to at various installation heights above the ground plane, or different positions on a structure for optimum performance. Arcing at the finial tip is not to be continuous and shall only occur during the process of lightning leader approach. Arcing shall not occur solely due to electro-static field build-up created by the presence of charged overhead thunderclouds. The materials of the air terminal shall be non-corroding in hostile environments. The centre grounded electrode tip shall be at least 0.8in. diameter, the curved conductive surface shall be of a conductive material of minimum thickness for air terminations as defined in IEC61024. The size of the collection volume and attractive radius of the air termination shall be traceable to known and acceptable lightning research and statistics.
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The air terminal shall be installed strictly to the manufacturers instructions. The isolating material supporting the curved conductive surface from the centre grounded electrode is to be manufactured from a glass/mineral reinforced polypropylene. This material shall exhibit the following properties, high impact strength, UV stabilized, high electrical dielectric, high comparative tracking index and operating heat capability up to 240 continuous. F The protective zone provided by the air termination shall be such that it becomes the preferred strike point for all discharges exceeding a peak amplitude return strike current of X kA according to the statistical level Y per IEC61024. The design shall take account of upward leader competing projections on the structure.
Table 9: Strike Current versus Levels of Protection Strike Current (X) 2.9 kA 5.4 kA 10.1 kA 15.7 kA Levels of Protection (Y) Protection Level I Very High Protection Level II- High Protection Level III Medium Protection Level IV - Low Exceedance Probability 99% 97% 91% 84%
Air Termination Support The air terminal support shall consist of a minimum of 6 ft. of insulating re-enforced fiberglass cylindrical mast. The conductor shall pass through the centre of the mast, with the high voltage termination contained to the upper 3 ft. of the mast. The support shall be securely bolted to other mast materials with guy wires used where necessary to enable the air termination and mast system to withstand maximum locally recorded wind velocities. Downconductor The down conductor shall consist of a polyethylene tubing, combined copper stranded and wound tape conductor, triple semi-conductive/insulation/semi-conductive layer, outer copper conductor, conductive compound sheath, all concentrically arranged. The main copper conductor shall be made of electrical grade copper, with a minimum cross sectional equivalent to 1/0 AWG. The main conductor shall consist of copper strands helically bound by a copper tape conductor designed to evenly distribute the lightning currents concentrically along the conductor length. The outer diameter of the conductor shall be no less than 1.3 in.
In the final 9ft to the ground and where it is exposed to human intervention, the down conductor shall be placed in a protective PVC pipe of 1/8in. minimum wall thickness so as to avoid mechanical damage and increase human safety. The down conductor shall not be routed through a ferrous metal pipe or tubing, so to avoid a resulting higher surge impedance. The down conductor should not be subject to bends of less than 1.5ft radius and shall be secured to the structure by approved metallic fastenings at least every 6 feet. Insulation breakdown ratings between conductors shall be no less than 250kV, i.e. core to screen 250kV based on 1/50us wave shape as defined under ANSI C62.41. Performance Recording Equipment Each protection system shall be supplied with a lightning event counter. The lightning event counter shall have an electronic register that activates one count for every discharge where the peak current exceeds 1500A. The test wave shape shall be the 8/20us standard as defined by ANSI C62.41 The lightning event counter shall be robust, easy to install and housed in a NEMA4 rated enclosure. The counter shall operate from the energy of the lightning discharge and not rely on external or battery power to operate. The lightning event counter shall be installed to the manufacturers instructions in a readily accessible manner so that readings can be taken at regular intervals. It shall be positioned such that its operating temperature is within the range -14F to +122F. Grounding The grounding system reading shall not exceed 10 ohms static impedance except with prior approval by the site engineer or manufacturer of the lightning protection system. Grounding shall be affected by copper wire or tape buried below the frost line (or to approximately 2 ft. deep in non freezing locations) or by deep driven UL listed copper bonded steel core ground rods with at least 10mil copper thickness. Bonding of the grounding system to metallic parts of the building, the structural reinforcing steel of the building and to arriving services is recommended. The resistance should be measured and the 10-ohm requirements achieved before such bonding is affected. Electrically conductive Ground Enhancing Materials may be used to achieve low ground resistance provided the materials are mixed and strictly in accordance with the manufacturers instructions.
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ANNEX A List of Preferred Brands of Electrical and Instrumentation Equipment and Components Equipment / Electrical Components 1. Variable Speed Drive 2. Soft Starter 3. Circuit Breaker 4. Dry Type Transformer 5. Motor Starter , Contactor, Overload Relays 6. Timers 7. Transfer Switch 8. Terminals 9. Isolators 10. Metering 11. Wires and Cable 12. Terminal Lugs 13. Valve Actuator 14. Fluorescent Lighting/Fixtures 15. Convenience Outlet 16. Lightning Arrester 17. Capacitor Bank 18. Motor 19. Power Transformer 20. Rigid Steel (RSC) Conduit 21. Submersible pumps 22. Aeration Blowers 23. Generator Set Instrumentation 1. Ultrasonic Flowmeter 2. Magnetic Flowmeter 3. Turbidity Analyzer 4. Residual Chlorine Analyzer 5. pH Analyzer 6. Ultrasonic Level Transmitter 7. Pressure Transmitter 8. PLC 9. Scada Software 10. Pressure Switches Manufacturer Allen Bradley, ABB, Danfoss Siemens, ABB, Danfoss, Allen Bradley, ABB, Klockner Moeller General Electric, Square D, Siemens, Allen Bradley, ABB, Klockner Moeller Omron, Sprecher & Schuh, Siemens Contact Plasma, Klockner Moeller Weidmuller, Klippon Contact Plasma, Klockner Moeller Multillin, G.E, Cutler Hammer Phelps Dodge, Columbia, Philflex Thomas and Betts, Pen-Union Rotork , Auma Philips, GE, Fumaco National, Toshiba, Eagle Erico, ABB, S & C Any brand but not tubular type Any US and Japan brand Motor, Teco Cooper, ABB, Philec Matsushita, Wheatland, Mcgill Tsurumi, Anlet, Ebarra, Flygt Tsurumi, Anlet, Hibon Caterpillar, Mitsubishi, Cummins Manufacturer Siemens, Endress Hauser, ABB Siemens, Endress Hauser, ABB Endress Hauser Endress Hauser Endress Hauser Siemens, Endress Hauser, ABB, Siemens, Endress Hauser, Danfoss, Rosemount Siemens, Allen Bradley Siemens, Allen Bradley Danfoss, Endress Hauser, Siemens
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ANNEX B Waste Water Standard Drawings

