06 Part A-1 CIVIL WORKS PR PDF

Bid Document Section-6: Employers Requirement
Contract Package No.: WBDWSIP/DWW/NCB/BK/03/2018-19 Particular Requirements for Civil Works
Section-6: Employer’s Requirements

Part-A1: Particular Requirements for Civil Works
Table of Contents
1.0 Project Background ....................................................................... 7

1.1 Background to the Project ................................................................................. 7
1.2 Project Output .................................................................................................... 7
1.3 Salient features of the Project............................................................................ 8
1.3.1 Intake, WTP and Primary Transmission Main ................................................................. 8
1.3.2 Overhead reservoirs and Water Supply Distribution Network......................................... 8
1.4 Supplementary information............................................................................... 8
1.4.1 Communication and Accessibility.................................................................................... 9
1.4.2 Climatic Condition and Annual Rainfall .......................................................................... 9
2.0 General Information .................................................................... 10

2.1 Scope of Work and Services ............................................................................ 10
2.2 Brief Description of Specification ................................................................... 11
2.3 Details of Activities ........................................................................................... 12
2.3.1 Preliminary Activities .................................................................................................... 12
2.3.2 Activities related to Project implementation .................................................................. 12
2.3.3 Project Sign Board ......................................................................................................... 13
2.3.4 Project Photographs........................................................................................................ 13
2.4 Contractors Submittals .................................................................................... 14
2.5 Rates of Work Items ......................................................................................... 15
2.6 CPM / PERT Schedule (Work Programme) .................................................. 16
2.6.1 Initial Schedule Submittals............................................................................................. 16
2.6.2 Schedule of Submittal of Work Programme .................................................................. 17
2.6.3 Contractors Monthly Progess Report ............................................................................. 17
2.7 Operation and Maintenance of the “As Built” Components ........................ 18
2.8 Battery Limits of the Work.............................................................................. 18
2.9 Interfacing of works ......................................................................................... 18
2.10 Safety Measures ................................................................................................ 19
2.10.1 Safety Plan...................................................................................................................... 19
2.10.2 Project Sign Board ......................................................................................................... 19
2.11 Applicable Standards and Codes .................................................................... 19
2.12 Protection and Maintaining Utility services during Construction ............... 20
2.12.1 General ........................................................................................................................... 20
2.12.2 Safeguarding Public Utility ............................................................................................ 20
2.12.3 Temporary protection of Utility Services ....................................................................... 20
2.12.4 Removal / Shifting of Utilities ....................................................................................... 21
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2.12.5 Temporary diversion of Utilities and drains................................................................... 21

2.13 Work Program and Methodology ................................................................... 21
2.13.1 Work Program ................................................................................................................ 21
2.13.2 Contractor’s Monthly Progress Report........................................................................... 21
2.13.3 Submission of Project Progress Photographs ................................................................. 22
2.13.4 Obtaining Permission and approvals .............................................................................. 22
2.14 Establishment of Site Office, Laboratory, Testing facilities ......................... 23
2.14.1 Establising Project Site Office ....................................................................................... 23
2.14.2 Facilities to be provided at Site ...................................................................................... 23
2.14.3 Establishment of Testing facilities and Laboratory ........................................................ 24
2.15 Contractors Project Facilities .......................................................................... 24
2.15.1 Storage Facilities and Labour Camp .............................................................................. 24
2.15.2 Electricity Provisions in the Camps ............................................................................... 24
2.15.3 Water Supply and Sanitary Provisions ........................................................................... 24
2.15.4 Maintenance of Camps and Offices ............................................................................... 25
2.15.5 Removal of Camps ......................................................................................................... 25
2.16 Confidentiality of data, documents and information .................................... 25
3.0 Survey and Investigation ............................................................. 25

3.1 Scope of Works ................................................................................................. 25
3.2 Bathymetric Survey .......................................................................................... 26
3.3 Geo-technical investigation .............................................................................. 26
3.3.1 Scope of Works .............................................................................................................. 26
3.3.2 Exploratory Borehole ..................................................................................................... 27
3.3.3 Plate Load Test ............................................................................................................... 27
3.3.4 Resistivity Survey .......................................................................................................... 28
3.3.5 Report and Recommendations........................................................................................ 28
3.4 Topographic Survey and Levelling ................................................................. 29
3.4.1 Survey Work Program .................................................................................................... 29
3.4.2 Equipments for Survey ................................................................................................... 29
3.4.3 Establishment of Bench-marks....................................................................................... 29
3.4.4 Contour / Area Survey.................................................................................................... 30
3.4.5 Survey along Roads, pathways for pipeline works ........................................................ 30
3.4.6 Submission Pattern ......................................................................................................... 31
3.4.7 Underground services ..................................................................................................... 31
3.5 Water Quality Analysis .................................................................................... 32
4.0 Design Norms and Criteria .......................................................... 33

