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3. PROPOSED WORKS
3.1 GENERAL OBLIGATION
1. The contractor will design, build, supply, install, test, commission and hand over to CPUC
a complete water treatment system
2. The project will be constructed under a Design-Build Contract (DB).
3. The model Form of International Contract for Process Plant Construction published by the
Engineering Advancement Association of Japan (ENAA) will be used, as adapted for use
by ADB.
4. Bids have to respect the Employer’s Requirements & technical specifications of tender
documents. Only few minor adjustments are permitted, provided they are justified in detail.

The Works shall be constructed by the Contractor and shall be fit for purpose in every way for the
service required.

The Contractor, whether or not it is specifically referred to in these Specifications shall provide all
materials, consumables, equipment, tools, construction plant, temporary works, manpower,
competent supervision, skills, expertise, services and transport necessary:
To perform all the procurement, construction, testing and commissioning of the Works; and
For the safe, convenient, reliable, efficient and satisfactory completion and commissioning of the
Works in accordance with the Contract.

The Contractor is responsible for the overall functionality of the Works and all other interfaces
arising from the Works including but not limited to securing permits from government agencies,
such as CPUC power Dept, Local Government Unit, Planning Office for bridge crossings, CPUC,
etc. The Contractor must perform the work in a professional, timely, safe and environmentally
responsible manner.

3.2 DETAILED SCOPE

The project concept is to take water from a run of river intake on the Wichen river and pump the
water to the site of WTP, where the 1MG Peniesene tank is currently located.

The existing 1MG steel storage tank will be dismantled and removed under this contract, and the
proposed WTP will be built on the existing slab. A specialist subcontractor will be used for the
dismantling and removal of the tank.

The access track (approximately 600m) up to the intake and WTP is currently useable by 4WD
vehicles but will require improvement and rehabilitation for heavy vehicle access.

A new package WTP is proposed at the existing site with dual-media filtration (anthracite + sand)
and disinfection.

Raw and treated water tanks shall be of Glass Fused to Steel (GFS), a material well suited for
the marine environment.

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Ongoing operational training and support will be provided to CPUC through periodic trainer site
visits (minimum 1 week every 3 months) and weekly online sessions for a period of 2 years
following commissioning.

As part of the WTP, the following works are included in the project:
1. Raw water intake structure
2. Raw water mechanical and electrical services
3. Raw water pumping station including 2 pumps and MCC panel
4. Raw water pumping main and connections to raw water storage tank
5. Raw water storage tank
6. WTP components
7. Electricity supply from transformer supplied by CPUC on pole at site entrance,
8. PLC, on-call and instrument panels, localised SCADA to be compatible with future CPUC
SCADA needs1
9. Treated water storage tank
10. Pipework and connections
11. ADB10 pump testing and possible borehole pump upgrade to match pump head to the
treated water storage inlet;
12. Site civils – creation of lay down and parking area; walkways, landscaping and site fencing
& security
13. Site civils – improvement of access track to the WTP site with supply of aggregate,
compaction, grading and roadside drainage
14. Building for chlorination
15. An office working space for the operators of minimum floor size 9ft x 7.5ft.
16. Site lighting (solar powered LED)

Weno is located within the cyclone corridor related to a category 3 scale (medium or Tropical
Cyclone). This category undergoes sustained wind varying between 178 – 208 kph on the
Saffir-Simpson Hurricane Scale.
Therefore all structures shall be designed to withstand a wind speed of 205 kph.

The WTP will be composed of the following components:

1. Raw water storage 132 000 G (500 m 3);
2. 3 pumps with Variable Frequency Drive (VFD), including one stand-by unit;
3. 2 bi-layer vertical pressure filters (anthracite and sand) with a capacity of 13 200 G/h (50
m3/h);

1 Reference “CWSSP SCADA Basis of Design report March 2023”

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4. 2 air boosters, including one stand-by unit;

5. 2 sets of air compressor, including one stand-by unit, with a 90L vessel and air dryer;
6. Chlorination room with a chlorination dosage system;
7. Electrical room including switch boards, VFD, PLC, HMI, instrumentation and radio
communication;
8. Treated water storage 132 000 G (500 m3)
As the turbidity measures are low, the stages of coagulation, flocculation, and clarification are
unnecessary.

3.3 OTHER INFORMATION

1. It shall be noticed that the contract being under Design-Build conditions the
Contractor’s responsibilities include:

 Provision of process design (and system analysis) for sizing all structures and control
system and to be approved by the Engineer;
 Provision of all hydraulic and equipment designs of any kind to be approved by the
Engineer (Hydraulic Profile, Schematic Diagrams, GA/civil guide drawings for structures,
P&ID);
 Provision of electrical design, single line diagram’s to be approved by the Engineer;
 Provision of equipment and instrumentation lists and detailed specifications to be
approved by the Engineer;
 Provision of all site layout and equipment arrangement design of any kind to be
approved by the Engineer;
 Provision of topographical and geotechnical surveys and surveys of any kind needed to
size the works and to be approved by the Engineer.
 Provision of soil reinforcement and foundation design: existing soils conditions and
seismic context require advanced soil reinforcement and foundation works (stone
columns, rigid inclusion, piles, vibro-compaction and other methods may be combined)
to be designed carefully with finite-element software;
 Provision of civil works and structural detailed designs (using finite-element method and
software) to be approved by the Engineer;
 Supply, transportation, storage, installation of equipment needed for the complete works
including materials unforeseen or not listed in the tender drawings or tender lists;
 Shop drawings of any type (Civil Works, Mechanical, Electrical, etc.); All documents
shall be provided in active electronic files for future adjustment;
 Supply of as built drawings and operation & maintenance manuals; to be approved by
the Engineer before commissioning and trial operation
 Test, commissioning, training of staff and hand over are included in the contract.

It shall be noted that topographical and geotechnical data provided by the tender documents are
indicative only for bidding purpose and that topographical and geological risk is under the
responsibility of the Contractor.

Design-build Contract period: 18 months

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Commissioning / Trial Operation period shall last 2 years and integrate the rainy season.
During this period, operation is under the responsibility of CPUC, with ongoing training and both
on-island and online support by Contractor for CPUC staff.

Defects Notification Period (DNP) shall last three years. During this period, CPUC staff operates
the plant under the supervision of the Contractor with regular contractor site visits.
At the end of the DNP, Employer will issue the Performance Certificate.

4. OTHER WORKS AND INTERFACE ISSUES

4.1 Other CWSSP Works:

The Chuuk Water Supply and Sanitation Sector Project (CWSSP) is currently divided into contract
packages, as follows:

Package No. Package Description

1 Wichen river WTP
2 Wichap/Epinup well development and Weno well consolidation
3 Water supply augmentation and rehabilitation
4 Supply of smart meters and prepayment
5A Weno sewerage rehabilitation: WWTP
5B Weno sewerage rehabilitation: network

The Contractor is advised that there will be other works ongoing in the area of the project,
including but not limited to those listed above, for which liaison may be necessary:

4.2 FSM:SRIIP Works: (Sustainable Road Infrastructure Investment Project)

The ADB has agreed a grant for preparing the FSM:SRIIP project. The purpose of this
assignment is to deliver the following outputs to prepare a subsequent pipeline of projects suitable
for ADB-financing.
 Output 1: Scope of sector policies, strategies, and investments identified.
 Output 2: Detailed engineering designs and bidding documents prepared and
implementation contracts procured.
 Output 3: Innovative tools for road rehabilitation works in the Federated States of
Micronesia piloted.
 Output 4: Capacity of executing and implementing agencies and implementation
arrangements tested.
After preparation work is successfully complete, construction works are due to take place in the
main islands of the four FSM States; Chuuk, Pohnpei, Yap and Kosrae. In Chuuk, the project
intends to rehabilitate two or three sections of road on Weno Island south of the main town.
The selection process is currently underway and a shortlist of roads in Chuuk is due to be
determined by end of 2023.

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5. SCOPE OF WORKS
5.1. DESIGN LIFE
Each part of the works to be constructed and installed under the Contract shall be designed to
maximise reliability and minimise maintenance requirements and energy consumption and shall
have a reliable operating life not less than the appropriate design life stated below.

Minimum Design
Category
Life (years)

Buildings and civil works: 30 years

Water distribution system (pipes): 50 years

Mechanical and Electrical
15 years
Equipment:
Instrumentation & Control: 10 years

SCADA & Computer Equipment: 5 years

"Design Life" shall mean the period of time for which an item or system is designed to operate at
or in association with normal working at full design output without major overhaul, serious
corrosion or necessity for substantial renewal of any anti-corrosion system, reduction of efficiency
or output in excess of 5 %, or replacement of major components or components essential to the
functioning of the item.

The renewal of wearing parts such as bearings, diaphragms, shaft sleeves, seals or any other
parts, which by virtue of their design and purpose are expected to be renewed within the above
periods are accepted as exceptions provided that those parts are manufactured to the
requirements of the mechanical and electrical and instrumentation specification.

Where replacement parts are anticipated to be required for any item of the works during the
appropriate design life, over and above the renewal of wearing part meeting the requirements of
the specification, then these should be identified by the Contractor.

5.2. RAW WATER INTAKE

The raw water intake will be cast in situ from reinforced concrete in the location shown in the
drawings. It will consist of a low dam of approximately 22 ft length, and will allow ecological flow
of water both over the top of this dam and around its edge. The intake site is approximately 300ft
from the WTP access road and is accessed along an established footpath through private land.
CPUC have secured the right to use this access for foot traffic. All equipment and materials will
need to be hand carried from the WTP access road to the intake site location.

5.3. ADB10 BOREHOLE TESTING

The existing ADB10 borehole shall be connected to the new treated water tank. The existing pump shall be
tested (step-test procedure is included in the Specifications) to check if it is suitable to match the head of
the new treated water tank. The borehole ADB10 is 27ft amsl, has a static water level of 10ft below ground

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level, and the bore is 94ft deep in weathered volcanic aquifer. When ADB10 was commissioned it was
providing 25GpM.

5.4. PERFORMANCE/DESIGN CRITERIA

5.4.1. CAPACITY FOR RAW WATER PUMP STATION AND TRANSMISSION LINE

Design shall follow the following requirements:

o maximum raw water flow rate of 264,170 G/d (1 000 m3/h), from the river to raw
water storage tank,
o Operation up to 24 hours a day.

Raw water transfer pipe to the new WTP shall be 6” (150 mm internal diameter minimum.

5.4.2. CAPACITY FOR WATER TREATMENT PLANT (WTP)

The new water treatment plant shall be designed:

o For a maximum raw water flow rate of 264,170 G/d (1 000 m3/h),
o Based on raw water quality and treatment capacities indicated in the table below,
o Based on the reagents treatment rates chosen by the Contractor.

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The entire treatment system, from raw water pumping to admission of treated water in storage, is
sized at 264,170 G/d (1 000 m3/h), without taking into account water losses. A peak flow for raw
water pump is not necessary as the raw water tank provides 1 day storage to feed the WTP, and
will be constantly filled during those months where the WTP is operational.

This estimate may be made on the basis of the information provided in the tender documents, or
from other sources (which shall then be indicated), or from samples and analyses that it has
carried out itself as part of the preparation of its tender.

The Contractor shall take into account the following requirements for the design of the dirty
backwash water treatment process:
o Minimum volume of the backwash pond(s): equivalent to 1 washing of filters,
For the sizing of reagent units and for the preparation of the forecast operating balance sheet,
the contractor shall take into account the characteristics of the following reagents (and their
content in active product) if they are used in the treatment line:

a) Coagulant,
b) Polymer,

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c) Lime,
d) Salt,
e) For reagents not included in this list, the Contractor will provide the specific information
of the products (water, thickening, etc.).

The reserved area for the complementary reagents proposed by the company will be defined
taking into account the requirements of this article "Reagents".
The contractor shall implement electrical installations which are dimensioned on the basis of the
energy requirements of all the facilities covered by the contract, plus a margin of 10 % (margin
calculated on the capacity achieved when all facilities are in operation),
The contractor must also ensure a minimum available space of 30% in addition to that required
for the operation of installations in electrical rooms, electrical cabinets, PLCs, supervision and
office automation stations, remote monitoring,
Finally, the power supply (AC converted) must be able to supply (full load) the programmable
controller, for a minimum of 2 hours.

5.5. PERFORMANCE FOR WTP

5.5.1. TREATED WATER QUALITY

1. When operated with the Contractor's instructions in order to deliver up to 264,170 G/day of
treated water, the water treatment plant shall be able of producing a reliable and
continuous supply of drinking water, free of water borne pathogenic organisms. The water
quality, sampled after treatment at the treated water storage outlet, shall comply with :
a) WHO drinking water standards,
2. The warranty domain in which the treated water quality requirements are to be met is shown
in the table below:

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Degraded
Parameters Units WHO guide
quality

pH UpH 6.5 - 8.5

Turbidity NTU 50 <5*
TSS mg/l 50 <600**
Conductivity µS/cm 400
Alkalinity mg/l -
Total Hardness (CaCO3) mg/l -
Calcium mg/l 50 100
Boron mg/l 1 2.4
Sodium mg/l 10 50
Magnesium mg/l 10 50
Chloride mg/l 10 250
Fluoride mg/l 1 1.5
Bromide mg/l 1 -
Sulfate mg/l 10 250
Nitrate mg/l 1 50
Ammonia mg/l 2 0.1
Sulfate mg/l 10 500
Aluminium µg/l 1 000 200
Potasium mg/l < 2.5 -
Manganese µg/l 50 80
Iron total µg/l 1 000 300
Arsenic µg/l <5 10
Cadmium µg/l <5 3
Lead µg/l <5 10
TOC mg/l 5 -
Esch. Coli unit/100 ml 1 000 0
Total colifor unit/100 ml 5 000 0
Enterococcus unit/100 ml 1 000 0

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5.5.2. NOISE EMISSIONS

Levels of noise during Operation are not to exceed (measured at property boundary):
 period from 6:00 AM to 9:00 PM 55 dB(A),
 period from 9:00 PM to 6:00 AM 45 dB(A).

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6-2- SPECIFICATIONS
1. GENERAL ........................................................................................................ 23
1.1. LAW, REGULATIONS, CODES AND STANDARDS ........................................................................................ 23
1.2. ADMINISTRATIVE REQUIREMENTS, PERMITS AND VARIOUS OBLIGATIONS ................................................. 23
1.3. TEMPORARY FACILITIES & EQUIPMENT.................................................................................................... 25
1.4. WORKS IMPLEMENTATION ....................................................................................................................... 28
1.5. MATERIALS AND EQUIPMENT .................................................................................................................. 30
1.6. PRODUCT SPECIFICATION & SUBMITTAL PROCEDURES ............................................................................ 32
1.7. COORDINATION & MEETINGS .................................................................................................................. 35
1.8. PROGRESS PROGRAMS .......................................................................................................................... 37
1.9. MANAGEMENT PLANS ............................................................................................................................. 42
1.10. CONSTRUCTION DOCUMENTS & AS-BUILT ............................................................................................... 45
1.11. STARTING OF SYSTEM / COMMISSIONING ................................................................................................. 50
1.12. OPERATIONAL, FIELD AND PERFORMANCE TESTING ................................................................................ 54
1.13. OPERATION AND MAINTENANCE MANUALS .............................................................................................. 55
1.14. CONTRACT CLOSE-OUT .......................................................................................................................... 57

2. CIVIL WORKS.................................................................................................. 61
2.1. MATERIALS ............................................................................................................................................ 61
2.2. EARTHWORKS ........................................................................................................................................ 75
2.3. CONCRETE AND FORMWORKS ................................................................................................................. 95
2.4. PROTECTION AND CURING .................................................................................................................... 102
2.5. STEELWORKS, BUILDING WORKS AND ARCHITECTURAL WORKS............................................................ 110
2.6. ROADWORKS AND DRAINAGE................................................................................................................ 127

3. PIPING WORKS............................................................................................. 131

3.1. SPECIFIC REQUIREMENTS ..................................................................................................................... 131
3.2. PIPE BEDDING ...................................................................................................................................... 132
3.3. TRENCH STOPS ON STEEP INCLINE PIPE ................................................................................................. 132
3.4. CONCRETE PROTECTION TO PIPES ........................................................................................................ 132
3.5. COMPLETION OF PIPES SURROUNDS ..................................................................................................... 132
3.6. PIPELAYING IN HEADINGS ..................................................................................................................... 132
3.7. PIPE JOINTING - GENERAL .................................................................................................................... 133
3.8. WELDED JOINTS IN PLASTIC PIPES ....................................................................................................... 133
3.9. ELECTROFUSION JOINTING IN POLYETHYLENE PIPES ............................................................................. 133
3.10. DUCTILE IRON PIPES AND FITTINGS ....................................................................................................... 134

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3.11. STEEL PIPES AND FITTINGS .................................................................................................................. 134

3.12. UNPLASTICIZED POLYVINYL CHLORIDE (UPVC) PIPES AND FITTINGS – WATER ...................................... 135
3.13. UNPLASTICIZED POLYVINYL CHLORIDE (UPVC) PIPES AND FITTINGS – SEWER OR DRAINAGE (IN CASE OF
DAMAGE DURING WORKS) ..................................................................................................................... 135
3.14. POLYETHYLENE PIPES AND FITTINGS .................................................................................................... 135
3.15. VALVES ................................................................................................................................................ 139
3.16. VALVES AND APPURTENANCES ............................................................................................................. 139
3.17. MATERIAL AND PROTECTIVE COATING FOR VALVES AND FLOWMETERS ................................................. 139
3.18. VALVE MARKING .................................................................................................................................. 139
3.19. BALL AND PLUG VALVES ...................................................................................................................... 140
3.20. SURGE ANTICIPATING VALVES .............................................................................................................. 140
3.21. CHECK VALVES .................................................................................................................................... 141
3.22. GATE VALVES ...................................................................................................................................... 142
3.23. BUTTERFLY VALVES ............................................................................................................................. 144
3.24. VALVE ACTUATORS INCLUDING HEADSTOCKS ........................................................................................ 146
3.25. AIR VALVES ......................................................................................................................................... 147
3.26. FLAP VALVES ....................................................................................................................................... 148
3.27. KNIFE VALVES ...................................................................................................................................... 148
3.28. LEVEL CONTROL VALVE WITH ALTITUDE PILOT ....................................................................................... 148
3.29. PRESSURE REDUCING VALVE ............................................................................................................... 149
3.30. FLOAT VALVE ....................................................................................................................................... 149
3.31. METERS AND METER BOXES ................................................................................................................. 149
3.32. HYDRANTS ........................................................................................................................................... 150
3.33. FLANGES.............................................................................................................................................. 150
3.34. DISMANTLING JOINTS ............................................................................................................................ 150
3.35. JOINT SEALS AND LUBRICANT .............................................................................................................. 151
3.36. FLANGES FOR PIPES ............................................................................................................................. 151
3.37. GASKETS FOR FLANGED JOINTS ........................................................................................................... 152
3.38. SLEEVE TYPE COUPLING ...................................................................................................................... 152
3.39. BRASS FITTINGS................................................................................................................................... 152
3.40. SADDLES ............................................................................................................................................. 152
3.41. HDPE ELECTROFUSION TAPPING SADDLES ............................................................................................ 153
3.42. RUBBER GASKETS FOR MECHANICAL AND PUSH-ON JOINTS ................................................................. 153
3.43. MARKER TAPES .................................................................................................................................... 153
3.44. FLANGED JOINTS.................................................................................................................................. 153
3.45. OGEE JOINTS ....................................................................................................................................... 153
3.46. WELDED JOINTS IN STEEL PIPES........................................................................................................... 153
3.47. THRUST BLOCKS .................................................................................................................................. 154
3.48. VALVE BOX .......................................................................................................................................... 154
3.49. TESTING AND DISINFECTION .................................................................................................................. 154