VERSION 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 DATE 07/08/2008 06/02/2008 06/03/2008 06/19/2008 09/10/2008 09/10/2008 09/11/2008 09/11/2008 09/11/2008 09/11/2008 01/27/2009 01/28/2009 08/17/2009 08/17/2009 08/17/2009 CONTENT LIST SEWER INSTALLATION Grease Trap Detail PVC Fiber Reinforced Pipe Assembly Detail Sewer Clean Out Box Detail Trenching Bedding & Backfilling of Pipes for Sewer Lines Proposed Diversion Weir For Open Creek-Detail Proposed Diversion Weir For Box Culvert-Detail Standard Interceptor Box-Detail Standard Sewer Manhole-Detail Sewer Manhole Cover-Details Standard Hook/Ladder Rung Conc. Encasement Detail Sewer Manhole for Pipe 900mm & Larger-Detail Miscellaneous Sewer - Hook & Bulb Water Stop-Details Perimeter Fence - Footing Perimeter Fence Type I Perimeter Fence Type I Perimeter Fence Type II Perimeter Fence Type II Perimeter Fence Type III Perimeter Fence Type III Entrance Gate - Swing Type Entrance Gate - Swing Type Entrance Gate - Sliding Type Entrance Gate - Sliding Type Service Connection Standard Clean Out Details Tapping Detail - FRP Tapping to existing Manhole DRAWING NO SD/GPTP/C001 SD/PFRP ASS/C001 SD/SCOB/C001 SD/TBP/C002 SD/PDW/C001 SD/PDW/C002 SD/SIB/C001 SD/SMH/C001 SD/SMH/C002 SD/SMH/C003 SD/SMH/C004 SD/MISC/C001 SD/PFENCE/C001 SD/PFENCE/C001a SD/PFENCE/C001b SD/PFENCE/C002a SD/PFENCE/C002b SD/PFENCE/C003a SD/PFENCE/C003b SD/EGATE/C001a SD/EGATE/C001B SD/EGATE/C002a SD/EGATE/C002B WW -C001 WW -C003 WW -C002 WW -C006
0 0 0 0
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AppH-1 SES