4.1 General Requirements ..................................................................................... 33
4.2 Design Standards to be adopted for General Civil Works ........................... 33
4.2.1 Indian Standard Specifications / Codes of Practice........................................................ 33
4.2.2 Design Life ..................................................................................................................... 33
4.2.3 Design Loads .................................................................................................................. 34
4.2.4 Dead Load ...................................................................................................................... 34
4.2.5 Live Load ....................................................................................................................... 34
4.2.6 Wind Load ...................................................................................................................... 34
4.2.7 Effect of Temperature .................................................................................................... 35
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4.2.8 Seismic Load .................................................................................................................. 35

4.2.9 Earth Pressure................................................................................................................. 35
4.2.10 Dynamic Load ................................................................................................................ 35
4.2.11 Load Combination .......................................................................................................... 35
4.2.12 Joints .............................................................................................................................. 35
4.2.13 Partly / Fully Underground Liquid Retaining Structures ............................................... 36
4.2.14 Foundations .................................................................................................................... 36
4.3 General Requirements for Construction ........................................................ 36
4.3.1 Concrete Pouring ............................................................................................................ 38
4.3.1 Batching Plant and Equipment ....................................................................................... 38
4.3.2 Design Mix Concrete ..................................................................................................... 38
4.3.3 Design of Formwork ...................................................................................................... 39
4.3.4 Setting Out and Leveling................................................................................................ 39
4.3.5 Grade of Concrete .......................................................................................................... 39
4.3.6 Placement of Reinforcement .......................................................................................... 40
4.4 Design Requirements and Submittals ............................................................. 40
4.4.1 Detailed Design and Drawings ....................................................................................... 40
4.4.2 Preparation of detailed layout plan ................................................................................. 41
4.4.1 Working drawings and Completion drawings ................................................................ 41
4.4.2 Submission and Approval of Drawings after award of contract .................................... 42
4.4.3 Detailed Drawings / Documents..................................................................................... 42
4.4.4 Approval of Sample ....................................................................................................... 42
4.4.5 Ground Conditions ......................................................................................................... 42
4.5 First Aid Kit ...................................................................................................... 43
4.6 Specific Requirements ...................................................................................... 43
5.0 Raw water Intake well and allied works ..................................... 47

5.1 Design of Raw Water Intake Well................................................................... 47
5.1.1 Construction of Raw water Intake Well ......................................................................... 47
5.1.2 Inlet arrangement............................................................................................................ 47
5.2 Raw water Pumping Station ............................................................................ 47
5.2.1 General Requirements .................................................................................................... 47
5.2.2 Layout of the Pump House ............................................................................................. 48
5.2.3 Rolling Shutter ............................................................................................................... 48
5.2.4 Windows and Ventilators ............................................................................................... 48
5.2.5 Flooring .......................................................................................................................... 48
5.2.6 Finishing ......................................................................................................................... 49
5.3 Approach Bridge............................................................................................... 49
5.3.1 General Requirement...................................................................................................... 49
5.3.2 Length and Width of Approach Bridge .......................................................................... 49
5.4 Electrical Sub-station Building........................................................................ 49
5.4.2 Doors, Windows and Ventilators ................................................................................... 50
5.4.3 Flooring .......................................................................................................................... 50
5.4.4 Furniture ......................................................................................................................... 50
5.4.5 Toilet Block .................................................................................................................... 50
6.0 Design and Construction: Water Treatment Plant .................... 52
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6.1 Scope of Works ................................................................................................. 52