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4. MECHANICAL WORKS ................................................................................. 158

4.1. SPECIFIC REQUIREMENTS ..................................................................................................................... 158
4.2. PUMPS ................................................................................................................................................. 160
4.3. COAGULATION, FLOCCULATION AND LAMELLAR CLARIFICATION ............................................................. 165
4.4. RAPID SAND FILTRATION ....................................................................................................................... 165
4.5. COMPRESSORS ...................................................................................... ERROR! BOOKMARK NOT DEFINED.
4.6. STAIRS, WALKWAYS, PLATFORMS AND HANDRAILS ................................................................................ 168
4.7. CORROSION PROTECTION ..................................................................................................................... 171
4.8. PIPEWORK............................................................................................................................................ 171
4.9. PRESSURE GAUGES (MANOMETER TYPE) .............................................................................................. 172
4.10. CHLORINATION EQUIPMENT ................................................................................................................... 173
4.11. EXHAUST FANS .................................................................................................................................... 174
4.12. FUEL STORAGE FOR STANDBY GENERATOR SETS ................................................................................. 174
4.13. GEN SET PIPING SYSTEM ...................................................................................................................... 175
4.14. ACOUSTIC LINING ................................................................................................................................. 176
4.15. FIRE PROTECTION SYSTEMS ................................................................................................................. 176
4.16. SURGE VESSEL .................................................................................................................................... 176
4.17. BEDPLATES AND MOTOR STOOLS .......................................................................................................... 178
4.18. FLEXIBLE COUPLINGS ........................................................................................................................... 178
4.19. FOUNDATION BOLTS ............................................................................................................................. 178
4.20. LIFTING AND TRANSPORTATION EQUIPMENT ........................................................................................... 178
4.21. VENTILATION ........................................................................................................................................ 178
4.22. GRILLES, DIFFUSERS AND LOUVRES ..................................................................................................... 178
4.23. SOUND ATTENUATORS ......................................................................................................................... 179
4.24. EYE SHOWER ....................................................................................................................................... 179
4.25. PADLOCKS ........................................................................................................................................... 179
4.26. LABELLING ........................................................................................................................................... 180
4.27. SIGNAGE .............................................................................................................................................. 180
4.28. SPARE PARTS ...................................................................................................................................... 180
4.29. STEP DRAWDOWN TEST FOR BOREHOLE PUMPS ..................................................................................... 181

5. ELECTRICAL WORKS .................................................................................. 183

5.1. SPECIFIC CONDITIONS .......................................................................................................................... 183
5.2. LOW VOLTAGE SWITCHBOARD .............................................................................................................. 211
5.3. MOTOR CONTROL CENTERS ................................................................................................................. 214
5.4. DISTRIBUTION BOARDS/CONTROL PANELS............................................................................................ 216
5.5. COMPONENTS ...................................................................................................................................... 217
5.6. SOFT STARTER..................................................................................................................................... 221
5.7. LOW VOLTAGE FREQUENCY DRIVE ....................................................................................................... 223
TRANSFORMER ................................................................................................................................................ 226

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5.8. EARTHING ............................................................................................................................................ 227

5.9. LIGHTING AND SMALL POWER ............................................................................................................... 228
5.10. INTERIOR WIRINGS ............................................................................................................................... 230
5.11. CONDUITS AND BOXES ......................................................................................................................... 232
5.12. INSTRUMENTATION AND CONTROLS....................................................................................................... 233
5.13. DEVICES SUBJECT TO MANUAL OPERATION .......................................................................................... 234
5.14. WIRING ................................................................................................................................................ 234
5.15. ELECTRO-MAGNETIC FLOW METERS ..................................................................................................... 235
5.16. PRESSURE TRANSMITTER .................................................................................................................... 235
5.17. PRESSURE SWITCH............................................................................................................................... 237
5.18. DISSOLVED OXYGEN ANALYZER ........................................................................................................... 237
5.19. PH/ORP ANALYZER ............................................................................................................................. 238
5.20. CHLORINE ANALYZER ........................................................................................................................... 238
5.21. INSTRUMENTATION PANEL .................................................................................................................... 239
5.22. CONTROL SENSORS AND EQUIPMENT.................................................................................................... 239
5.23. LIGHTNING PROTECTION ....................................................................................................................... 240

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3. PIPING WORKS
3.1. SPECIFIC REQUIREMENTS
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 Standard
C600
b) Polyvinyl Chloride - Manual
(PVC) Pipe M23
c) Steel Pipe - Manual
M11
d) Concrete Pressure Pipe - Manual
M9
e) Fiberglass Pressure - ASTM
Pipe D3839
f) Polyethylene Pipe (PE) - ASTM
D2774

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.

Pipes shall be laid on setting blocks only where a concrete bed or cradle is used.
Where pipes are required to be bedded directly on the trench bottom, the Final Surface
shall be trimmed and levelled 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.

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.

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.
Where pipeline marker tape is specified, it shall be laid between 6 inches and 12 inches
above the pipe.

Where a tracer system is specified it shall be continuous and adequately secured to

valves and fittings.
Over-excavation shall be backfilled with material shown on the drawing or approved by
the Project Manager.
Final manufacture of special or cut pipes shall not be undertaken until actual on-site
dimensions have been determined.

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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.
Unless otherwise detailed in the Bid Documents, the Contractor shall submit details of
its proposed method of crossing rivers and canals.
Preliminary details should have been submitted with the Bid.

3.2. PIPE BEDDING

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.

3.3. TRENCH STOPS ON STEEP INCLINE PIPE

The trench stops shall be provided along the sections with more than 15% slopes and to
be spaced every 15 feet.
The trench stops shall cover the full trench width and cover the trench up to 20 inches
below the ground level.
The trench stop shall be made of mass concrete of 15 MPa.
3.4. CONCRETE PROTECTION TO PIPES
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.
Concrete, provided as a protection to pipes shall be Class B (2465 psi), minimum 6
inches thick, placed to the required depth in one operation.
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.
Rapid hardening cement shall not be used in concrete for the protection of plastic pipe.
Plastic pipes shall be wrapped with a layer of plastic sheeting before being surrounded
by concrete.

3.5. COMPLETION OF PIPES SURROUNDS

After completion of the relevant operations, fill material shall, where required, be placed
and compacted over the full width of the trench in layers not exceeding 6 inches before
compaction, to a finished thickness of 6 inches above the crown of the pipes.

3.6. 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 2465 psi 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

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grout. Grouting shall be carried out at the end of each shift or after three settings have
been packed; whichever is the shorter interval.

3.7. PIPE JOINTING - GENERAL

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.
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.

3.8. WELDED JOINTS IN PLASTIC PIPES

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 the Project Manager.
When solvent welded uPVC 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.
A pipe section containing a completed weld shall achieve the same strength
characteristics as the parent pipe.
Butt fusion and electrofusion joints in polyethylene pipes shall be carried out entirely in
accordance with manufacturer’s instructions.

3.9. ELECTROFUSION JOINTING IN POLYETHYLENE PIPES

ASTM F1055 shall be followed for all electrofusion jointing of HDPE pipes.
Electrofusion Processors shall be maintained and calibrated per manufacturer’s
requirements and recommendations.

Electrofusion joining shall be done in accordance with the manufacturers recommended

procedure. Other sources of electrofusion joining information are ASTM F 1290, PPI TN
34, and PPI Municipal Advisory Board (MAB) Generic Electrofusion Procedure for Field
Joining of 12 Inch and Smaller Polyethylene (PE) Pipe. The electrofusion processor must
be capable of reading and storing the input parameters and the fusion results for later
download to a record file. Qualification of the fusion technician shall be demonstrated by
evidence electrofusion training within the past year on the equipment to be utilized for
this project.

The employer of the fusion machine operator is responsible for the fusion joint quality of
the fusion weld made by that individual. The employer is responsible for documenting all
training and qualification records for that individual, including compliance to any code
requirements for fusion/bonder operators.

All HDPE fusion equipment operators shall be qualified to the procedure used to perform
pipe joining. Fusion equipment operators shall have current, formal training on all fusion
equipment employed on the project. Training received more than two years prior to
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operation with no evidence of activity within the past 6 months shall not be considered
current.

3.10. DUCTILE IRON PIPES AND FITTINGS

Ductile iron pipes and fittings shall comply with the relevant provisions of EN 545:2010.
Pipes and fittings shall have an outside coating of coal tar base approximately 25 microns
thick.
Ductile iron pipes and fittings shall be cement mortar lined to conform to either AWWA
C104 or ISO 2531.

Wall Thickness for Ductile Iron Pipes:

Nominal Outside *Minimum Wall
Diameter Diameter Thickness
(inches) (inches) (mm)
3 3.96 0.25
4 4.80 0.25
6 6.90 0.25
8 9.05 0.25
10 11.10 0.26
12 13.20 0.28
14 15.30 0.31
16 17.40 0.34
20 21.60 0.38
24 25.80 0.43
* Wall Thickness is strictly minimum, no negative tolerance is allowed.

3.11. STEEL PIPES AND FITTINGS

Steel pipes and fittings shall comply with the relevant provisions of AWWA C200.
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.
Steel pipes shall be coated either in accordance with AWWA C203 (coal tar enamel) or
AWWA C205 (cement mortar lining and coating).
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.

Dimensions for steel fittings shall conform to AWWA C208.

Joints may be of the following types:
 Mechanical Type
 Push -on-type
 Welded joints
 Shop Welded flange
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 cannot be lined
centrifugally, it shall be lined by hand.
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Minimum Wall Thickness for Steel Pipes (for depth of cover of 3 feet to 8 feet only) shall
be as follows:
Nominal Diameter (inches) Nominal Wall Thickness
(inches)
16 0.50
18 0.562
20 0.594
24 0.688

42

Acceptable Joints
 16 inches to 20 inches – Joints shall be flanged, or shall be plain end on sleeve-type
coupling.
 24 inches 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.

3.12. UNPLASTICIZED POLYVINYL CHLORIDE (UPVC) PIPES AND FITTINGS – WATER

Unplasticized PVC pressure pipes and fittings shall comply with the relevant provisions
of AWWA C900 and C905.
Unplasticized PVC pressure pipes and fittings shall be extruded blue.
Pipe rating shall be Series 8.
Joints shall be push-on-type joints or plain end on couplings.

3.13. UNPLASTICIZED POLYVINYL CHLORIDE (UPVC) PIPES AND FITTINGS – SEWER OR DRAINAGE
(IN CASE OF DAMAGE DURING WORKS)

Unplasticized PVC pipes and fittings for sewers and drains shall conform to the
provisions of ASTMD2729, ASTMD 3034, ASTM F679 and ISO 4435.
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.
The tolerances for outside diameter and wall thickness for unplasticized sewer and
drainpipes shall be in accordance with ISO 3606.

3.14. POLYETHYLENE PIPES AND FITTINGS

3.14.1. DESCRIPTION OF WORK
This section includes material and installation requirements necessary for furnishing and installing HDPE
pipe, fittings and specials in the locations and quantities as shown on the drawings.

3.14.2. QUALITY CRITERIA

Reference to industry standards as contained herein shall be construed as to be in reference to
the latest revision or edition.

The pipe fittings and specials shall be made by a manufacturer experienced in producing pipe,
fittings, and specials of the type, size, configuration, and quality specified herein. The
manufacturer shall have produced pipe, fittings and specials having a record of at least five years
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successful performance.

3.14.3. SUBMITTALS
The Contractor shall submit shop drawings showing the pipe lengths, design details, joint details,
specials, etc., for the Project Manager/Architect’s approval. Pipe shall be fabricated in
accordance with these plans.

The Contractor shall submit a notarized statement of certification from the pipe manufacturer as
to conformance with the specified ANSI/AWWA Specifications listed herein, and modifications
thereto, at the time of submitting shop drawing data on the pipe and fittings.

3.14.4. DELIVERY, STORAGE AND HANDLING

The Contractor shall be responsible for the acceptability of all material furnished by him and shall
assume responsibility for the replacement of all such material found damaged in shipping, or
defective in manufacture. This shall include the furnishing of all material and labor required for
the replacement of installed material discovered to be defective prior to the final acceptance of
the work.

The interior, as well as all sealing surfaces of all pipe, fittings, and other accessories shall be kept
free from dirt and foreign matter. Consult the manufacturer for specific storage recommendations.
Materials shall, at all times, be handled properly to prevent damage in accordance with
manufacturer’s recommendations. Pipe and fittings shall not be thrown, dropped, or dragged.

3.14.5. HDPE PIPE

Polyethylene pipe shall be manufactured in accordance with ASTM F714. The diameters shall be
as shown on the drawings.

The polyethylene pipe shall be rated for use with water at 73.4F. at a hydrostatic design stress
of 800 psi and a minimum working pressure of 160 psi.
All HDPE pipe shall be IPS sizing, and shall be DR 11.

Polyethylene extrusion compound from which the polyethylene pipe is extruded shall comply with
application requirements for PE-3408 high molecular weight polyethylene plastic material.
Material shall be as described in ASTM D1248 and shall comply with the following:
 Pipe resin shall have a minimum inherent viscosity of 2.5 when run according to ASTM
D1601.
 Exceed 5,000 hours on ESC as determined by ASTM D-1248-345434C.
 Have a specific gravity of between 0.9141 and 0.955.
 Contain a minimum of 2% and a maximum of 3% of carbon black and shall produce a
finish product that is uniformly black.

Marking on the pipe shall include a blue stripe for water transmission main; the nominal pipe or
tubing size; the type of plastic material, i.e., PE-3408; the standard thermoplastic pipe dimension
ration or the pressure rating in psi for water at 73.4oF. (160 psi); the ASTM designation with which
the pipe complies; and manufacturer’s name or trademark and code.

3.14.6. FITTINGS AND JOINTS

Fittings shall be fabricated to the same standards as the pipe from the same raw materials by
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thermal fusion. Jointing shall be by the thermal butt fusion method as recommended by the
manufacturer. Fittings and joints shall have a pressure rating equal to the pipe and shall have
machined fusion ends matched to pipe wall.
3.14.7. EXECUTION
Installation of all polyethylene pipe, fittings, specials and appurtenances shall be in accordance
with Section 02730 and Manufacturers Instructions.

Openings such as stubs, tees and other services along the lines shall be securely closed by
means of an approved stopper that fits into the pipe and is recommended by the pipe
manufacturer. This stopper shall be jointed in such a manner that it may be removed at some
future time without injury to the pipe itself. At the close of each day’s work and other times when
the pipe is not being laid, the end of the pipe shall be temporarily closed with a close-fitting
stopper.

Cleaning - All necessary precautions shall be taken to prevent the entrance of mud, sand or other
obstructing material into the pipelines. As the work progresses, the interior of the main shall be
cleaned of all dirt, jointing material, and superfluous materials of every description.

Joining of piping shall be performed by experienced fusion technicians with a minimum of five (5)
years or more experience in field application involving large diameter (over 12-inches)
polyethylene pipe. Experience record shall be submitted for review.
Handling:
 Pipe must be handled in a way to insure that it is not gouged or scratched to a depth
of more than 10% of the wall thickness.
 Pipe shall not be bent to a radius of less than 20 diameters at any time during
installation.
Pipe shall be handled at all times with strapping that a combined width at each load area of at
least half the pipe diameter to prevent point damage to the pipe. No wire rope slings shall be
used.

3.14.8. TRAINING OF ELECTROFUSION WELDING OF HDPE PIPES FOR CPUC

On-the-job training in the correct use of electrofusion equipment in joining pipe and fittings shall
be provided to CPUC over the first 6 months of the construction period, to a level that will enable
them to carry out electrofusion jointing by themselves using equipment owned by CPUC.

The training shall include, as a minimum;

 Classes and ratings of HDPE and what they mean
 Key HDPE processing techniques
 Joint preparation
 Defects in HDPE and how to identify/avoid them
 Practical electrofusion
 Inspection and testing
 Health and safety
 Care and storage of electrofusion equipment

3.14.9. TESTING IN THE TRENCH

Hydrotesting of pressure pipe lines shall be in accordance with Section 4, AWWA C-600.

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Fill the pipeline with water after it has been laid; bleed off any trapped air. Subject the lowest
element in the system to a test pressure that is 1.5 times the design pressure, and check for any
leakage. When in the opinion of the engineer, local conditions require that the trenches be
backfilled immediately after the pipe has been laid, apply the pressure test after backfilling has
been completed but not sooner that a time which will allow sufficient curing of any concrete that
may have been used. Typical minimum concrete curing times are 36 hours for early strengths
and seven days for normal strengths.

The test procedures consist of two steps: the initial expansion and the test phase. When test
pressure applied to a water-filled pipe, the pipe expands. During the initial expansion of the pipe
under test sufficient make-up water must be added to the system at hourly intervals for three
hours to maintain the test pressure. After about four hours, initial expansion should be complete
and the actual test can start.

When the test is to begin, the pipe is full of water and is subjected to a constant test pressure of
1.5 times the system design pressure. The test phase should not exceed three hours, after which
time any water deficiency must be replaced and measured. Add and measure the amount of
make-up water required to return to the test pressure and compare this to the maximum allowance
in Figure 4.1.

An Alternate leakage test consists of maintaining the test pressure (described above) over a
period of four hours, and then dropping the pressure by 10 psi (0.069Mpa). If the pressure than
remains within 5% of the target value of one hour, this indicates there is no leakage in the system.

NOTE: Under no circumstances shall the total time under test exceed eight (8) hours at 1 ½ times
the system pressure rating. If the test is not complete within this time limit (due to leakage,
equipment failure, etc.), the test section shall be permitted to “relax” for eight (8) hours
prior to the next test sequence. Air testing is not recommended. Additional safety
precautions may be required.

TABLE
ALLOWANCE FOR EXPANSION UNDER TEST PRESSURE

Nominal Pipe U.S. Gals/100 feet of Pipe Nominal U.S. Gals/100 feet of Pipe
Size inches (2) Pipe Size (2)
(1) Inches (1)
1-Hour 2-Hour 3-Hour 1-Hour 2-Hour 3-Hour
2 0.08 0.12 0.15 20 2.80 5.50 8.00
3 0.10 0.15 0.25 22 3.50 7.00 10.50
4 0.13 0.25 0.40 24 4.50 8.90 13.30
5 0.21 0.41 0.63 28 5.50 11.10 16.80
6 0.30 0.60 0.90 30 6.20 12.60 19.10
8 0.50 1.00 1.50 32 7.00 14.30 21.50
10 0.75 1.30 2.10 36 9.00 18.00 27.00
12 1.10 2.30 3.40 42 12.00 24.00 36.00
14 1.40 2.80 4.20 48 15.00 27.00 43.00
16 1.70 3.30 5.00 54 18.00 30.00 50.00

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18 2.20 4.30 6.50

(1) mm* 0.03937 (2) multiply by 11.53 to convert to liter/100 meters of pipe

3.15. VALVES
Valves for pipeline installation shall comply with the relevant provisions of the appropriate AWWA
standard as set out below:

Type STANDARD
Resilient Seated Gate Valve AWWA 509
Air Valve AWWA 500
Check Valve AWWA 500
Rubber Seated Butterfly Valve AWWA C504

Valves shall have flanged ends in accordance with ISO 7005/2 (DIN2501).
All valves shall be coated and lined with 100 % powder epoxy.
The pressure rating of valves shall be as stated in the Contract Specific Specification.