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STANDARD ENGINEERING SPECIFICATIONS (SES) WASTE WATER GENERAL CONTENTS

13 ANNEX A ANNEX B ANNEX C

MWC Standard Engineering Specifications

MWC Standard Engineering Specifications

3.1 3.2 3.3 3.4 3.5 3.6

MWC Standard Engineering Specifications

MWC Standard Engineering Specifications

MWC Standard Engineering Specifications

7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8

137 137 137 137 138 138 138

MWC Standard Engineering Specifications

SEWER AND WATER MAIN RENOVATION

10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8

153 153 153 153 154 154 154

MWC Standard Engineering Specifications

MWC Standard Engineering Specifications

MWC Standard Engineering Specifications

MWC Standard Engineering Specifications

MWC Standard Engineering Specifications

MWC Standard Engineering Specifications

MWC Standard Engineering Specifications

around the excavation

EXPLOSIVES AND DANGEROUS SUBSTANCE

Drawing Sequence as follows: WWTP 0XX/XXXXX / 4000 / S001 Contract Number

CAD Standards Set-Up

Pen Color Red

Pen Thickness 0.20

MWC Standard Engineering Specifications

Yellow Green Cyan Blue Magenta White

0.50 0.40 0.05 0.30 0.10 0.60

MWC Standard Engineering Specifications

Line number shall be used for wiring and terminal identification.

MWC Standard Engineering Specifications

MWC Standard Engineering Specifications

Project tag number used herein and on the Contractor's Drawings;

MWC Standard Engineering Specifications 24 Waste Water

As Built Manufacturing Drawings/Information

MWC Standard Engineering Specifications

Overall Max (dB) 70 50 40 70 40 40

Allowable 5 Minute Max (dB) 85 55 45 85 45 45

Monday-Friday Monday-Friday Monday-Friday Saturday Saturday Sunday

3. Noise assessments shall be included in method statement.

MWC Standard Engineering Specifications

MWC Standard Engineering Specifications

MWC Standard Engineering Specifications

MWC Standard Engineering Specifications

MWC Standard Engineering Specifications

MWC Standard Engineering Specifications

PIPE MATERIAL CI/DI PVC

STANDARDS AWWA C600 AWWA M 23

AWWA M 11 ASTM D3839 ASTM D2774

Over 300 to 550

MWC Standard Engineering Specifications

Percent by Weight passing 100 90-100 10-50 0-20 0-5

Percent by Weight passing 100 90-100 10-50 0-20 0-5

Nominal Mix by Mass Cement Sand 1 1 1 3 10

Part of BS 903 A1 A26 A2 A2 A16

Cement: lime Putty:Sand

Masonry Cement: Sand

1:0 to :3 1 1 1: /2:4 to 4- /2 1:1:5 to 6 1:2:8 to 9

1:2 to 2- /2 1 1 1:2- /2 to 3- /2 1:4:5 1 1 1:5- /2 to 6- /2

NOMINAL DIAMETER MM 50 75 100 150 200 250