3.16. VALVES AND APPURTENANCES

The Contractor shall supply gate valves and butterfly valves to shut off and sectionalize the
pipeline and isolate individual items of equipment on the pipeline as required. Unless specified
otherwise, gate valves shall be used for diameters less than 12 inches and butterfly valves shall
be used for diameters larger than 14 inches.

Valve ends shall be supplied double flanged.

Unless specified otherwise, valves for Transmission Mains shall be operated by a square
operating nut of minimum 1.2 inch using a removable key and shall turn anti-clockwise to open.

3.17. MATERIAL AND PROTECTIVE COATING FOR VALVES AND FLOWMETERS

The body and bonnet shall be ductile iron with not less than GGG 40 (DIN 1693).
Unless specified otherwise herein, valves shall be coated externally and internally with fusion
bonded or electrostatically applied epoxy coating 300 microns thick. Materials and application of
the coating shall comply with AWWA/ ANSI C213 or equivalent. The color of the coating shall be
approved by the Project Manager. A certificate verifying the suitability of the epoxy coating for
use with drinking water is required from the manufacturer, endorsed by the NSF, or a similar
independent national body. The valves and flowmeters shall be supplied complete with gaskets,
nuts, bolts and washers

All surfaces that cannot be coated shall be made of corrosion resistant metal or material.

3.18. VALVE MARKING

All valves shall have the direction arrow for opening, the name of the manufacturer, the working
pressure and size for which they are designed cast in raised letters upon an appropriate part of
the body.

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3.19. BALL AND PLUG VALVES

All plug valves shall be of the ¼ turn operation type.
All valves shall comply with the requirements of AWWA C507-91. All interior parts of the valve
shall conform to the requirements of ASTM B62.

3.20. SURGE ANTICIPATING VALVES

The Contractor shall be responsible for the design, supply, installation and testing of One (1) set
surge anticipated valve, associated pipes and fittings as indicated on the plan Contract drawing
and as detailed herein.

Surge Anticipated Valve - SAV is an automatic control valve designed to protect pumps, valves,
fittings and pipelines from pressure surge damage resulting from the sharp flow velocity changes
associated with pump starting and stopping and especially with abrupt pump stoppage caused by
power failure.

The main valve of SAV shall be a center guided diaphragm actuated globe valve of either
oblique(Y) or angle pattern design. The body and cover shall be cast iron with bronze seat. The
internal and external surfaces of the valve body shall be fusion bonded coated. End connections
shall meet the ANSI, ISO or other internationally recognized standard as required. The body shall
have a replaceable non-threaded seat ring that is held in place by set screws which tighten into a
body groove. This seat should be accessible and serviceable without removing the valve from
the pipeline. The seat area shall have a flow opening without stem guides, bearings or
supporting ribs.

The actuator assembly of SAV shall be a double chamber design with a separating partition
between the lower surface of the diaphragm and the main valve. The entire actuator assembly
consisting of the seal disk, valve shaft, bearing, diaphragm assembly, separating partition and top
cover must be removable from the valve as a single unit. The control chamber between the
diaphragm and the separating partition shall be capable of being open to or isolated from the
valve internal body pressure.

The stainless steel valve shaft shall be guided throughout its travel by a bearing in the separating
partition.

The high and low pressure relief pilots of SAV shall be direct acting, adjustable, spring loaded
diaphragm actuated valves. The high pressure pilot shall have a built-in needle valve to adjust
the main valve closing speed. The body and cover of the pilot valves shall be of brass or bronze
construction with stainless steel
trim and resilient seal. The main valve shall be equipped with either a mechanical or hydraulic
flow limiting device. Liquid to the pilots must be filtered and cock valves must be provided to
isolate the control loop.

SAV shall be included within this scope of works and shall highlight their positions on the design
drawings to be submitted for approval by CPUC.
The basic layout for the pipework is as shown on contract drawing.
Air Valves

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The Air Valve must be designed to automatically operates so that they will:
The Air Valve shall positively discharge and admit large amount air when a pipeline is
filled with water and while the pipeline is being dewatered, respectively.
 The air valve should not close prematurely. The air valve must discharge air up to 11
psi differential pressures between the internal pressure and the atmospheric pressure.
Valve with sizes greater than 100mm shall be combination type (1-large orifice and 1-small
orifice).
Maximum operating pressure shall be 10 bars.
Valve body shall be as follows:
 < 50mm Reinforced nylon or engineering plastic
 > 50mm Cast iron
The body of a metal valve shall be coated with 100% food grade powder epoxy.
Float shall be as follows:
 < 50mm Engineering plastic or polypropylene
 > 50mm Polypropylene or stainless steel 13.12.7 The float seat shall be EPDM
Inlet shall be as follows:
 < 50mm Threaded
 > 50mm Flange (ISO 7005/2 DIN 2501)

3.21. CHECK VALVES

Check valves shall be double flanged type specially designed for use in pumping systems, giving
rapid non-slam closure and low head loss characteristic when the door is in the open position.
Perforated check valves for surge vessels shall comply with the same specifications.

Check valves shall conform to AWWA C508 requirements for resilient seat full waterway swing
type check valves complemented with the modification required by this specification.

Valve body and flanges shall be made either of cast-iron conforming to ASTM A48 class 40 (or
GG25 to DIN 1691, or ASTM A126 Class B), or ductile iron conforming to ASTM A 536 Grade 65-
45-12, or cast steel conforming to ASTMA-27 (or A 216 WCB). Steel and Stainless Steel. Body
bolt, stud, and nut material shall conform to ASTM A307. Carbon Steel castings shall conform to
ASTM A27; grade U-60-30. Stainless steel parts, when used, shall conform to ASTM A276 or
ASTM A240.

Hinge Pin shall be made of Brass or bronze from copper alloy according to ASTM B16,- UNS
C36000, ASTM B21 –UNS C46400 and ASTM B138- UNS
C67500. Seat ring shall be made of Brass or bronze from copper alloy according to ASTM B62-
UNS C83600 or ASTM B271- UNS C92200 or ASTM B584- UNS C83600.

Seat facing or O-ring seat facing used to provide a seating or resilient hinge material shall be
made of EPDM or elastomeric rubber compound, having uniform dimensions, and size and shape,
and resiliency as to withstand ordinary wear and tear, rough usage, compression stresses, and
damage caused by pipe scale or foreign matter carried by the water. These materials shall have
minimum tensile strength of 1500psi and, minimum ultimate elongation of 150 percent or minimum
tensile strength of 2200psi and minimum ultimate elongation of 100 percent. A maximum set of
0.38in (9.4mm) will be acceptable when the 2 –in. (50mm) marks are stretched to 6 in. (150mm),
held for 2 min, then measured 2 minutes after release.
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All cast iron internal and external parts shall be coated completely with electrostatic epoxy powder
coating conform to DIN 30677 – T2 and DIN 3476 or in accordance with the quality and test
requirements of RALGZ662.

The valves shall be designed to prevent any permanent distortion of the body, cover, or seats and
to avoid any strain upon the seats that would be sufficient to force them out of alignment under
any condition.

The closure assembly shall assume the closed position by gravity under no-flow conditions in a
horizontal pipeline.

Internal working parts shall be readily accessible and shall be replaceable without the use of
special tools and without removing the valve body from the pipeline.
When the check valve is wide open, the disc/hinge assembly shall bear against a definite stop.
The point of contact is located so that any impact or loading applied by water flow will tend not to
twist or bend the disc parts.

The valve when fully open shall have a net flow area not less than the area of a circle with a
diameter equal to the nominal pipe size.

Valve ends shall be flanged and provided with gaskets, bolts and nuts conforming to ASTM D2000
and ASTM A153, respectively. Flanges and drilling to conform to ISO 7005-2 (DIN 2501) PN10/
PN16. All valve flanges shall be at right angles to the axis of the base and concentric with the
bore. Flanges shall be furnished with shallow serration.

All check valves shall have a direction arrow for flow, the name of the manufacturer or logo and
the working pressure for which they are designed embossed in raised letters or as a sticker on
the appropriate part of the body.

The resilient seat may be integral or separate resilient ring, fastened securely to the disc.
Bolts and nuts for flanged ends shall conform to ASTM A307, Grade B and shall be hot-dipped
galvanized as per ASTM A153. Gland and bonnet bolts shall be ASTM A164 zinc coated or
stainless steel countersunk to valve bonnet and body in such a way as to prevent from being
exposed to neither the outside nor to the inside elements.
Testing shall be in accordance with Section 5.2 of AWWA C508.
For pumping stations, non-slam check valves shall be used.

3.22. GATE VALVES

Gate valves must be suitable for continuously operating at up to 158°F. The maximum rated
working pressure at 68°F shall be PN 16 (230 psi).

Flanged gate valve shall comply with ISO 7259 type A with an overall length (face to face)
complying with ISO 5752 series 15 (short length). Flanges and drilling shall be PN 16 and shall
comply with ISO 7005-2 (DIN2501).

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The valve gate shall be completely covered with EPDM rubber or equivalent, the stem nut shall
be manufactured from alloy type CuZn39Pb in accordance with UA 10 N.
The valve must be designed so that the wedge nut will fail should the valve be overtorqued. The
manufacturer to ensure a failure will happen only when the wedge is in closed position - thus
avoiding an uncontrolled leakage.

The stem shall be manufactured of stainless steel Z20C13 in accordance with DIN 17440 - with
the threaded portion being formed by a rolling process - causing high strength and optimum
durability.
Gate valves shall conform to AWWA C509 requirements for resilient seat gate valves
complemented with the modification required by the specifications below. It shall have non-rising
stem, solid wedge gate coated with corrosion resistant synthetic elastomer to form the perimeter
seal between the gate and the body of valve.

Valves with nominal diameter greater than 400mmØ must be supplied with bypass valves.
Valves with nominal diameter greater than 400mmØ for interconnection purpose should comply
with face to face dimension of DIN 3202, part 1, F4.

Valve body and flanges shall be made either of cast-iron conforming to ASTM A48 class 40 (or
GG25 to DIN 1691, or ASTM A126 Class B), or ductile iron conforming to ASTM A 536 Grade 65-
45-12, or cast steel conforming to ASTMA-27 (or A 216 WCB).

The valve shall have a minimum of three (3) O-ring seals to ensure 100% tight stem seal and one
(1) dirt seal that prevent mud from entering the stem sealing assembly that are replaceable under
full working water pressure while the valve is in the fully open position.
Gate valve shall have stem made of cold rolled stainless steel with a minimum quality grade
1.40021 – according to DIN17440 X20Cr13.

All cast iron internal and external parts shall be coated completely with electrostatic epoxy powder
coating conforming to DIN 30677 – T2 and DIN 3476 or in accordance with the quality and test
requirements of RALGZ662.

Valves shall be tested to 10 bars. Test certificates for all the tests conducted in the production the
valves and the reference standards used shall be supplied.
The internal diameter of the waterway shall not be less than the nominal diameter of the valve
when in the open position to allow the valve to be used as tapping valve. A drilling machine bit of
the same nominal size as the valve will pass through the opened gate valve with a clearance of
about 12 mm. Valves to have full clear bore.

The body shall support the wedge movements by means of guide rails in the body and the wedge.
For valves with DN>400mmØ, no direct contact between body and wedge is allowed and
preference will be given to gate valves that will have the least torque requirement to operate and
close drop tight. Valves >400mmØ shall be positioned with the stem horizontal but the operating
nut must turn about a vertical axis and provided with position indicator. Valve ends shall be
flanged and provided with gaskets, bolts and nuts conforming to ASTM D2000 and ASTM A153,
respectively. Flanges and drilling to conform to ISO 7005-2 (DIN2501) PN10. The type and
minimum thickness of the flange shall conform to DIN 2531. All valve flanges shall be at right
angles to the axis of the base and concentric with the bore. Flanges shall be furnished with shallow
serration.

All valves shall have a direction arrow for opening, the name of the manufacturer or logo and the
working pressure for which they are designed embossed in raised letters or as a sticker on the
appropriate part of the body.
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Resilient seated gate valves shall be suitable for use under working pressure of 1000 Kpa and
torque shall conform to AWWA C509 or DIN 3352 part 4 and DIN 3230.
The 50-mm square operating nuts shall turn counter clockwise to open. An arrow indicating
direction to open should be visible from the ground level through a valve box when the valve is
buried.
Bolts and nuts for flanged ends shall conform to ASTM A307, Grade B and shall be hot-dipped
galvanized as per ASTM A153. Gland and bonnet bolts shall be ASTM A164 zinc coated or
stainless steel countersunk to valve bonnet and body in such a way as to prevent from being
exposed to neither the outside nor to the inside elements.

Wedge shall be made of ductile iron GGG40/50 to DIN 1693 corrosion protected inside, fully
encapsulated with EDK-70/EPDM rubber, vulcanized inside and outside and provided with drain
hole. Wedge nut in CZ132 dezincificated (Navy) brass suitable for drinking water applications.
Extension spindle/stem when required for pipe cover depth of 1.50 m and below shall be made
of galvanized steel or stainless steel St0037 with protecting tube made of PE and spindle head
and coupling made of ASTM A126 Class B.

3.23. BUTTERFLY VALVES

Butterfly valves shall be EPDM rubber seated valves conforming to the requirements of DIN 3354
Part 2. The maximum rated working pressure at 20 degrees Celsius shall be 16 bars.
Flanges and drilling shall be PN 16 and shall comply with ISO 7005-2 (DIN2501).

Butterfly valves of all sizes shall be designed to be buried in waterlogged ground. For all cases,
a visual indicator shall be provided to indicate the position of the disc. When the valve is buried,
the indicator shall be mounted at the surface box.

Valve seats shall mate with Type 304 stainless steel seat surface. Shafts shall be made of
stainless steel Z20C13 in accordance with DIN 17440.

Unless specified otherwise, valve operators shall be manual and shall be operated vertically by a
1.2 inch square cap using a tee key. A gearbox shall be provided for operators for ease of
operation. Valves shall be designed to withstand an operating torque of 450 Nm.
Meanwhile, it is requested that these valves shall be adapted to be operated by electric actuators
in the future.

All pump control valves shall be of the butterfly type, designed and manufactured in accordance
to AWWA C504 or ISO 10631-1994 standards and in accordance with the following:
The butterfly valve shall be rubber-seated with flanged-ends allowing the downstream dismantling
under the full pressure rating of the valves. Wafer type body or lug with through holes valves will
not be permitted for potable water applications.

The butterfly valve shall be positioned with the shaft horizontal but the operating nut must turn
about a vertical axis. When installed, one must be able to remove with ease, the actuator or shaft
without removing the valve. iii. Butterfly valve primary function shall be for throttling purposes to
a minimum of 5% opening.

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Butterfly valves shall be designed and manufactured in accordance to AWWA C504 Short Body
or ISO10631-1994 & ISO 5752 Short (F-4) with ISO 5211 (flange matching for the actuator)
standards.
Butterfly valves of all sizes shall be designed for submerged operation. A visual indicator has to
be provided in order to see the position of the disc which shall be mounted at the surface box. vii.
For rubber-lined concept butterfly valves, the disc is centered and must provide a complete tight
shut off with few (5%) degrees allowance before and after the 90 degrees closure.

Shafts shall be made of stainless steel AISI 431 (DIN X12 CrMoS17) or other approved materials
with the same tensile strength, yield stress & Brinell hardness and designed for both torsion and
shearing stress when the valve is operated under its greatest dynamic or seating torque. The
shaft shall be of the stub shaft type inserted in two parts from each side of the valve. Shafts shall
be accurately drilled and pinned to the disc to positively assure concentricity with the rubber seat.
Shafts shall be connected to the disc by internal connections provided by spline arrangements or
parallel keys.

EPDM shafts seals of valve with exposed shaft to fluid shall be designed to allow replacement or
adjustments without removal of valve shaft or operator assembly.
Rubber lined butterfly valves without any internal packing gland will be preferred. Valve body and
flanges shall be made either of cast-iron conforming to ASTM A-48 class 40 (or GG25 to DIN
1691, or ASTM A126 Class B), or ductile iron conforming to ASTM A 536 Grade 65-45-12, or cast
steel conforming to ASTM-A-27 (or A 216 WCB). Body shall be provided with lifting device
facilities. Double-Flange connections according to ISO 7005-2 (DN2501), PN10. External/Internal
Coating shall be Powder Epoxy with minimum thickness of 200 microns.

Valve seat or lining shall be EPDM mounted on the body or the disc to the body.
Disc shall be Ductile Iron GGG-40 to DIN 1693 coated with minimum of 340 microns thick of food
grade epoxy or made of Stainless Steel AISI 431. Disc shall seat at a 90 degrees angle to the
axis of the pipeline.

Butterfly valves shall be equipped with position indicator to show the disc position and adjustable
mechanical stop-limiting devices to prevent overhand of the valve disc in the open or closed
position. All vertical loads from the valve shall be carried on supports and not to be transmitted to
the adjacent pipe. Valves maybe supported in the flanged ends or by the use of support legs
fabricated of cast-iron or integrally cast to the valve body. The bearing flanges of support legs
shall rest on the sole plates mounted with non-shrink type grout onto the concrete supports.
Alternatively, supports can be mounted at the pipe section on both sides of the valve.

Butterfly Valve Testing shall follow the Testing methodology shall be as per AWWA testing
standards. Shell test pressure shall be 1.5 times the pressure rating. Seat test pressure shall
be1.5 times the pressure rating (for AWWA designed valves) and 1.1 times the pressure rating
(for ISO designed valves).

Butterfly Valves shall also conform to the following:

Product Guarantee - A minimum of ten (10) years warranty from defects in material and
Workmanship from the Supplier/Manufacturer.

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Spare parts/Service Facilities - That after sales, service and spare parts will be available in Chuuk
Area and when needed for the next ten (10) years for future maintenance of the valves. iii. Proven
good track record and performance of the unit being offered. List of at least five (5) customers,
which were issued with a ten (10) years warranty period.

3.24. VALVE ACTUATORS INCLUDING HEADSTOCKS

Hand operated valves and penstocks shall be fitted with cast iron handwheel actuators not
exceeding 20 inches diameter incorporating any necessary gearing to allow opening and closing
against the maximum unbalanced head without undue effort. Gearing shall be totally enclosed.
The direction of closing shall be clockwise.

Power operated valves shall be fitted with pneumatically or electrically operated actuators and
shall also be fitted with an emergency manual handwheel.
Gate position indicators shall be fitted to all actuators.

Actuators for flow control valves shall be fitted with suitable low gearing to allow precise control.
All valve operating handwheel, including power actuator emergency handwheels, shall be located
in a convenient position for operating by a person standing at floor level, or on an operating
platform, and all necessary extension spindles and heastocks shall be provided.

Headstocks shall be the rising stem type with cast iron columns and casings complete with a
graduated indicator. The pillar shall not be less than 30 inches high measured from the base to
the handwheel and shall be drilled for fixing. Bevel gearing, when required, shall be provided in
totally enclosed oil bath, or grease lubricated bevel gear housing equipped with oil-impregnated
bushes and ball thrust bearings.

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.

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 AC electromechanical 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 IP 68 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 using Profibus
DP connection. Control systems shall include facilities for valve modulation.

Local position indication shall be provided integral with the actuator housing. Actuators shall have
position feedback circuits giving for remote indication. Modulating actuators shall also have
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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, anticondensation 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 500861:1994. Cable glands shall
be provided for each actuator. Cable connection to actuator motor shall run in liquid-tight flexible
conduit.
The actuator shall have volt free contacts to indicate when the valve is fully open, fully closed or
has failed.

For actuators to be supplied with Butterfly Valves, the following shall be complied with:
 Valve actuator designed to operate quarter-turn on continuously submerged to 6
meters of water application for various sizes as per bid form from 400 to 2000mm
diameter quarter-turn butterfly valves.
 Valve data:
o Line Pressure: 80 psi
o Application: Modulating
 Actuator specifications:
o Housing Material: Cast Iron
o Worm Gear: Alloy Bronze
o Worm: Alloy Steel
o Spur Gear: Heat-treated steel
o Input Shaft: Chrome plated
o Paint: Powder epoxy suitable for 500 hours salt spray test
o Enclosure Position: Continuous submersible at 20 ft.
o Calibration: Adjustable mechanical stop (+ or – 5%)

3.25. AIR VALVES

Air release valve assemblies shall comply with AWWA C512 or equivalent.
They shall be of the size indicated with ISO PN 16 flanged 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. Ball floats shall be of brass coated steel covered with rubber. The seat
of the large orifice shall be of elastomer.

The body shall be coated inside and outside with epoxy (average thickness 250µm).
Valves shall be designed for a minimum of 16 bars water working pressure.
 Single Air Release Valves (Type 1):
 Single Air Release valve shall be equipped with integrated isolating valve and drain
valve.
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 The isolating valve shall be made of chromium-plated brass.

 Combination Air Release Valves (Type 2):
The pipeline system shall utilise only Type 2 air release valve assemblies ('Combination Air
Valves' with small and large orifices or air relief valve with double orifice valve for air release and
venting). They shall be supplied with independent stop valve, of flanged type, complying with
above specifications on gate valves. Type 2 valve shall comprise an air release valve in
combination with an air and vacuum valve. Air and vacuum valves shall be capable of venting
sufficient quantities of air while pipelines are being filled, and allowing air to re-enter while
pipelines are being drained.
Operation of the valves shall under no circumstances induce water hammer in the pipeline, and
the valves shall be fitted with suitable safety devices.

3.26. FLAP VALVES

Flap valves shall be ductile iron body for wall mounting and shall be suitable to avoid incoming of
drainage water in the flush out system. Seat shall be Buna N or stainless steel.

3.27. KNIFE VALVES

Knife valves shall be fitted with pneumatic actuators. Knife and stem shall be SS316 or SS317
stainless steel. Seat shall be PTFE or hard faced Satellite 6.
It shall be provided with a conventional packing chamber in order to eliminate leakage problems
associated with standard knife valves.
Working pressure: 16 bars (230 psi).
Bidirectional shutoff from 0 to 16 bars.
Max. working temperature: 150°F.

3.28. LEVEL CONTROL VALVE WITH ALTITUDE PILOT

It shall be fully compliant for the purpose of reservoir filling control.

The valve shall shut off at a pre-set reservoir high level and fully opens in response to an
approximately 3 feet level drop, as sensed by the altitude pilot mounted on the valve.
The valve shall be self-operated so that it can work without external power.
The valve shall be PN 25 (360 psi).
The valve body and actuator shall be Ductile Iron.
The bolts, nuts and studs shall be Stainless Steel.
All the internal part of the valve shall be of one of these material, stainless steel, tin bronze, coated
steel.
The seals shall be synthetic rubber.
The coating shall be dark blue fusion bonded epoxy.
The control system accessories shall be one of these material, stainless steel, bronze, brass.
The control system tubing shall be either stainless steel or copper.
The control system fittings shall be stainless steel or brass.
The pilot body and cover shall be either brass or stainless steel.
The pilot elastomers shall be synthetic rubber.
The pilot spring shall be stainless steel or galvanized steel internal.

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The altitude adjustment range shall be 7 to 46 feet.

3.29. PRESSURE REDUCING VALVE

The pressure reducing valve shall be of direct acting type spring operating and using a rolling
diaphragm.
It shall maintain a constant reduced downstream pressure regardless of changing flow rate and/or
inlet pressure.
The Pressure Reducing Valve inlet shall be PN 25 (360 psi)
The outlet pressure range shall be adjustable from 1.5 (22 psi) to 6 bars (87 psi).
The Pressure Reducing Valve shall be self-operated so that it can work without external power.
The cover and valve body shall be fusion bonded epoxy coated ductile iron in accordance with
ASTM A-536.
The diaphragm washer shall be epoxy coated steel.
The diaphragm shall be fabric-reinforced EPDM
The shaft and springs shall be respectively Stainless Steel AISI 303 & 302
The seat and seal disc shall be Stainless Steel AISI 410
The O-Rings shall be EPDM material
The internal bolts, external bolts, studs, nuts and disks shall be Stainless Steel AISI 316.

3.30. FLOAT VALVE

The float valve shall allow automatic control of the filling level of the reservoirs.
The body and cover material shall be Cast Iron that complies with GG25 (DIN 1693).
The valve shall be PN 10 (145 psi).
The obturator material shall be Stainless Steel.
The float rod, the levers and the float shall be stainless steel.
The float valve shall be flange end.
The internals shall be in stainless steel.

3.31. METERS AND METER BOXES

The meters have been already purchased; the Contractor is not supposed to purchase new ones.
Yet, in case new meters need to be purchased the meters shall be identical to those purchased
by CPUC and conform to the following specifications:

Meter specification:
 Composite meters
 US Gallons
 US fittings
 Integrated check valves

Prepay unit specifications:

 IP 68
 Lifespan of batteries not less than 10-years
Meter box and connection:

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 US fittings
 Non-return valve integral to the meter
 Two manual stop valves

AMR Requirements
 Drive by reading (minimum reading distance not less than 330 feet)
 Reading via handheld device with GPS mapping ability
 Data set stored hourly for a period of 12 months
 Batteries to be user field changeable
 Clip-on device waterproof (IP 68) with anti-tamper
 AMR system compatible with Utility Star billing system
Warranty:
 5 years hardware warranty
 10 years battery warranty
 Warranty shall include replacement of all units that malfunction during normal use

3.32. HYDRANTS

Unless otherwise indicated in the Drawings or Contract Specification, hydrants shall be of U/G
spring type, manufactured in accordance with AWWA C502.
5 ¼” (valve size) washout/fire-hydrant
Working pressure not less than 350 psi
For spring type hydrant, hinges, washers, bolts and valve keys shall be stainless steel as per
ASTM A276 type 304.
The hydrants shall have 3-ways main valve (2 hose nozzles and 1 pumper nozzle used for
flushing)
The hydrants shall be placed in a box and covered by a cast iron lid Class D400
Certified performance meets or exceeds requirements of ANSI/AWWA C502
10-year limited warranty

3.33. FLANGES
Flanges shall conform to the dimensions specified in ISO 7005-2 (DIN2501) PN 16 (230 psi)
standard, applicable to the working pressure, not less than 16 bars (230 psi) excepted otherwise
stated. Where required by the Project Manager special flanges shall be provided at connections
with existing pipework at the connection points. Identification of connecting flange is part of the
contractor scope of survey.

3.34. DISMANTLING JOINTS

All on-line accessories and instruments (valves of all types, flow meters) shall be designed with
dismantling joints allowing dismantling and adjustment.

Dismantling joints shall be for pipes 100mm DN and larger, and shall be able to connect pipes to
other fittings and appurtenances for easy installation and dismantling. Each joint shall consist of
a flange spool, follower gland, gasket, threaded rod and bolts. Dismantling joint for pipe sizes
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300mm DN and below shall be of steel, cast iron or ductile iron. For pipe sizes greater than 300
mm DN, dismantling joints shall be steel. The dismantling joint shall have a pressure rating as
specified by AWWA. Maximum length, minimum length and thickness shall be as specified below.
Flange material shall be of cast iron, ductile iron or steel. Flange face and drilling shall conform
to ISO 7005-2 (DIN2501). Thickness of flange shall conform to either ISO 7005-2 (DIN2501) or
AWWA C207. Flange bolts and nuts shall be hot-dipped galvanized in accordance with ASTM
A153.
Rubber gasket shall conform to ISO 4633 and suitable for drinking water. Gasket material shall
be made of EPDM rubber. Dimension shall be in accordance with AWWA C111.

Interior and exterior coating of the dismantling joint and gland follower shall be epoxy powder
(food grade) in accordance with AWWA C550. Coating and lining shall have a minimum thickness
of 200 microns.

Bolts, stud bolts and nuts shall conform to ASTM A307 and shall be hot dipped galvanized in
accordance with ASTM A153.
The manufacturer/supplier shall provide test certificates for the following:
 Chemical Analysis
 Tensile Test – including bolts and nuts
 Hydrostatic pressure test

3.35. JOINT SEALS AND LUBRICANT

Elastomeric joint seals for water mains and drainage pipes for push-o and mechanical joints shall
be generally Stylene Butadiene Rubber (SBR), unless specified otherwise by the manufacturer
and shall be obtained from the manufacturer.

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, odour or colour
to the water and shall not support bacterial growth.
The Contractor shall submit a non-toxicity test conducted by an independent laboratory
acceptable to the Project Manager at his expense.

3.36. FLANGES FOR PIPES

Flanges for pipes and fittings shall comply with the standards given in the following table as
applicable:

PIPE/FITTING TYPE FLANGE SPECIFICATION

STANDARD
CI ISO 13
DI ISO 7005-2 (DIN2501)
SP AWWA C207

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Flange mating dimensions and drilling shall conform to ISO 7005-2 (DIN2501).
Pressure rating for flanges shall be as stated in the Contract Specific Specification.

3.37. GASKETS FOR FLANGED JOINTS

Gaskets for flanged joints shall generally be of the inside-bolt-circle type. They shall have a
nominal thickness of 3 mm and shall be EPDM Rubber or Neoprene.

3.38. SLEEVE TYPE COUPLING

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.
The coupling shall be coated and lined with 100 % powder epoxy.

3.39. BRASS FITTINGS

Brass fittings shall be manufactured of leaded red brass with the following analysis:

Metal Component
%
Copper 85
Tin 5
Lead 5
Zinc 5

The composition, sampling and testing of the metal shall be in accordance with ASTM B 584.
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.

Service stops and angle valves shall be female threaded ISO 7 tapered threads on the outlet end
and compression joint at the inlet end.

Compression joints for tubing shall be provided with stainless steel stiffener and lock ring to
prevent pull out.

3.40. SADDLES

Saddles for uPVC pipe shall be made of cast iron.

Saddles for cast iron and ductile iron pipe 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.

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Saddles shall be constructed from one or a combination of the following metals:

 Ductile Iron - Minimum tensile strength of 415 MPa in accordance with ASTM A 536.
 Red Brass - 85-5-5-5 in accordance with ASTM B 584.
 Cast Iron - Gray Iron in accordance with ASTM A 48, Class 30.
 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.

3.41. HDPE ELECTROFUSION TAPPING SADDLES

Saddle shall be made of PE100 material in accordance with AWWA C-906

Saddles shall be PN 16 (230 psi)
Electrofusion fittings shall comply with ASTM F1055.

3.42. RUBBER GASKETS FOR MECHANICAL AND PUSH-ON JOINTS

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.

3.43. MARKER TAPES

Marker tape for buried water mains and electric cable shall be coloured orange PVC or
polyethylene mesh or ribbon at least 50mm wide, incorporating a corrosion resistant tracing
system.
The ribbon shall be printed with the words “WATER PIPES BELOW" or “ELECTRICAL CABLE
BELOW” in bold capital letters at intervals not exceeding 20 inches.

3.44. FLANGED JOINTS

Flanges shall be properly aligned before any bolts are tightened.

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.

3.45. OGEE JOINTS

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.

3.46. WELDED JOINTS IN STEEL PIPES

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The process of welding steel pipelines shall be in accordance with AWWA C206.
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 1 inch from the end of the pipe on both internal
and external faces.
The alignment of abutting pipe ends shall be such as to minimize the internal offset between
surfaces.
The Contractor shall submit his proposed welding procedure to the Project Manager for codifying.
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.

3.47. THRUST BLOCKS

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.
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.
Thrust blocks shall be allowed to develop adequate strength before any internal pressure is
applied to the pipeline.
Rapid hardening cement shall not be used in concrete for thrust blocks to plastic pipes.
Plastic pipes shall be wrapped with a layer of plastic sheeting before being surrounded by
concrete.

3.48. VALVE BOX

Each valve on buried piping shall be provided with a valve box and accessories as shown on
plans of suitable size for the valve on which it is to be used.
Surface valve box shall be made of ductile iron not less than GG 25 (DIN 1693) with adjustment
module up to 6 inches. The inside diameter shall be not less than 5 inches.
Valve box cover shall be as shown on the drawings. Valve box cover shall be designed to
AASHTO H-20 Highway Loading Standards, and shall conform to ASTM A48.

3.49. TESTING AND DISINFECTION

All the requirements below also apply to the private connections when they are realized before
the testing and commissioning of the distribution pipe.

3.49.1. CLEANSING OF PIPELINES

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.

3.49.2. PRECAUTIONS PRIOR TO TESTING PIPELINES

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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.
No pipeline with the following features shall be tested until the curing periods have elapsed:
Feature of Pipeline Curing Period
Cement Mortar lining and coating 7 days
Cement Mortar at joint 8 days
Thrust Block 7 days

Open ends and open outlets from appurtenances shall be plugged properly.

3.49.3. NOTIFICATION OF TESTS

The Contractor shall notify the Project Manager at least one clear working day beforehand of his
intention to test a section pipe.

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.

3.49.4. INFILTRATION

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.

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.

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.

3.49.5. SWABBING OF WATERMAINS

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.

3.49.6. CLEANSING OF STRUCTURES

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.

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3.49.7. TESTING OF CONCRETE STRUCTURES DESIGNED TO RETAIN AN AQUEOUS

LIQUID

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 6.6 feet in 24 hours.

A period of 21 days shall be allowed by the Contractor for stabilisation, 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 0.4 inch, whichever is less.
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.

3.49.8. DISINFECTION OF STRUCTURES FOR POTABLE WATER

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.

After 24 hours the Project Manager 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.

3.49.9. DISINFECTION OF WATERMAINS

Disinfection of watermains shall be in accordance with AWWA C-651.

Prior to putting into service, all new water mains shall be disinfected with chlorine in accordance
with AWWA C651, except as provided otherwise below.

Before disinfection, the interior pipe surface shall be cleaned and swabbed with a 1 percent
hypochlorite disinfecting solution. If dirt in the pipe will not be removed by the flushing operation,
the interior of the pipe shall be cleaned by a suitable mechanical means. The cleaning method
used shall not force mud or debris into the joint spaces.

The new water main shall be kept isolated from any active distribution system by physical
separation. Water required to fill the new main, if supplied from the distribution system, shall be
via a temporary connection with appropriate backflow prevention devices.

3.49.10. CHLORINATION

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The ‘Continuous-Feed Method’ shall be used unless otherwise agreed by the Project Manager.
The dosage of chlorine introduced into the main shall result in the water having not less than 50
mg/litre free chlorine. The chlorine water shall then be retained in the main for at least 24 hours,
during which time all valves and hydrants in the treated section shall be operated to ensure
disinfection of the appurtenances. At the end of this 24-hour period, the treated water in all
portions of the main shall have a residual of not less than 25 mg/litre free chlorine.

The chlorinated water shall then be flushed from the main until chlorine measurements show that
the concentration in the water leaving the main is no higher than 0.75 mg/litre but not less than
0.25 mg/litre.

The Contractor shall dispose of the chlorinated water used in the disinfection process in a way
not to cause any harmful effect to the environment.

3.49.11. BACTERIOLOGICAL TESTS

After final flushing, two consecutive sets of acceptable samples, taken at least 24 hours apart,
shall be collected from the new main. At least one set of samples shall be collected from every
300m of the new water main. All samples shall be tested by an approved laboratory for
bacteriological quality in accordance with Standard Methods for the Examination of Water and
Wastewater, APHA/AWWA/WEF and shall show the absence of coliform organisms.

The Contractor shall submit to the Project Manager a record of compliance showing the
bacteriological test results certifying the new water main is free of coliform bacteria contamination.
If the initial disinfection fails to produce satisfactory bacteriological results, the new main shall be
re-flushed and shall be re-sampled. If check samples also fail to produce acceptable results, the
main shall be re-chlorinated until satisfactory results are obtained.

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4. MECHANICAL WORKS
4.1. SPECIFIC REQUIREMENTS

4.1.1. PREAMBLE
All mechanical equipment furnished and installed under this contract shall conform to the
general stipulations in this section except as otherwise specified in other sections.

The Contractor shall carry out all work in skilled and workmanlike manner in compliance with
modern methods of engineering and recognized rules of workmanship. As far as not expressly
stipulated otherwise, all design, calculations, materials, equipment, manufacture, construction,
installation work, and testing shall conform to the latest applicable standards and regulations.
Further, the Contractor shall follow all instructions issued by the Employer and his
representatives.

Prior to placing any purchase order or beginning manufacturing a piece of equipment, the
Contractor shall submit his Method Statement together with the relevant material technical
specifications, to the Engineer for his approval.

4.1.2. STANDARDS
This Specification establishes the mechanical features and the corresponding minimum level of
quality required for all permanent mechanical equipment and appurtenances in the contract.
This specification shall be read in conjunction with the following standards:

AWWA C504-74/ISO 10631 Butterfly Valves

ASTM B62 Composition Bronze or Ounce Metal Castings
ASTM B584-74 Copper-Alloy Sand Castings for General Applications
ASTM A307-74 Carbon Steel Externally/Internally Threaded Standard
Fasteners
ASTM A153-73 Zinc Coating (Hot-Dip) on Iron and Steel Hardware
ISO 7005-1, PN16 International Organization for Standardization, PN16
ISO R261-73 ISO General purpose Metric Screw Threads – General Plan
ASTM A48/ASTM A126 Class B Gray Iron Casting for valves, flanges, and fittings.
ASTM A167 – 74 Stainless and Heat Resisting Chromium – Nickel Steel Plate,
Sheet and Strip
ASTM B584 C86700, C85800, C86200 Copper Alloy Sand Castings for General Application
ASTM A743/AISI 303 Stainless Steel for General Application.
AWWA C550 Internal and External Protection for Grey Cast Iron Castings
ASTM A312 Seamless and Welded Austenitic Stainless Steel Pipes
ASTM D3935 Polycarbonate Standard
ASTM D3011 Polystyrene Standard.
ASTM D4181 Acetal Standard
ANSI/ASTM D4066 Nylon Standard
AWWA C508 Swing Check Valve for Waterworks Service
AWWA C512 Air Release, Air Vacuum and Combination Ari Valves for
Waterworks service

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4.1.3. SUITABILITY OF DESIGN AND EQUIPMENT

In the Contractor’s proposal and subsequent selection of equipment and installations, attention
shall be paid to the following:
 Safety of operation
 Little and easy maintenance
 Well-proven and reliable components
 Ability to withstand the service conditions
 Protection against vermin, dust and humidity
 Corrosion protection
 Availability of spare parts in FSM
 Availability of service in FSM
 Mitigation of noise

4.1.4. SUBMITTALS
The following drawings and documents as a minimum shall be submitted to CPUC for review:
 Outline general arrangements showing overall dimensions and all pertinent details
including equipment, valves and pipes including all supports and clamps/guides etc.,
and any requirements for access for installation and maintenance;
 List of proposed manufacturers and types of main components;
 Detailed general arrangements showing dimensions, fixing details and approximate
shipping weights;
 All drawings shall be submitted in Autocad electronic file with a printed copy on size
A3.
 A fully detailed parts listing including quantities, materials and manufacturers part
numbers (if applicable).
 As-built drawings of the mechanical facilities.
 The following drawings and documents as a minimum shall be submitted for review:
o Equipment mounting and general arrangement drawing, complete with
parts and materials listing, dimensions and weight;
o Piping layout showing the location of valves and pumps and other
appurtenances;
o Equipment sectional drawings detailing all internal components and
associated parts lists;
o Performance curve for each pump size;
o Equipment data sheet;
o Valve and actuator datasheets.
 Each datasheet shall incorporate all relevant data associated with each specific valve
which shall include but not be limited to:
o principal dimensions;
o any pertinent construction details;
o materials used for all parts;
o torque limits;
o pressure rating;
o connection details.
o
4.1.5. SCOPE OF WORKS

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The Contractor shall prepare the detailed design, construction and installation drawings as well
as calculations, material specifications, operation and maintenance instructions, etc.

All mechanical equipment shall be manufactured, supplied, installed and put into operation
complete in every respect with all necessary accessories for reliable continuous operation,
even if not all details are expressly stated in the Specifications. The Contractor shall consider
the consequences due to the influences of the various articles on each other.

The scope of delivery and performance shall include all works and the provision of all materials,
permanent and temporary equipment, tools, hoisting equipment, compressed air, power,
combustibles, accessories, transport including loading, unloading, storage, protection from
adverse ambient conditions, installation, scaffolding, protection of personnel and equipment,
first lubricant filling, painting, putting into operation, provision of testing instruments, and testing
of all the parts of the plant and accessories contained in the Specifications, as well as cleaning
of the installation site.

The Contractor shall make competent and experienced staff available for the training and
assistance of the operating staff during commissioning and test service and, if required by the
Employer, for a period after completion of the trial operation which shall be agreed separately.

4.1.6. METHODOLOGY IN EXECUTING THE EXTENT OF THE CONTRACT

Certification
 The Contractor shall submit three (3) “fair” copies of all Test Certificates (including
results of tests) as required by the Contract.
 “As Built” Manufacturing Drawings/Information
 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 USB drive in AutoCAD 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.

4.1.7. NAMEPLATES
A nameplate shall be fitted in a prominent position on each equipment and valves giving the
following minimum information:
 Manufacturer’s name and address.
 Identification and/or serial number.
 Month and Year of manufacture.
 Working and Test Pressure
 The direction of flow in the form of an arrow
 Speed in rpm for equipment.

4.2. PUMPS

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4.2.1 GENERAL
These rules and regulations define the requirements for single and multi-stage centrifugal pumps
or units with axial, semi-axial and radial flow, and for submersible pumps with electric motors.
Pumps shall be capable of satisfying the performance requirements as specified; be quiet in
operation and free from vibration.
Pumps shall be mounted on base plates or suction stools manufactured of cast iron or steel plate.
The pumps shall be accurately aligned and fixed by dowels or machined spigots. Holes shall be
provided in the base plates or stools for foundation bolts.
Production of pumps shall conform to current standards such as ISO 9905, ISO 5199 and ISO
9908, and IEC standards (International Electrotechnical Commission). Pumps shall be driven by
electric motors.
A label made of non-deteriorating material shall be attached to each pump and motor in a place
where it can be easily read and shall show the following information:
 Serial number of the pump/motor and type
 Nominal flow in Gpm
 Manometric head in feet
 Net positive suction head (NPSH) in feet
 Power consumption, voltage, current, power factor, efficiency
 Number of rotations per minute

Pumps shall withstand continuous operation at full load (8000 hours/year)

Pump and impeller shall be designed in such a way that the duty point at nominal flow can be set
as near as possible to the maximum efficiency point rate. The duty point(s) shall be guaranteed
according to ISO 9906 Class 1. If one or several pumps are installed in parallel the characteristics
of the manometric lift depending on flow shall be perfectly identical.
The maximum output of the pump shall be related to the maximum nominal performance of the
motor.
The characteristics of the well for vertical submersible pumps given on the plan are only of a
preliminary nature. The pump manufacturer shall make proposals on the configuration of the
suction chamber and make the necessary recommendations for adequate suction and, if possible,
prevention of cavitation under all operational conditions. Pumps shall be supplied with all
supplementary equipment, as necessary to fulfil these conditions.
The regime of the pump shall be stable up to 130% of the nominal flow and the characteristic
curve shall be sufficiently inclined.
Pump and motor material shall be suitable for the water they transport (aggressiveness, abrasion,
temperature, etc.).

4.2.2 CONSTRUCTION ELEMENTS: CENTRIFUGAL PUMPS

General
Pump shall be standardised single stage volute casing low pressure pump, for horizontal
installation, rotating part statically and dynamically balanced, with bearing bracket in back pull-
out design. Bearings shall be grease-lubricated, maintenance-free, deep groove ball bearings,
sealed for life, shaft seal shall be uncooled soft-packed stuffing box packing, suitable for potable
water, asbestos-free, flanges drilled to ISO 7005/2 (DIN 2501).

Motor

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Motors shall be 2, 4 or 6 poles as required. Motors between 1.1 kW and 90 kW and shall comply
to CEMEP Voluntary Agreement (European Committee of Manufacturers of Electrical Machines
and Power Electronics) and / or EPACT (Energy Policy Act, USA) requirements for energy saving,
be squirrel cage induction motors, efficiency class EFF1 “high efficiency”, and bear the
corresponding values on the rating plate, protection class IP 55 (TEFC) and IK 08 for mechanical
protection, continuous duty class S1, basic design, normal rated output for ambient temperature
up to 40°C at altitudes up to 1,000 m above sea level, de-rating at higher altitudes. Larger electric
motors shall be similar to the “high efficiency” motors; the efficiency at 4/4-load has to be at least
95.0% for ratings above 90 kW and below 200 kW, and has to be at least 95.5% for ratings of 200
kW and above. Thermal class shall be according to International IEC and EN standard, fabricated
to ISO 9001 quality standard, electrical standards IEC 60034, IEC 60038 and IEC 60085, and
mechanical standards IEC 60072 and IEC 60034, dynamic balancing to ISO 8821. However, all
motors shall be designed according to thermal class F, but the temperature rise shall be allowed
to class B only, allowing a service factor of 1.15. Permissible temperature rise to IEC 34-1.

Rated voltage shall be 240/480 Volts +5/- 5%, exceeding IEC 60038 standard, delta/star,
frequency 60 Hertz.

Number of starts shall be not less than 5 per hour, 3 minutes between restart.
Materials of pump and motor

 Volute casing: Grey cast iron JL 1040 (GG-25)

 Bearing bracket: Grey cast iron JL 1040 (GG-25)

 Discharge cover: Grey cast iron JL 1040 (GG-25)

 Impeller: Bronze CC480K-GS (G-CuSn10)

 Pump shaft: Steel C45 or chromium steel 1.4021

 Wear rings: Bronze CC495K-GS (G-CuPb10Sn) or equivalent

 Shaft protecting sleeves: Stainless steel 1.4122 or equivalent

 Outside coating: 2-pack zinc-rich primer and top coat of epoxy resin
with a dry film thickness of 100 microns at least.

 Inside coating: 2-pack zinc-rich primer and top coat of epoxy resin
with a dry film thickness of 125 microns at least.
Scope of Supply of a standard pump unit:
 Pump and motor completely mounted, painted, c/w soft-packed stuffing box, with
strong type plate of corrosion-resistant material properly secured to the casing

 Common base plate / base frame for pump and electric motor in torsion-resistant
design, including foundation bolts and nuts
Accessories
 Flexible coupling with spacer sleeve allowing dismantling of impeller without

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loosening of pipework or motor

 Coupling guard as per EN 294

 Flushing / sealing water pipe

 Pressure gauges of CrNi-steel, 0 to 10 / 16 bar at discharge, –1 to 1.5 bar at

suction side, measuring range to be checked and selected for the application,
muting, cocks, vents, Accuracy: class 1.6, filled with glycerine, diameter: 100 mm.

 Drain, horizontal

 Spare parts for 5-year service for the pump and the electric motor

 Packing and Shipment

Unless stated otherwise in the specifications, the pump unit shall be supplied completely
assembled and mounted on the common base plate / base frame in a strong and suitable case /
crate / wooden box suitable for shipment to the place of ultimate installation.

Submersible pumps
The submersible pumps shall have the following features:
 Design to DIN 19569, where applicable.

 Casing with large-flow cross-section and replaceable wear ring where applicable.

 Impeller with large, unobstructed flow ways to ensure non-clogging and non-
stringing operation considering the media to be pumped.

 Impeller with means to reduce end thrust.

 Common motor/pump shaft supported in anti-friction bearings with grease and/or

oil lubrication. Shaft not to be in contact with pumped medium.

 Intake and discharge side of pump with flanged connection

 The motor cooling system must be highly efficient. Cooling shall be based on
indirect cooling.

 Duck foot bend for automatic coupling of pump to discharge pipe.

 Guide bar system for lowering/lifting of pump.

 Fixing components.

 The pumps shall be suitable for reversing by backflow in the pipe after pump stop.

 Cable shrouds should preferably be of steel wire mesh instead of synthetic

material.
Materials
The materials given below are the minimum requirements. The Contractor must state in the
appropriate sections the materials proposed by him.
 Pump casing, motor casing: Grey cast iron EN-JL1040 (A48 class 35)
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 Impeller: High chromium alloy cast iron or stainless steel

 Pump shaft: 1.4571 stainless steel

 Type of seal: mechanical seal suitable for liquids with a high

concentration of abrasive solids

 Fastening components: 1.4571 stainless steel

 O-rings: Nitrile rubber (NBR)

Drive
The motor shall have the following features:
 dry-running three-phase asynchronous motor in watertight casing according to
IEC standard

 protection type IP 68

 insulation class H

 operating mode S3 or S8 (frequency converter)

 internal cooling

 moisture/water sensor device to prevent damage to motor windings and bearings

 tandem mechanical shaft seal

 thermo-elements in coil for motor protection

 sensor for bearing temperature

 pump completely cabled

 thermal winding protection by temperature sensors

 motor housing monitoring by conductive moisture sensor electrode

Installation
 Wet well installation designed for automatic connection to an installed discharge
elbow

 Guide system by double pre-stressed stainless steel guides (stainless steel

1.4404)

 Lifting device using stainless steel lifting chains (stainless steel 1.4404)

 The pumps will have factory-installed underwater-cable for the motor and the
monitoring. Length sufficient to reach a receptacle at the shaft entrance. The cable
shall be fastened to the chain to avoid stress.
Pumps installed in dry pits

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Pumps installed in dry pits or at suction with a power of 7.5 kW or more will be equipped
with protection against unpriming and bearings with positive-safe temperature contacts.

Installations shall be designed in such a way that any hydraulic failure on a pump does
not cause the draining of the structure or tank. In addition, it must be possible to remove
pumps without draining tanks or pipelines (implementation of isolation valves and valves
in sufficient numbers).

The suction and discharge lines of the dry pit pumps will be accessible without having to
enter the pumped tank. The suction will be placed at a low point to avoid deposits in the
tank.

Positive displacement pumps

All positive displacement pumps are equipped with variable frequency inverters that can
be remotely controlled.

Dimensioning must be adapted to the flow rate to be pumped. Pumping below 15% of
the flow rate and above 95% of the flow rate must be avoided (operating range between
15% and 95%).

Eccentric screw pumps will be equipped with dry-running protection devices,

overpressure protection devices (pressure switches) and inspection hatches.

Plunger pumps will be equipped with pulsation dampers and back-pressure valves as
well as discharge valves for atmospheric pressure control at the discharge. The hourly
flow rate will be adjustable while the pump is on or off.

For plunger pumps or similar, sealing shall be provided with valve devices; feeding will
be driven by a hydraulic motor.

4.3. COAGULATION, FLOCCULATION AND LAMELLAR CLARIFICATION

Deleted

4.4. RAPID SAND FILTRATION

4.4.1 GENERAL DESIGN

Water distribution system on the filters and air washing system must be simple, reliable, robust
and designed to limit the risk of material deposits.

The backwash system of each filter is designed to prevent the flow of filter material.
A technical gallery is provided for each filtration stage.

4.4.2 OPERATION
Filters operation including washing is fully automatic. Nevertheless it will also be possible to
control it in manual mode.

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Filters operating modes (production, washing, etc.) involve automatic valves with integral passage
equipped with limit switches allowing their status to be transferred to supervision. These valves,
preferably pneumatically operated, are in line with manual valves. The pilot air production is
ensured for each line by two compressors, one of them as a back-up.

Washing sequences are triggered at least once a week:

 on pressure loss detection with a security level,

 and clockwise.

Operating status of each filter (filter duration since the last wash, pressure drop, etc.) is monitored.
Contractor describes precisely the procedures for shutting down and restarting filters.

4.4.3 SUPPORT MATERIAL

The origin and characteristics of the filter material are indicated by the contractor.
Loss rate of substrate material shall not exceed 1 % per year.
Unless otherwise specified in chapter 2 of this document, material shall meet the following
characteristics:

 Nominal Effective Size (TEN): 90% of the grains have an equal or larger size than the size defined
by the Contractor,
 Uniformity coefficient (UC): the average grain size is as close as possible to the actual size defined
by Contractor.

Moreover, in all cases, offered materials are highly resistant to attrition.

Filters are designed and positioned so that the filling and emptying of the carrier material can be
easily achieved.
Filling and draining of one filter must be possible without stopping the other filters.

4.4.4 MAINTENANCE
Solution is designed to facilitate maintenance operations on air distribution systems in each cell.
These operations must be carried out without the need to empty the filter.
Safe access to the filter beds must be provided.
A manhole is provided for access under each filter floor (cover has a gripping device for handling).
Clearance under the floor shall not be less than 1 m.
Required safety equipment for maintenance personnel must be permanently on site.

4.5. SCOUR AIR BLOWER (ROOTS/ROTARY POSITIVE DISPLACEMENT TYPE)

4.5.1 GENERAL
The scour air blowers shall be rotary positive displacement (Roots type) blowers as specified herein and
shall be supplied by a company that has been in the business of manufacturing air blowers for at least five
years. The blowers shall comply with the Water Industry Mechanical and Electrical Specification 8.04 Air
Blowers. In particular, the blowers shall be rotary lobe blowers as specified in 6.02.

a Performance

The discharge pressure shall be sufficient to blow the air at given capacity through the pipe system, filter
underdrain system, gravel/sand filter and maximum water column as per Contractor design.

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Each blower shall be rated for the design as specified. The scour air is added to the treated water during
backwashing and must be 100% free of oil or other traces of pollution.

b Base Plate

The motor-blower unit shall be mounted on a common heavy duty cast iron or fabricated steel base plate
and motor pedestal. If concrete foundation is necessary in addition, such information must be given in the
Contractor’s proposal.

c Vibration Isolation

The Contractor shall supply and install elastomeric foundation pads for placement between the base plate
and concrete blower foundation.

d Expansion Joints

Expansion joints shall be furnished for the blower piping. These joints to be single arch, moulded type joints
with standard ISO PN 10 drilling and flanges supplied with steel retaining rings. Material of joints to be
suitable for 120ºC service.

e Noise

The blower shall have a separate prefabricated noise protection cover to protect the surroundings
for the noise produced when the blower is running. The engine shall be easy accessed for
inspection and maintenance. To avoid overheating the noise protection cover shall have a
ventilation fan that will be started automatically at the same time as the blower is starting. The fan
shall run an adjustable time after the blower has stopped; typically 10-30 minutes. A temperature
indicator is to be supplied with the blower.

f Other Equipment

The blower shall be completely equipped for the given task, i.e, to be in use once for up to 10 minutes every
time a filter is backwashed. It is the Contractor’s responsibility that all necessary equipment is included.
Some main components are mentioned below i.e, (the list is incomplete):

4.5.2 PIPEWORK AND VALVES FOR COMPRESSED AIR

All air lines shall be of the galvanised heavy gauge steel tubing type, to BS EN 10255:2004 Non-
alloy steel tubes for welding and threading. All bends, tees, unions and other fittings shall be of
galvanised steel to BS 143 and shall be of the correct size and type for the steel tubing in use.
Screwed or flanged joints may be incorporated. Pipes shall be flanged to BS 4504, PN 10 where
required to make connections with plant items, and shall be designed for a pressure of not less
than 3 x relief valve pressure blow point. Air main velocity shall not exceed 6 m/s.

Pipework shall be installed horizontally and vertically but shall fall in the direction of airflow to
facilitate draining of condensate. Automatic drains shall be fitted to prevent the accumulation of
condensate at low points in the system. The nominal fall of the pipework shall be 1-in-80.

Pressure relief valves and condensate drain valves shall be provided as required by the operating
system. Isolation valves shall be full bore diaphragm or ball pattern
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The air receiver shall be cylindrical and constructed to PD5500. The air receiver volume shall be
at least six times the total volume of the air compressed in 1 minute, at duty pressure, and shall
include the following fittings and equipment:
 air relief valve

 pressure gauge

 drain valve

 air line connections

 pressure switch for automatic control of compressor.

4.5.3 PRESSURE AND VACUUM GAUGES

Gauges shall comply with BS 1780 and shall, unless otherwise specified, be of not less than
100 mm diameter. Scales shall be calibrated in both psi and bar with zero representing
atmospheric pressure. Lettering shall be black on a white background. Where the working fluid is
of a dirty or corrosive nature, gauges shall be protected from the working fluid by a diaphragm or
similar arrangement. All gauges shall be fully protected from dust and water ingress and shall be
provided with a suitable isolation valve on the supply line adjacent to the gauge. Pressure gauges
shall be filled with glycerine and their accuracy shall be class 1.6.

4.6. STAIRS, WALKWAYS, PLATFORMS AND HANDRAILS

4.6.1 GENERAL
All stairs, walkways, platforms and handrails shall comply to US standards or local regulations if
they are more stringent.

All open sides of stairs, landings, walkways and platforms shall be guarded with handrails.
Handrails shall include top handrail, intermediate rail, handrail, balusters and toe kick plates. Two
hanging chains shall guard access openings to stairs and ladders, which shall be secured at one
end and detachable at the other.

The height of the handrails shall be 1,100 mm with an intermediate rail at a height of 550 mm.
Handrail height shall be measured vertically from finish floor level to the handrail centreline. The
height of toe plates shall be 150 mm. Toe plates shall be fixed securely to the stanchions.
Sloping handrails shall be as specified for horizontal handrails, but with top rail 900 mm vertically
above the line of pitch and stanchions vertical and spaced at not more than 1,500 mm measured
parallel to the line of pitch.

All mounting flanges shall be of substantial construction, with horizontal flanges drilled for not less
than three bolts with two bolts on a line parallel to and on the walkway side of the line of handrails.
Vertical flanges shall be drilled for not less than two bolts, the lines through the bolts being vertical.
Fittings shall be screwed or secured by means of grub screws.

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Handrails shall be able to withstand a vertical force of minimum 0.8 kN/m on the top rail. The
deflection of the rails shall not exceed 0.8% of the span between stanchions, and the deflection
of stanchions shall not exceed 0.8% of their height.

Handrail and balusters shall be manufactured from either aluminium, hot dip galvanised steel or
stainless steel tube with bore not less than 32 mm. Toe plates shall be of 5 mm thick aluminium,
hot dip galvanised steel or stainless steel plate. Distance between balusters shall not exceed
1,500 mm.

Handrails, balusters and toe plates shall include all necessary joints to facilitate easy installation
and to provide a smooth and neat appearance. The Contractor shall ensure that unless specified
to the contrary all handrails shall be prefabricated and of uniform appearance and manufacture.
The Contractor shall submit working drawings of the handrails to the Engineer for approval.

4.6.2 STAIRCASES
Stairs shall have handrail on both sides. The height of the handrail on stairs shall not be less than
900 mm. If handrail is attached to a wall, it shall have at least 75 mm clearance from the wall.
Staircases pitch line shall preferably be within the range of 38 to 45° with rise and going
dimensions in accordance with the formula: Twice the rise plus the going should not be less than
572 mm nor more than 635 mm. Overlap shall be at least 16 mm.

Staircases shall be designed to carry a uniform load of 3.5 kN/m2 in addition to dead weight and
loads during operation calculated on the plan area of the stair. The Contractor shall design the
staircases for the actual point-load adequate for the equipment to be unloaded, however, no less
than 3.0 kN in the middle.

Treads shall be with non-slip pattern surface.

Material: Hot dip galvanised steel.

4.6.3 ACCESS LADDERS

Ladders shall be fabricated of mild steel and hot dip galvanised after fabrication. The stringers
shall be flat section not less than 65 mm x 13 mm spaced 380 mm apart and shall be flanged and
drilled for wall fixing at both ends. The distance between stringers shall be widened over the top
where they shall be not less than 600 mm apart. Ladders over 3,000 mm long shall have additional
intermediate stays at not more than 2,500 mm centres.

Rungs shall be 25 mm diameter solids at 300 mm centres riveted or welded to the stringers.
Rungs shall be not less than 225 mm from the wall.

All ladders shall have safety cages, which shall be constructed of three flat vertical strips
supported by flat hoops, with a diameter of 750 mm. The hoops shall be approximately 700 mm
centres and the first hoop shall be 2,400 mm above ground or platform level.

Where the rise exceeds 6,000 mm an intermediate landing shall be provided.

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4.6.4 OPEN MESH & CHECKER PLATE FLOORING

Open mesh flooring and gratings shall generally comply with EN ISO 14122 except where
otherwise specified hereinafter. Such flooring and gratings shall be of rectangular mesh and non-
slip and shall be mild steel and hot dip galvanised after manufacture. Alternatively open mesh
and chequer plate flooring may be of stainless steel (1.4404) as specified in section Error!
Reference source not found. or glass fibre reinforced polyester.

Flooring shall be adequately supported by means of substantial members.

Flooring shall be designed to carry a uniform load of 3.5 kN/m2 in addition to dead weight and
operational loads. The Contractor shall design the flooring for the actual point-load adequate for
the equipment to be unloaded, however, no less than 3.0 kN in the middle.

The deflection shall not exceed 0.2 percent of the span. Flooring shall be provided with curbing
at the edge of walkway. Each floor panel shall be separately secured to the supporting members
by means of fixing brackets. However, each floor panel shall be secured in a way that when not
fixed by brackets it shall be fixed in all horizontal directions.

Both the load bearing and transverse bars in rectangular open mesh flooring panels shall be
positioned symmetrically around the centre lines of the panels in both directions so that when the
panels are fixed in extensive areas or in long runs, the bars of all panels are in line.
Chequer plate flooring shall be of the non-slip type, not less than 6 mm thick measured excluding
the raised pattern. The flooring shall be secured to its frame by A4 stainless steel countersunk
screws.

All flooring shall be removable and set flush in frames of similar material. Where frames are to be
fixed over openings the frames shall be provided with lugs for building in.
Flooring shall be provided in sizes suitable for lifting and removal by one man and with the
appropriate cut-outs to permit its removal without disturbing or dismantling spindles, supporting
brackets, cables or pipe-work.

4.6.5 HATCHES
Hatches shall consist of a frame with a hinged cover. The frame shall be designed for mounting
in recesses in the concrete slab. Hatches on dry wells shall be watertight. Detailed design for
sealing shall be subject to the approval of Employer’s representative.

A handle for opening of the hinged cover shall be integrated in the cover. The cover shall be
provided with a safety mechanism, which locks the cover in open position whenever opened. The
mechanism shall be manually released before the hatch can be closed again.

The hatches shall be designed to withstand a load of minimum 15 kN depending on the location.
Hatches shall be prefabricated and shall be from a recognised manufacturer specialised in the
manufacturing of hatches for similar purposes.

Heavy hatches shall be provided with spring-loaded mechanisms or similar facilities which reduce
the force required for safe opening and closing of the hatch.

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The hatches shall be made of hot dip galvanised steel. Alternatively hatches may be made of
stainless steel.

4.7. CORROSION PROTECTION

The whole of the plant shall be adequately protected against corrosion and damages during
transport, storage and service.

Surfaces shall be prepared and protective coatings applied at the manufacturer's works and
on site as specified hereunder.

Items not particularly specified shall be given a protective or decorative coating compatible
with the remainder of the plant.

Items of plant having a manufacturer's standard finish may be left with such finish, subject to
the approval of the Employer’s representative.
Mechanical equipment shall be protected against corrosion by painting or other appropriate
treatment to a degree sufficient for the intended function and location within the works.

All bright metal parts shall be covered before shipment with an approved protective compound
and adequately protected during shipment to site. After erection, these parts are to be cleaned.

Where the Contractor has a possibility to select different coatings that comply with technical
requirements then the coating that has the smallest possible impact on workers’ health and
safety must be used. Documentation of the choice should be made available to the Employer’s
representative.

The life before first maintenance shall be at least 15 years.

4.8. PIPEWORK
All pipework associated with pumping units and associated fittings shall be flanged to SDR11 in
accordance with ISO 7005-2 (DIN2501).

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 EPDM material in accordance with ISO 4633.

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. All
pipe supports shall be fabricated from either concrete or hot dip galvanized mild steel; in either
case adequate clamping and guides shall be designed and installed.

The Contractor shall be responsible for the detailed design and dimensioning of the pipework.

Valve Specifications

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The Contractor shall be responsible for the design, selection and procurement of all valves
required under this project.

All butterfly valves shall be designed for a pressure rating of 16 bars.

The Contractor shall submit for review a complete valve schedule including manual valve and
actuated butterfly valves.

The Contractor shall submit the specifications of each valve for review before procurement.
Valve ends, mating dimensions and drilling shall be in accordance with ISO 7005-2(DIN2501),
Table I, Class PN-16. The type and minimum thickness of flange shall conform to AWWA
standard.
All manually actuated valves shall be clockwise closing and shall have the direction arrow to
signify opening.

All manually operated and actuated valves shall be supplied with permanently installed hand
wheels orientated in such a position as to allow easy operation. All hand wheels shall be
manufactured from cast iron, or equivalent, and shall be located via a keyway onto the shaft. A
locking nut shall secure the hand wheel to the shaft.

Bronze interior parts of valves shall be manufactured from “85-5-5-5” bronze (except valve stems)
and shall conform to the requirements of ASTM B62 unless otherwise stated.
The composition, sampling and testing shall be in accordance with ASTM B62.
All valves shall be coated over 100% of the interior of the valve by a powder epoxy coating.
All valves shall include, but not be limited to, the following markings, which shall be raised and
cast in a prominent position into the main valve body:
 Manufacturer's name and address,
 Identification and/or serial number,
 Month and Year of manufacture,
 Working and Test Pressure,
 The direction of flow in the form of an arrow.

4.9. PRESSURE GAUGES (MANOMETER TYPE)

Pressure gauges shall comprise of brass or black moulded phenol plastic construction with acrylic
plastic or toughened glass windows. Dials shall be at least 6 inches diameter except where fitted
to small pumps having branch connections 3 inches internal diameter and below.

For such pumps 4 inches 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 aluminium shall be used in the construction of the gauges.

Diaphragms shall be fitted to gauges subjected to liquid containing suspended matter.

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.

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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.

4.10. CHLORINATION EQUIPMENT

4.10.1. 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.

4.10.2. CHLORINATION MIXING & DOSING EQUIPMENT

Calcium hypochlorite powder will be used for disinfection.

In general the dosing system will include the following:

 Two chemical mixing/holding tanks. One will be in use to feed the chemical solution while the
other is used to mix the next batch of chemical solution.
 Mixers for the tanks.
 One rotameter for flow measurement. These are to be mounted at a height for convenient
reading, but the top shall be below the top level in the mixing tank to ensure reliable flow in the
system.
 Flushing connection downstream of the rotameter for flushing the dosing pipeline.
 All associated valves and fittings for the operation of the dosing system.
 Control panel including starters for the mixers

4.10.3. MATERIALS

Suitable chemical resistant materials shall be used for all parts of the chemical dosing system,
including tanks, pipes and valves.

All the solution tanks shall be of pre-manufactured corrosion resistant material, such as fiberglass
or polyethylene, complete with required outlets (flanged).
Pipes shall be uPVC or ABS. All materials must be suitable for the actual chemical system and
the degree of exposure to sun and weather.

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4.11. EXHAUST FANS

The air requirements for adequate ventilation in the buildings shall be designed based
on the requirements of ASHRAE Standard 62.

Air moving devices shall be installed as indicated on the drawing. Fan bearing shall be in
accordance with AFBMA 9, L-10 life at 100,000 hours, self-aligning, and grease-lubricated ball
bearings. The fan assembly sound rating shall be in accordance with AMCA 300. Types of air
moving devices shall be as herein.

Fans construction materials shall be suitable for the contaminants in the air.
Exhaust fans shall be propeller types, direct driven with mounting collar, back draft damper, insect
screen and weather louver where applicable. Fan shall be dynamically and statically balanced
and shall be fabricated of galvanized steel. Fan panel shall be constructed of steel and coated
with a thermally fused powdered epoxy. The guard shall be constructed of heavy gauge wire and
finish with zinc plated surface. Motor shall be explosion proof. The Contractor shall submit the
design of the said system for the approval of CPUC.

4.12. FUEL STORAGE FOR STANDBY GENERATOR SETS

This specification establishes the features and minimum level of quality required for the following
works associated with the design, supply, installation, testing and commissioning of a new prime
generator, fuel storage tank, day tank and level control system. System shall be as per NFPA 30
Code.

Generators shall be provided with minimum storage capacity for main fuel storage tank as
indicated below computed at full load operation of the genset, together with pertinent associated
supply pipework and valving to the day tank.

Water Supply Facility – minimum Three (3) Days storage

Wastewater Facility – minimum Two (2) Days Storage
The day tank shall have a minimum of 8-hours at full load operation of the genset. The maximum
capacity of a day tank shall be 2,500 liters.

The day tank shall supply the standby generator. The fuel storage tank shall be elevated to
eliminate fuel transfer pumping from fuel storage to the day tank.
Day tanks and Main Storage tanks of fuel shall be provided with Bund Walls. Bund Walls shall be
able to contain 110% of the capacity/volume of the tank and shall be provided with the proper
lining as maybe required by CPUC.

The fuel storage fuel tank shall be fabricated in accordance with the pertinent provision of the
latest edition of the PSME Code. Construction shall be from mild steel plates with a minimum
tensile strength of 55,000 ps) and shall be at least 5mm thick for 2000 US Gallons and above and
4 mm thick for below 2000 US Gallons. Day tank shall be 4mm minimum thickness.

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All welded joints shall be double welded joints and all electrodes shall be in accordance with the
ASME/AWS Codes. The general layout of the fuel tank shall be in accordance with the contract
drawings.

4.13. GEN SET PIPING SYSTEM

The piping system shall be provided with one inlet pipe for refilling 50 mm diameter minimum, one
storage tank outlet pipe to day tank, one outlet pipe from day tank to engine bracket and one fuel
return pipe from engine bracket to the day tank. The mouth of fill line shall be lockable and
installed at the lower end of the tank and accessible to fuel supplier tanker. Fuel-return and outlet
shall be flexible hose (standard fuel hose material shall be used) from the bracket to the fuel filter
and engine injection pump. Air vent pipes shall be equal to the size of refilling inlet pipe and 25
mm diameter for day tank. Piping shall be laid on a ground at concrete trench with holes and
shall not be buried, covered with removable steel grating. Stainless steel drain plug shall also be
provided with a minimum of 32 mm and 19mm for storage and day tank respectively. Pipes shall
be black iron seamless minimum of 19 mm diameter, schedule 40 with primer and color brown
anti-corrosion paint. Valves shall be installed at the inlet and outlet of each tank with flange or
union for easy replacement. Gate valves shall be used for all valves, globe valves are not
acceptable. Additional piping installation is acceptable as per recommendation of the generator
set manufacturer.

Fuel storage and day tank shall be provided with level sight glass visible to the operator, it shall
be removable for cleaning, protected against breakage and provided with cock valves at upper
and lower ends. Scales shall be 50 liters per graduation for day tank and maximum 500 liters per
graduation for storage tank. Fuel storage tank shall also be provided with low and high level
switch and alarm connected to the generator set panel.

The Contractor shall be responsible for the surface preparation and coating of the tank, however
as a minimum all surfaces shall be shot blasted to SA 2 ½, primed with a general purpose epoxy
primer to a minimum thickness of 75 microns followed by two further coats of high build epoxy
resin each coat being minimum of 200 microns. The finished color of the tank shall be black base
coat with yellow stripping.

Welding of the structure shall be in accordance with AWS-D1.1 E70XX. Bolts for fixing of the
same shall be stainless steel grade 316 complete with nylon washers to prevent galvanic reaction.
Further, the Contractor shall be responsible for the design, excavation and construction of one
reinforced concrete bulk storage tank support structure and retaining wall known as a bund. The
volume of the bund shall be 1.1 x the volume capacity of the storage tank. The bund shall be
provided with a drain valve for proper fuel disposal should the need arise. The type of valve shall
be suitable for diesel fuel.

The Contractor shall determine the number of silencers required to suit the supplied generator. It
shall be residential type.

All brackets shall be hot dip galvanized in accordance with ASTM A153. The silencer shall be
fitted with a drain cock to allow any condensate to be removed from the same. All welding of the
silencer(s) and exhaust system shall be in accordance with AWS-D1.1 E70XX. The Contractor
shall pay particular attention to the thermal expansion of the exhaust system and shall design the
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clamps and guides accordingly. The silencer shall be either coated with hi temperature paint or
clad with aluminum around a heat retardant material. The external discharge point of the exhaust
pipe(s) shall be protected from rain intrusion. This maybe in the form of a rain cowl or a “flapper”,
however it shall be noted that whichever is preferred by the contractor shall not limit the flow of
the exhausting gas from the pipe(s). Details of the same shall be required to be submitted by the
Contractor for the approval of CPUC.

4.14. ACOUSTIC LINING

The Contractor shall be responsible for the selection, supply and installation of an acoustic lining
on internal walls of the generator room in accordance with the following:

a. Material - High density cladding of rigid construction, rockwool board designed for thermal
and acoustic insulation of flat concrete surfaces where excellent compressive strength and high
sound transmission loss shall be supplied and installed. Insulation materials shall be bio-soluble.
b. Physical Characteristics
i. Nominal Thickness- 50 mm ii. Standard size- 2,300mm x 1,200mm iii. Nominal Density- 80 Kg/
cu m iv. Mass/ Unit area- 2.0 Kg/m2
v. Service Temperature- sub-zero to 3400C vi. Thermal Conductivity- 0.032 W/ mk at 200C mean
temperature vii. Sound absorption coefficient - 1.02 @ 2000 Hz viii. Noise Reduction Coefficient-
0.70 ix. Moisture Absorption - 0.1% by vol when tested in an atmosphere of 65%RH @20 0 C.
x. Alkalinity- pH9, slightly alkaline (neutral is pH7)
Bolts and nuts required for fixing shall be structural steel ASTM A36 with hot-dip galvanized ASTM
A153 with lock washers.

4.15. FIRE PROTECTION SYSTEMS

4.15.1. FIRE EXTINGUISHERS

Portable Fire Extinguishers shall be dry chemical, ABC type, 10 lbs. Fire Extinguishers with Ozone
Depleting Substances (ODS) such as Chlorofluorocarbons and Halons shall not be used. Latest
DENR regulations on ODS shall apply.

One portable fire extinguisher shall be placed for every minimum radius of 37 feet.

4.16. SURGE VESSEL

4.16.1. GENERAL

Each pipe has to be protected against water hammer. The vessel shall be designed to maintain
the pipeline pressure between -0.6 bar to 16 bar in the water pipe. Surge vessel dimensioning
shall be determined by the vessel manufacturer using surge analysis computer software. The
surge vessel shall be designed for anchor bolting to a concrete foundation. The supports shall be
designed to withstand all natural loading, any hydraulic and pneumatic thrust, resulting from
surges.
 Vessel type: gas pressure, bladder type, vertical mounted on legs & suitable for open-
air installation;
 Material: The surge vessel shall be made of welded steel shells and dome ends
according to BS 1501 Part 1 or equivalent.

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 Configuration of the vessel: four feet, transport eyes, manhole, pressure gauge with
three-way cock and water connection at the center of the bottom, gas at the center of
the top and connections for the water level switches;
 Volume of the tank shall not be less than 80 cuft;
 Internal coating, applied after sandblasting, shall be of epoxy with a minimum thickness
of 0.3 mm.
 Corrosion allowance of not less than 1 mm shall be allowed;
 Bladder: thermoplastic polyurethane or butylene each approved perfectly watertight
and airtight after the installation inside the vessel;
 Anti-extrusion grid: In the hut connecting with the pipe, there shall be an anti-extrusion
grid for the protection of the bladder.

The vessel shall be provided with all pipe works and connections, tapping points for
instrumentation, vents and drains. The vessel shall be protected with a safety valve.
The surge vessel shall be equipped with the following:
 a manometer;
 an inflation valve;
 a digital level gauge equipment;
 a removable anti-extrusion grid;
 a flanged connection pipe;
 a non-return valve perforated (size confirmed by calculations).

An isolating valve with dismantling joint. The surge vessel shall be painted as indicated below.
 Internal painting shall be free of solvant, and of epoxy anti corrosion type.
 External painting shall be polyurethane lacquer type.

The surge vessel will be connected to the common discharge pipe by a welded steel pipe via
butterfly valve and dismantling piece. The connection flange size shall be the same size as the
header. The protection equipment shall be maintenance free, easy to monitor and reliable. The
flanges are to be for PN 16 according to DIN 2533. With replaceable membrane DIN 4807 or
balloon in correspondence with the sewerage regulations.

4.16.2. QUALITY ASSURANCE

The surge vessel manufacturer shall have a test certificate for total quality assurance of the
manufacturing process, from the relevant authority (BSL, ISO etc.,) for the manufacturing facility
of the surge vessel.

Total Quality Assurance system shall comply with ISO BS 5750, ISO 900 or 9002 series. EN ISO
9001 or 9002 series or an equivalent acceptable to the Project Manager. The certificates valid for
current production shall be produced with the offer.
The surge vessel shall be hydrostatically tested at 1.5 times the maximum working pressure for
not less than 60 minutes.

Performance Test

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The surge vessel shall be factory tested for its performance. The supplier shall submit the test
results before shipment of the vessel. Test results should show how the pressure transients very
with the time.

4.17. BEDPLATES AND MOTOR STOOLS

Bedplates and motor stools shall be of rigid cast iron or fabricated steel. All welding shall be stress
relieved. Mounting surfaces shall be machined for correct alignment of shafts.

4.18. FLEXIBLE COUPLINGS

Flexible couplings shall be of the non-rigid rubber bushed steel pin type with easily removable
coupling guards where necessary.

4.19. FOUNDATION BOLTS

All necessary foundation bolts, ragbolts, etc. required for the Plant shall be provided by the
Contractor, and shall be complete with plates or hooks manufactured form suitable material and
treated to prevent corrosion. Ragbolts maintaining machinery shall comply DIN 529. All nuts and
washers used with foundation bolts shall be either stainless or cadmium plated steel.

The use of " Rawlbolts " or other approved foundation bolt with an expanding shaft or bolts utilising
epoxy resin cement grout in sockets cast into the foundation concrete is to be preferred and the
contractor shall only supply rag-bolts where, in the opinion of the Project Manager, their use
absolutely necessary.

4.20. LIFTING AND TRANSPORTATION EQUIPMENT

To allow chlorine transport and evacuation.

4.21. VENTILATION

Ventilation fans shall be provided in the manned areas listed below to give the air changes shown
in the following table:

Location Type of System Air Change

Rate
Enclosed accessible spaces Natural via wall louvers/Mechanical 10
Storage rooms Natural via louvered door/Mechanical 6
Work Shop/Admin. Building Natural via louvered door/Mechanical 6

4.22. GRILLES, DIFFUSERS AND LOUVRES

4.22.1. SUPPLY GRILLES

Supply grilles shall consist of an extruded aluminium flanged frame with non-inter-cellular
neoprene sealing gasket containing two banks of adjustable aluminium blades, the front set being
horizontal and the rear vertical with a maximum spacing between blades of 19mm.

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An opposed blade aluminium volume control damper shall be fitted at the rear of each grille
arranged to be adjustable through the face of the grille.

4.22.2. FIXED BLADE DIFFUSERS (LOUVRES)

Fixed blade supply air diffusers shall be supplied and fitted as necessary to suit the design of the
System. Each diffuser shall consist of a square extruded aluminium flanged frame with fixed
aluminium blades mounted on a removable centre core. An opposed blade aluminium volume
control damper shall be fitted at the rear of each diffuser arranged to be adjustable through the
face of the diffuser. Alternative with hard wood may be acceptable if consistent with architectural
design.

4.22.3. EXHAUST GRILLES

Exhaust grilles shall be supplied to suit the design of the system and shall be complete with
aluminium volume control damper as detailed above. The grilles shall be of the egg-crate type
with a 12mm x 12mm grid.

4.22.4. TRANSFER GRILLES

Non vision transfer grilles shall be of the inverted chevron type comprising a non vision insert core
held firmly between two mating flanged frames. In the case of door mounted applications, these
shall be rattleproof and provided with screw fixings.

4.22.5. GENERAL

All grilles and diffusers shall be manufactured from extruded aluminium, with suitable finishes.
All grilles and diffusers shall be supplied with concealed fixing devices for easy removal for
cleaning. Face screw fixings will not be accepted.

4.23. SOUND ATTENUATORS

The contractor shall incorporate attenuators as necessary to ensure that the minimum noise
criteria for rooms.
The sound attenuators shall be constructed from galvanised sheet steel at least 0.80mm thick
and of sufficient strength to withstand the internal duct pressures. Drilled flanges painted with zinc
rich paint shall be provided at both ends.
The Contractor shall check and ensure that the duties of the attenuators supplied are sufficient to
meet the noise requirements.

4.24. EYE SHOWER

See/import EN specs on suppliers website such as:

[Link]

4.25. PADLOCKS

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All provisions for external access, including surface boxes, manhole covers and duct covers shall
be lockable and provided with padlocks or other appropriate locks.

4.26. LABELLING

All labelling shall be in English. Each main and auxiliary item of Plant shall have permanently
attached to it in a conspicuous position a railing plate of weather resistant material. The
Manufacturer's name, type and serial number of Plant, details of the loading and duty at which
the item of Plant has been designed to operate shall be engraved on each plate. Where the Plant
may have its railing plate in an inconvenient position then the Contractor shall supply an additional
plate summarizing the particulars, which shall be fixed in a suitable location on the operating
platform. The labels shall be of non-corrodible metal embossed with the lettering or traffolyte
engraved type with black letters on white background and shall be fixed with brass or stainless
steel screws. The labels shall be conspicuous and consistently located relative to the equipment
to which they apply so that they can be read from the normal operating positions. Where tanks or
vessels contain chemicals they shall be labelled with the chemical name with letters not less than
150 mm high together with a HAZCHEM storage sign in statutory colours. The label character
sizes shall be selected with regard to the maximum distance at which the label must be read and
the ambient lighting conditions.

All safety signs shall comply with ISO 3864 or equivalent. Plant when may start automatically
shall carry labels (minimum size 200mm x I00mm) incorporating a hazard warning symbol and
the following warding: "WARNING - THIS PLANT IS REMOTELY/AUTOMATICALLY CONTROL
AND MAY START AT ANY TIME". A metal "Emergency Resuscitation Treatment" notice (approx.
600mm x 400mm) and "Electricity at Work Regulations" notice (approx. size 750mm x 500mm)
shall be appropriately mounted in each electrical control room.

4.27. SIGNAGE

Warning and municipal address signage shall be prepared in coordination with CPUC.
The Contractor shall provide a plastic laminate fact sheet with information such as lowest dwelling
elevation, hydraulic grade line, and overflow invert elevation. Overflow pipe information shall
include pipe size, location, and flow rates at 25, 50, 75 and 100 percent capacities, at 3 ft above
overflow pipe obvert. Include other pumping station information as required by the Employer. The
fact sheet shall be a minimum size of A3 and mounted adjacent to the control panel.
Appropriately placed warning signs for slippery areas, non-potable water fixtures, low head
clearance, open service maintenance holes, hazardous material storage areas, flammable fuel
storage areas, etc.

The Contractor shall design, provide and install colour wall charts containing process layout,
process schematic diagrams and brief descriptions of the scheme and unit process, outlining their
general functions and capacities, for display at each building and each unit process. These should
be made of durable weather resistant material such as a standard easily understood by the
general public and secondary school children. Such charts shall be provided at the subsidiary and
main pump stations. Minimum size of wall charts shall be 1.0 m H x 1.2 m W.

4.28. SPARE PARTS

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Upon receipt of approval from the Project Manager, the Contractor shall procure the required
spare parts.

All spare parts shall be strictly interchangeable with the corresponding parts of the plant.
The quality of spare parts shall not be inferior to that of the original plant.
Spare parts shall be adequately protected and packed in suitable containers to withstand storage
under site conditions and shall be handed over with four copies of a detailed itemised list of the
spare parts.

All spare parts shall be delivered prior to the tests on completion, and the taking over certificate
will not be issued until the spare have been handed over.

4.29. STEP DRAWDOWN TEST FOR BOREHOLE PUMPS

The following procedure shall be followed for step drawdown tests on boreholes.

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5. ELECTRICAL WORKS
5.1. 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 this specification unusually
difficult, then details should be submitted in writing to the ‘Project Manager’, who may grant an
exemption, Any such exemption granted shall be obtained in writing from the ‘Project Manager’
by the party seeking the exemption.

Any items of equipment offered and not listed under ‘Preferred Equipment’ must be approved by
the ‘Project Manager’. Any such exemption granted shall be obtained in writing from the ‘Project
Manager’ by the party supplying the equipment.

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 CPUC, 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/pump house/facility building shall carry out a risk
assessment to determine the classification of any hazardous areas within the plant/pump
house/facility building in accordance with NFPA 70E. The classification shall be reviewed by the
‘Project Manager’ and the design and specification of all electrical equipment installed in the plant
shall be in accordance with any hazardous area classifications determined by the risk
assessment.

5.1.1. CODES AND REFERENCES

This specification shall be read in conjunction with the following documentation:
Contract Documents and Standard References
NEC : National Electrical Code
NEMA : National Electrical Manufacturers Association
IEEE std 141-1976 : Protection and Coordination
IEEE Pub. No. 142 : Grounding of Industrial Power System
IEEE : Institute of Electrical and Electronic Engineers
IEC : Institute of Electromechanical Commission
NFPA : National Fire Protection Association
UL : Underwriters Laboratories, Inc.
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American National Standards Institute (ANSI) standards

National Electrical Safety Code (NESC)
Occupational Safety and Health Administration (OSHA) standards

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.

5.1.2. Definitions
ACB : Air Circuit Breaker
MCCB : Molded Case Circuit Breaker
PFC : Power Factor Capacitor
MCC : Motor Control Center
MCB : Miniature Circuit Breaker
FLC : Full Load Current
O/L : Overload
RSC : Rigid Steel Conduit
uPVC : Unplasticized Polyvinyl Chloride
ELCB : Earth leakage circuit breaker

5.1.3. Technical Specification

The following supply conditions apply:
 Voltage Primary voltage 13.8kV, secondary voltage 120/208V
 Frequency 60 Hz
 Phases 3, 4 Wire, D/Y connected
 Fault level, at service connection – 25kA
 Voltage fluctuation - +/- 10%
 Frequency fluctuation +/-2%
 Neutral Earth Neutral Link at the star point of transformer
 Power system grounding type – TN.
 Control Voltage 120 VAC
 No other control voltage shall be used unless approved in writing by the ‘Project
Manager’.

5.1.4. Climatic Conditions

Temperature Highest Maximum 113°F
Humidity Average annual range 72-95% RH non-condensing

5.1.5. Degree of Protection

General

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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 below.
Outdoor Control Enclosure .. NEMA 6/6P – IP67/IP68
Outdoor / (Indoor) Instruments .. NEMA 6 – I67
Outdoor / (Indoor) Motor .. NEMA 6/3S-IP67/54
Indoor Control Cubicles / Panels .. NEMA 3S-IP54

Refer to NEMA standard for other Enclosure classification for electrical works not included in table
above.
Material Requirements
Where applicable, in chlorine and hydrofluosilicic (HFS) acid areas, sealing fittings shall be
provided.

NEMA 6X 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 aluminium where used with aluminium 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.

All outdoor panel/enclosures shall be provided with minimum 2mm thick stainless steel 304 or
above for normal area.

All indoor floor mounted panels such as MCC/ICA/UPS shall be provided with 2mm mild steel,
Zinc Chromate primed and passivated, undercoated, two topcoats of high gloss enamel paint
“wrinkle beige” exterior and interior.

All panel/enclosures shall be provided with 316 stainless steel or plastic in chlorine environments.

5.1.6. Protection from water

All outdoor equipment shall be fitted with a hot-dipped galvanized cover to provide effective
protection against rain and corrosion.

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
‘Project Manager’.

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Thermostatically controlled low surface temperature heaters shall be provided where necessary to
prevent condensation of water.

5.1.7. 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 non-corrodible
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 ‘Project Manager’.

5.1.8. 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 Chuuk (ex stock), or which
cannot be replaced by other components dimensionally and functionally identical, which are held or
available in Chuuk (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.

5.1.9. Color and Identification

[Link]. 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.
 Green – safe start, on.
 Black, white, gray– 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
 480 V , 3 – phase - Red, White, Blue
 240 V , single phase - Phasor colour, when switched – red
 Earth - Green/Yellow
 Neutral - Black
 24 VDC + VE Brown
- VE Violet
Multicore cables and their cores do not have to be colored as above but must be uniquely
identified at both ends.

[Link]. Label Colors

Labels shall be engraved black lettering on a white background.
Warning labels shall be white lettering on a red background.

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[Link]. 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 these requirements are short lengths not exceeding 100
mm which are used to connect between CB’s 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 mm2 for Electronics/Instrumentation signals
 1.5 mm2 for control circuits
 2.5 mm2for Power and CT circuits

All wires 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.

[Link]. 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.
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All power, control and instrumentation cabling shall be identified at all terminations by use of a
durable type tag and approved by Project Manager.

[Link]. 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.

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 Project Manager.

5.1.10. Installation
[Link]. 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.

[Link]. 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
ultraviolet 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.

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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.
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.

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 CPUC.

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, a 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.
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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 CPUC.

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.
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 ‘Project Manager’.

Cable support systems shall be installed in accordance with the manufacturer recommendations
to give a maximum between support deflection of 10 mm when carrying the final number of cables
to be installed.

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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. (Don’t use spray 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.
Cable trays shall be installed using hangers and supports on 8 ft centers, 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.
 13.5 kV Primary Feeders
 480 V Feeders
 240 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 50 mm.

Particular attention shall be taken to ensure the correct segregation of intrinsically safe circuits.

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[Link]. 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 CPUC 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
 Poured in Place Manholes/Handholes
 Cable Trench
 Manufacturer’s Instructions
 Manufacturer’s directions for use of ground megger with proposed method.
 Termination kit Manufacturer’s installation instruction.

Installation
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.

[Link]. 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.

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Table: Minimum Radius Requirements

Conduit Minimum Bend
Diameter Radius
< 75 mm 457 mm
75 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
If Single core power cables used, 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
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 Project Managers approval. Cable sizing calculations shall be submitted to the Project
Manager for approval.

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 armored 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

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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 manufacturer’s 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 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
‘Project Manager’, 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 Project Manager).

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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.

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 at the dry session “earth ground” not exceeding 10 Ohms.

The minimum ground rod depth shall be 3m deep, except unavoidable site condition, if so,
contractor shall drive three rods with triangle shape or, copper plates min 600mmx600mm with
min 2mm thickness.

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 manufacturer’s written

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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.

5.1.11. Power Transformer

The transformers shall be mounted on either a power pole or concrete pad/foundation. If on a
foundation pad, 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 manufacturer’s 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 by the Utility provider. Additional ground rods/cables
shall be provided in order to attain this value specified by CPUC, at no additional cost to CPUC.

5.1.12. Interior Wirings

Wiring Method
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 6.5 ft 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 center
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.

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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
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
manufacturer’s 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 CPUC.

5.1.13. Instrumentation
Installations for instrumentation and control systems shall conform to the applicable requirements
of the latest approved edition of the NEC (NFPA 70), IEEE and ISA Standards.
The instrumentation and accessory equipment shall be installed in accordance with the
manufacturer’s 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 CPUC.

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

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cable size and number are found to be insufficient, the Contractor shall provide the proper size
and additional cables at no additional cost to CPUC.

The Contractor shall furnish the services of the manufacturer’s servicemen as necessary or when
required by CPUC.

Such provisions shall include all special tools, test manometers, calibration weights, temporary
materials, and labor to perform the tests at no additional cost to CPUC. Certified copies of the tests
shall be furnished in duplicate to CPUC for reference.

Uninterruptable power supply

Input/Output Voltage: The input voltage shall be 240V AC, 3-phase, 60Hz. The output voltage shall
be 240V AC, 3-phase, 60Hz.

Backup Time: The required backup time of the UPS system shall be 20 minutes at full load.

Efficiency: The UPS system shall have a minimum efficiency of 95% at full load.

Battery Maintenance: The UPS system shall include a battery maintenance schedule that ensures
batteries are properly maintained and replaced as needed.

Environmental Conditions: The UPS system shall be suitable for operation in an environment with
a temperature range of 0-104F and a relative humidity range of 0-95% non-condensing.

Compliance: The UPS system shall comply with UL 1778, CSA C22.2 No.107.1, and FCC Part 15
Class A standards.

Warranty and Support: The UPS system shall include a minimum 3-year warranty and 24/7
technical support.

5.1.14. 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.

5.1.15. Electrical Drawings/Submittals

The Contractor shall submit, for CPUC’s approval, the following calculation and documentations
relevant to the electrical works, including but not limited to:
 Electrical drawings (A3 size)
 Instrumentation drawings (A3 size)
 Panel drawing (A3 size)
 Automation drawings (A3 size)
 Manufacturer’s 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, MCC’s, panels (A3 size)
o Cover
o Index
o 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, labelling, 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 ‘Project Manager’ 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.

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.

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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.

Graphical symbols used on drawings shall comply with the symbols contained in the current version
of the appropriate standard (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.

[Link]. 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.

[Link]. CAD Standards

Set-Up
Drawings shall be created in model tab with [Link] 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 Pen Color Pen Thickness
1 Red 0.20
2 Yellow 0.50
3 Green 0.40
4 Cyan 0.05
5 Blue 0.30
6 Magenta 0.10
7 White 0.60
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.

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A1 Size A3 Size
Application
Height Thickness Height Thickness
Titles, Drawing
6 0.6 4 0.40
Numbers
Sub-titles 4 0.40 3 0.30
General Notes,
Material Lists 2.5 0.2 2 0.2
Dimensions, others

Line Number
All drawings for MCCs, Switchgear and Control Panel shall have the following line number
allocation.

AC Distribution 1001 – 2000

DC Distribution 2001 – 3000

Control Wiring Diagram 3001 – 5000

Digital input/output diagram 5001 – 6000

Analog input/ouput diagram 6001 – 7000

Termination Diagram 7001 – 9000
Line number shall be used for wiring and terminal identification.

5.1.16. Post Contract Drawings & Documentation

[Link]. 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 shall likewise be submitted as part of post contract
documentation.
[Link]. 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.

[Link]. 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.

[Link]. Plant Layout

Drawings shall show the location of all electrical equipment in relation to the plant.

[Link]. 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.
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[Link]. 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 ‘Project Manager’ shall be incorporated. Drawings shall be in Ladder
diagram format.

[Link]. Connection Diagrams/Termination Diagram

Connection diagrams shall include all control panel and junction box connection diagrams and also
interconnection diagrams.

[Link]. 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.

[Link]. 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.

5.1.17. Operation and Maintenance Manuals

The Contractor shall send direct to the CPUC, three (3) hard copies of the approved Operations
and Maintenance Manuals and on soft copy on USB drive. These hard copy 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
Manufacturer’s 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, manufacturer’s reference and
purchaser’s reference.

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 Plant and parts list giving manufacturers name, address, catalogue number or re-
ordering 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.
 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

5.1.18. Tools
A full set of any special tools required for the operation, maintenance, or repair work on electrical or
instrumentation equipment shall be supplied.

5.1.19. 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.

5.1.20. Exemptions
Where special conditions exist which would make compliance with these Specifications unusually
difficult, then details should be submitted in writing to the ‘Project Manager’, who may grant an
exemption. Any such exemption granted shall be obtained in writing from the ‘Project Manager’ by
the party seeking the exemption.

5.1.21. Preferred Equipment

Any items of equipment offered and not listed under ‘Preferred Equipment’ must be approved by
the ‘Project Manager’. Any such exemption granted shall be obtained in writing from the ‘Project
Manager’ by the party supplying the equipment.

5.1.22. 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.

5.1.23. Testing
[Link]. 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.

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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 manufacturer’s 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 CPUC.

Works and field testing shall be witnessed by a company representative or the Project Manager
and all testing and results shall be recorded. The checklist (record sheets) shall be obtained from
the Electrical Engineer.

[Link]. Field inspection and Testing

All plants provided under this contract shall be available for inspection and testing as required by
the Project Manager or his inspector, during manufacture. The costs of the tests including the
provision of all necessary test equipment at the manufacturer’s 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%.
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 months 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 Project Managers 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.

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Grounding test
Ground testing of all grounding electrodes shall be performed before operating the equipment.
Subsystem testing shall occur after CPUC has accepted the proper operation of alarm and status
contacts, and after process control devices have been adjusted as accurately as possible.
Ground resistance tests shall be performed in the presence of CPUC. 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 f”all 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 test

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 Manufacturer’s 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:
 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

Control and Operation

Contractor shall submit control philosophy as per design accordingly.
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.

[Link]. 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.

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Inspections and Testing

The Contractor shall give at least 5-days notice so that CPUC 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 before and after connection of fixtures
and equipment.

Acceptance Checks, Settings and Tests

Acceptance checks, settings and tests shall be performed in accordance with the manufacturer’s
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 CPUC, 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.

[Link]. 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.
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)

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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.

[Link]. 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 Project Manager.

Cable Insulation Resistance Testing

480/240-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 13.5/34.5-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 CPUC for review at least 30 days prior to plant operation, any
system testing or equipment energization.

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The results shall state the equipment tested and time of test.

[Link]. 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

5.1.24. 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.

5.1.25. 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

manufacturer’s instructions. All control cable shielding shall be grounded at one end only, with
reference at the receiver station (control panel).

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Equipment (case) grounds shall be in accordance with drawings and manufacturer’s 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.

5.1.26. Calibration
[Link]. 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.

[Link]. Calibration Data Sheets

Calibration data sheets shall be prepared and submitted for file reference for all critical
measurements.

5.1.27. 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.

5.1.28. 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 Project Manager or Company Representative and carried out to
the Project Manager’s Company Representative satisfaction.

5.1.29. 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.

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Commissioning shall not be completed until all training has been provided to the Project Manager’s
satisfaction.

5.2. LOW VOLTAGE SWITCHBOARD

General
All equipment shall be designed, in accordance with IEC 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 480 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.

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.

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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.

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 beige” exterior and interior.

All low voltage switchboards shall be type-tested.

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
All main switchboards shall be design as defined in and of comparative type construction.
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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.
A suitable sized earth bar shall extend the length of the switchboard.

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 CPUC’s approval:
 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.
Enclosures
The enclosure for the switchgear assembly shall be NEMA 12 gasketed dead front, freestanding
indoor construction, with devices as shown on the drawings.

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

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high. A master nameplate giving switchgear designation, voltage/ampere rating, short-circuit

rating, manufacturer’s 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 manufacturer’s 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
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 manufacturer’s 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.

5.3. MOTOR CONTROL CENTERS

General
The work covered by this Specification includes the design and manufacture of motor control center
(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 anybody having jurisdiction over the equipment particularly CPUC
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

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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 480 Volt 3 phase 4 wire 60 Hz supply.

All MCC shall be type-tested.

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 panel’s stiffened return surround on one side and the door’s 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.

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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.

MCC’s 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 Project Manager.
All fields wiring to remote control panels or instrument shall be terminated into a terminal rail, not
wired directly to devices.

5.4. DISTRIBUTION BOARDS/CONTROL PANELS

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.

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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.

5.5. 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.

ACB’s shall be of the withdrawable type and equipped for manual stored energy operation. They
shall have shunt release coils. ACB’s 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.

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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 - Coloured Green
 Stop pushbutton - Coloured Red
 Emergency Pushbutton - Coloured Red
 Reset pushbutton - Coloured Amber

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.

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Indicating lights shall comply with the following:

 Off or De-energised - Coloured Red
 Run or Energised - Coloured Green
 Trip or Fault - Coloured Amber
 Ready or Permissive - Coloured White

Starters
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 2.5 [Link] 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 IEC standard 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 DOL/VFD if it requires automation
 7.5 and above 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
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

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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 pins 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 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 ‘Project Manager’.

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.

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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 IEC 831 or Approved Equal
 Type: Dry type Design
 Frequency 60Hz
 Degree of protection IP42
 Execution Indoor
 Discharge Resistor 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.
 Losses 0.5 W/kvar
 Max. ambient temperature +122 °F
All capacitor enclosures shall be type-tested.

5.6. SOFT STARTER

This section covers the general requirements applicable to the design, manufacture of Soft
Starter Drive to provide ramp starting and stopping of AC motor rated as indicated in the
drawing and its associated equipment and accessories completely assembled.

The Vendor shall also provide technical assistance during the installation and placement in service
of the equipment, if requested by the Purchaser.

All equipment shall be designed, built, rated, tested and shall perform in accordance with the latest
editions of the applicable standard.

The controller shall provide a soft start with selectable Kickstart and a soft stop option.
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.

Where specified, the starter shall be fitted with an energy saving feature. This system shall provide
energy optimization when the motor is operating at no load or part load, by automatically reducing
the applied voltage and hence losses, without reduction in performance. This system shall be
provided with a manual by-pass switch, which will revert control to a standard soft start/stop system.
The thyristor stack heatsink on this type of starter, shall be fitted with a temperature sensor, which
shall automatically shut down the unit in the event of a pre-determined temperature being exceeded.
This sensor shall also light the failed lamp on the face of the starter

Starters shall incorporate a by-pass contactor for the thyristor stack, this shall automatically by-pass
the thyristor stack when the drive has ramped up to full speed.

The SS shall be of high efficiency and low maintenance.

The SS shall be equipped with Capacitor to improve the power factor to 98%.

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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 : up to 140 °F
 Relative Humidity : 95%

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.
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 panel. Adequate
ventilation must be allowed to ensure the internal temperature of the enclosure does not exceed
140 °F.

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.

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.
The SS shall have the following electrical characteristics:
 Input Power Voltage 480 V +/- 10%
Frequency 60 Hz +/- 2 Hz
 Output Power Voltage 480 V +/- 10%
Efficiency 95%

User Adjustments
The acceleration ramp time shall be adjustable from 0-30 seconds.
The initial torque setting shall be adjustable from 0-90% of locked rotor torque.
Current limit starting shall be adjustable from 50-600% of the motor’s full load current.
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.

Protection and Diagnostics

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

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 Starter Overtemperature
 Line Fault
 Power loss
 Ground Fault
 Reverse Rotation

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.

Monitoring
The controller shall provide the following monitoring functions indicated through the built-in LCD
display:
 Three phase line current
 Phase-to-phase supply voltage
 Watts in kW
 kWh
 Elapsed time
 Power Factor
 Motor Thermal capacity
 SS status
The SS must make available the following output signals for the external controller in addition to
summary alarm voltage free contact:
 Run
 Start/Run
 Motor Current (4-20 mA)
 Motor Thermal Model (4-20 mA)
 Fault indication
The SS shall have RS485 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.

5.7. LOW VOLTAGE FREQUENCY DRIVE

General
The VFD manufacturer shall demonstrate at least five years experience in manufacturing VFD’s, to
demonstrate their capability to provide parts and service support. A users list of similar design
equipment, complete with contact names and telephone numbers, shall be furnished upon request.

The VFD shall have an efficiency of 97%. The efficiency shall exceed 90% at 50% speed and load.
The VFD shall maintain the line power factor at no less than 0.95, regardless of speed and load.

The VFD shall be capable of operating existing motor induction motor, regardless of manufacturer,
with a horsepower and current rating as indicated.

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.

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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.

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.

Standard operating condition

 Ambient temperature range: 0 to 140 °F
 Elevation: up to 3300ft
 Atmosphere: non condensing relative humidity to 95%
 AC line Frequency Variation: +/- 3%

Monitoring and displays

The VFD’s 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
 VFD shall have integral Modbus/Profibus communication capability.
 VFD parameters, fault log and diagnostic log shall be downloadable
Input/Output Features
Two programmable analog inputs (0-20 mA/0-10V).
One programmable analog outputs (0-20 mA).
Five programmable digital inputs (24 V DC).
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.

Protective Functions
The VFD shall include the following protective features at minimum:
 Overcurrent
 Overvoltage
 Undervoltage
 Ground/Earth fault
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 Inverter fault
 Phase loss
 Output phase loss
 Undertemperature/Overtemperature
 Motor overload/underload

Enclosure
All VFD components shall be factory mounted and wired on a dead front, grounded, NEMA-12
enclosure. If a free-standing enclosure is provided, it shall be suitable for wall mounting.

Control Functions
The standard operator interface shall consist of a LCD keypad located on the front of the VFD.
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
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
 Catch a spinning motor start or normal start selection
Other features
 VFD Automatic Control
 PID utilization an internal or external setpoint.
 Auto start functions: On/Off, Operable from a 4-20 mA signal or from the PID output,
command, or feedback signal.

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.
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.

Diagnostic Features and Fault Handling

The VFD shall include a comprehensive microprocessor based digital diagnostic system which
monitors its own control functions and displays faults and operating conditions.
The “Fault Log” shall record, store, display and output to a serial port upon demand, the following
for the most recent events:

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 Date and time of day

 Type of fault
A historic log shall record, store and output to a RS-232, RS-422, or RS- 485 serial link port upon
demand.

Drive Options
Provide the following options to the VFD. All special features shall be factory mounted and wired
within the VFD enclosure unless otherwise specified.
Pressure transducer in the VFD to convert a 0-100psi pneumatic signal to an electrical signal for
automatic speed control.
The VFD shall be provided with circuit breaker for disconnecting power supply. The circuit breaker
shall be interlocked with the door or cover of the starter. All switches include handle operators, door
interlocking and are padlockable.

TRANSFORMER
General
Furnish and install, single phase 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 428 °F insulation system.
Required performance shall be obtained without exceeding the above indicated temperature rise in
a 104 °F maximum ambient, with 86 °F 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.

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On outdoor units, provide suitable weather shields 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:
 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.

5.8. 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,
 All other equipment as required by the NEC
 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 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.

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Insulation and earth loop impedance tests shall be made in the presence of the Project Manager.
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 Project Manager.

5.9. 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 Manufacturer’s
Association.
All lighting shall be LED.

Submittals
The Contractor shall submit, for CPUC’s 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.
 Pole-mounted fixtures, including complete data on the pole material, finish, hand-holes,
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 include 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 CPUC’s evaluation of the product’s 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.

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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 CPUC.

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 240V, 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 T-5 model,
either directly mounted to the ceiling or by pendant suspension. For 20 ft 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 aluminium ballast housing with electro-coat gray paint finish;
 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 aluminium 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 manufacturer’s recommendations.

Ballasts

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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 86 °F 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 100 mph. Poles shall be pedestal-based
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 480/240/220V/208/120V, 3-phase, 3-wire
system with the neutral directly grounded.
High pressure discharge lamps shall be 240V, 60 Hz.

Illumination Levels
The standard illumination levels shall be based on the latest edition of NEC

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.
1-phase 220 V – 2 flat pin + E

Wall Switches
Wall switch shall be of closed flush or surface mounting tumbler type, single pole 240V, 5A, 10A or
15A, and shall be fully recessed within boxes fitted with plates for covering.

5.10. INTERIOR WIRINGS

General

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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 CPUC’s 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 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 1.5 mm2 for Class 1 remote-control and signal circuits, 1 mm2 and for Class 2 low-
energy remote-control and signal circuits, 1 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
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.

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 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.

5.11. 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 20 mm (3/4in) conduit shall be minimum
size used for exposed work and 25 mm (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 UL-6.

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 ultraviolet light.
Where mounted on moving parts of machinery or where subject to mechanical damage the conduit
shall be flexible PVC covered galvanized steel.
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, labelling etc.

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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 fibreglass reinforced polyester (FRP).

Sheet Steel Boxes

Steel boxes for outlets, switches and junction boxes shall be of pressed sheet steel, hot-dipped
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 non-corrodible
materials shall be utilized to prevent corrosion. All nuts, bolts, and washers shall be stainless steel
304.
Loading capacities shall meet NEMA weight classification with a safety factor of 1.5.

5.12. 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 Pacific region.
All field instrumentation and junction boxes shall be rated to IP65.
Analogue signals shall be 4-20 mA 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
Project Manager).
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 CPUC’s 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

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 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
 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 CPUC 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 CPUC, an acceptable list of installations with similar equipment shall be
provided to demonstrate compliance with this requirement.

5.13. 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.

5.14. 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 CPUC.

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 manufacturer’s 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
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 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.

5.15. ELECTRO-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 digital display shall be of US inits.
The flow meter shall measure a flow range of 0 to 25 MGD and feature an accumulator with a single
digit count of 10G.
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 and accumulator volume. 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 center. The
instrument panel shall have a numerical display with US units that includes at least; velocity, flow,
daily flow and accumulator volume. The indicator shall be an eight-digit, 12 mm high, fluorescent
discharge flush mounted panel meter.
Signal cables (minimum 10 feet) 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. Battery back-up shall be included.
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
Contractor’s proposed testing procedure shall be fully detailed in the Schedule of Guaranteed
Technical Information.
Magnetic flowmeters shall all be installed in a watertight chamber as per 2.3.17. Additional required
measures for magnetic flowmeter chambers in particular are;
-The chamber shall be waterproof, clear of obstacles, even, rigid, and not slippery.
-The chamber shall be located at least 20 feet away from electrical cables, overhead lines as
well as other magnetic field areas and vibrating heavy machines.
-The chamber shall be protected from getting buried by sand, rainwater, flooding and barricaded
to prevent vehicles from parking on the chamber.
-Wireless/radio signals for the instrument communication must be able to pass through the
chamber cover.

5.16. PRESSURE TRANSMITTER

Pressure transmitters shall consist of a measuring element and associated signal conversion
circuitry

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designed to measure pressure or differential pressure and produce a proportional 4-20 mA

analogue
signal.
Wetted parts shall be grade 316 stainless steel. Process connections shall be 1/2 inch NP F female
threads. Transmitters shall have a threaded conduit entry for cables and the terminals shall be
accessible via a threaded cap. The degree of protection shall be at least IP65/NEMA 4X
Transmitters shall beVI.4.2 - 64
designed for mounting to a 50mm nominal bore pipe and shall be supplied complete with suitable
brackets and pipe clamps.
The differential pressure transmitter shall produce a 4 DC signal either in proportion to the applied
differential pressure or as a square root functions of the differential pressure. The transmitter shall
have screw adjustments for span (over the full range) and zero, and the adjustments shall be
continuously adjustable: The zero adjustment should be externally accessible. The transmitter shall
have variable damping adjustable tip to 2.5 seconds. Temperature compensation shall be provided.
The terminals shall be in an enclosure isolated from the transmitter mechanism.
Accuracy shall be ±0.25% of calibrated span, including the effects of repeatability, linearity and
hysteresis.
Each transmitter shall have an integral indicator calibrated in engineering units with an accuracy of
±0.2% of reading.
The process pressure transmitter shall be an electronic unit for gauge pressure measurements. The
transmitter shall include easily accessible span and zero adjustments, The terminals shall be in an
enclosure that is isolated from the transmitter mechanism. The output signal shall be 4-20mA DC
in
proportion to the measured pressure.
The transmitter shall withstand an overpressure 1.6 times the specified upper pressure limit. The
accuracy shall be ±0.25% of the calibrated span, including the effects of linearity, hysteresis and
repeatability. The wetted parts shall be made from 316 stainless steel.
Each transmitter shall have an integral indicator calibrated in engineering units with an accuracy of
±0.2% of reading.

Hydrostatic level transmitter

The immersion type level transmitter shall utilize the principle of the varying actuated head water
pressure of the sensing diaphragm as a function of the level of immersion. The transmitter shall
consist of a submerged detector, counterweight type stand, a transmitter, cable junction box and
special cable (hollow cable).
The transmitter shall be designed and manufactured in accordance with the following conditions:
- Output signal : DC 4 to 20mA
- Power supply : DC 48/24V
- Type : Diaphragm sensing type
- Accuracy : 0.5% of full scale
- Allowable over pressure ; 150% of measuring range
The submerged detector and stand shall be Type 316L and 304 stainless steel respectively.
The detector shall be designed to be placed on the bottom of the structure and shall be of lifting
type. Special cable shall be hollow cable and be composed of electric wire and atmosphere
pressure
introduction [Link] transmitter shall be connected to the submerged diaphragm detector by
means of special cable having an air-introduced pipe.

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Section 6 - Employer’s Requirements – Final Section 6 - Page 237

The transmitter shall have water proof type housing, and a field indicator (class 1.5 and 0 to 100%
linear scale). The transmitter shall also include built-in arrester.
The following spare parts shall be furnished for each immersion type level transmitter.
One (1) set of diaphragm detector
One (1) set of special cableVI.4.2 - 67
The transmitter shall be provided with a protection pipe for the detector and special cable as
required.

Level switch, (float type, electrode type)

Level switches shall be of the electrode type operating on the conductivity principle. Multiple
electrodes shall be provided and supported with suitable brackets to ensure the electrodes do not
deflect because of surges in the water. The length of electrode shall be adjusted to provide the
correct pickup and droop points for the controller.
The liquid level controller shall contain the isolation transformer and voltage source be the electrode
supply as well as an output relay for switching the controlling device (pump or valve). The output
relay shall have a single changeover contact rated at 5A. 240V AC

5.17. PRESSURE SWITCH

The pressure switch component type is electromechanical.
It shall withstand a maximum pressure of 10 bar (145 psig).
It shall be designed for a fluid temperature ranging from 32°F to 150°F.
The fluid connection type shall conform to NPT (National Pipe Tapered) thread.
The adjustable range of switching point on rising pressure shall range between 0.6 and 10 bars
(8.70 psig and 145 psig).
The maximum permissible accidental pressure shall be 22.5 bars (326.33 psig).
The pressure actuator shall be diaphragm type.
The material in contact with the fluid shall be of Zinc alloy or Fluorocarbon or Fluororubber.
The enclosure material shall be of Zinc allow.
The pressure switch shall be IP67.
The mechanical durability shall be not less than 5,000,000 cycles.
The maximum operating rate shall be 120 cycles/min.

5.18. 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
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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.
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.

5.19. PH/ORP ANALYZER

PH/ORP monitoring systems shall comprise a transducer, transmitter and interconnecting cable.
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 240 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.

5.20. CHLORINE ANALYZER

Measurement of total free chlorine residual is important to allow chlorine dosing to be controlled to
ensure that treated water 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

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Section 6 - Employer’s Requirements – Final Section 6 - Page 239

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 240VAC, 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.

5.21. INSTRUMENTATION PANEL

Instrument control and automation panels (ICA) will be provided to monitor and display the incoming
and discharge flow. Such equipment shall be located in the main electrical room. The front shall
be fabricated of heavy gauge steel of not less than 2 mm thickness with suitable bracing and
turnbuckles. Other parts shall be fabricated from heavy gauge steel of not less than 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 manufacturer’s test certificates shall be
submitted to CPUC. Field installation by the Contractor shall consist of fixing and setting the panel
in place and making all electrical connections.

5.22. 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 or analogue 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

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Section 6 - Employer’s Requirements – Final Section 6 - Page 240

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 “Project Manager”.

5.23. 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.
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 10 years.
The lightning protection system shall be installed strictly to the manufacturer’s 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 center 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.
The air terminal shall be installed strictly to the manufacturer’s instructions.
The isolating material supporting the curved conductive surface from the center 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 °F
continuous.

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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: Strike Current versus Levels of Protection

Strike Current Levels of Protection (Y) Exceedance
(X) Probability
2.9 kA Protection Level I – Very 99%
High
5.4 kA Protection Level II- High 97%
10.1 kA Protection Level III – 91%
Medium
15.7 kA Protection Level IV - Low 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 center 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 manufacturer’s 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 -14F to +122F.
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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 manufacturer’s instructions.

Single-Stage: One Envelope Procurement of Plant Bidding Document for Wichen River WTP & Headworks