6.2 Requirements of Pump House ......................................................................... 52
6.3 Requirements Administrative Building .......................................................... 54
6.3.1 Finishing ......................................................................................................................... 54
6.3.2 Lightening Arrestor ........................................................................................................ 55
6.3.3 SCADA Control room .................................................................................................... 55
6.3.4 Air Condition arrangement............................................................................................. 55
6.3.5 Water Supply facilities ................................................................................................... 55
6.3.6 Sanitary and Drainage facilities ..................................................................................... 55
6.4 Design and Construction of Staff quarters..................................................... 55
6.4.1 Scope of Work ................................................................................................................ 55
6.4.2 Platering and Painting .................................................................................................... 56
6.4.3 Doors and windows ........................................................................................................ 56
6.4.4 Water Supply facilities ................................................................................................... 56
6.4.5 Sanitary and Drainage arrangement ............................................................................... 56
6.4.6 Furniture ......................................................................................................................... 57
6.5 Laboratory Room and Equipment .................................................................. 57
6.5.1 Laboratory Room ........................................................................................................... 57
6.5.2 Sampling Equipment ...................................................................................................... 57
6.5.3 Laboratory Equipment.................................................................................................... 58
6.6 General Requirements of Electric Substation Building ................................ 59
6.6.2 Doors, Windows and Ventilators ................................................................................... 60
6.6.3 Flooring .......................................................................................................................... 60
6.6.4 Furniture ......................................................................................................................... 60
6.7 Requirements of Guard Room ........................................................................ 60
6.8 Requirements of Back-wash reservoir ............................................................ 61
6.9 Scaled Model of the WS System ...................................................................... 62
6.10 Infrastructure arrangement inside WTP ....................................................... 62
6.10.1 Levelling, Landscaping and Horticulture ....................................................................... 62
6.10.2 Construction of Approach Road ..................................................................................... 63
6.10.3 Internal Road Layout...................................................................................................... 63
6.10.4 Plant Drainage ................................................................................................................ 63
6.10.5 Waste-water Disposal from Plant ................................................................................... 63
6.10.6 Boundary wall ................................................................................................................ 64
6.10.7 Requirements of Gate ..................................................................................................... 64
7.0 Design and Laying of Transmission main system ...................... 65

7.1 Design and Drawing of Transmission Mains ................................................. 65
7.1.1 Scope of Work................................................................................................................ 65
7.1.3 Resistivity Survey .......................................................................................................... 66
7.1.4 Pipe material for Transmission mains ............................................................................ 66
7.1.5 Head loss in Pressure Pipes ............................................................................................ 67
7.1.6 Provision of valves and pipeline appurtenances............................................................. 67
7.1.7 Provision of Isolation Valves ......................................................................................... 67
7.1.8 Provision of Air Valve ................................................................................................... 68
7.1.9 Provision of Control Valves ........................................................................................... 68
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7.1.10 Thrust block and Anchor block ...................................................................................... 68

7.1.11 Design submittals ........................................................................................................... 68
7.1.12 Preparation of Working Drawings ................................................................................. 68
7.1.13 Completion Drawings .................................................................................................... 69
7.1.14 Trial run and Commissioning ......................................................................................... 69
7.1.15 Outcome of the Work ..................................................................................................... 69
7.2 Surge Control System ....................................................................................... 70
7.2.1 Design of Surge Control System .................................................................................... 70
7.2.2 Surge Analysis................................................................................................................ 70
7.2.3 Surge Protection using Air Vessel.................................................................................. 71
7.2.5 Working of Automatic Level Control System................................................................ 72
7.2.6 General Requirement for Air Compressor ..................................................................... 72
7.3 Arrangement of Traffic during Construction ................................................ 73
7.3.1 General ........................................................................................................................... 73
7.3.2 Passage of traffic along a part of existing carriageway .................................................. 73
7.3.3 Passage of traffic along a Temporary diversion ............................................................. 74
7.3.4 Traffic Management Plan ............................................................................................... 74
7.3.5 Traffic Safety and Control.............................................................................................. 74
7.3.6 Maintenance of Diversions and traffic control devices .................................................. 74
7.3.7 Access to abutting properties ......................................................................................... 75
7.3.8 Road Restoration ............................................................................................................ 75
8.0 Supply and Laying Pipeline Works............................................. 76

8.1 General Requirements ..................................................................................... 76
8.1.1 Tools and Equipments .................................................................................................... 76
8.1.2 Preparatory Work ........................................................................................................... 76
8.1.3 Transportation and Handling of Pipes and Specials ....................................................... 76
8.1.4 Damage to Pipes and Specials ........................................................................................ 77
8.1.5 Pipe Installation in Trenches .......................................................................................... 77
8.1.6 Trench Excavation to be commensurate with Laying progress...................................... 78
8.1.7 Dewatering ..................................................................................................................... 78
8.1.8 Pipe Bedding .................................................................................................................. 78
8.1.9 Backfilling ...................................................................................................................... 78
8.1.10 Backfilling with Sand ..................................................................................................... 79
8.1.11 Backfilling With Excavated material ............................................................................. 79
8.1.12 Anti-floatation and anchor blocks .................................................................................. 80
8.2 Supplying and Laying of DI pipes ................................................................... 80
8.2.1 Scope of Work ................................................................................................................ 80
8.2.2 Applicable Codes ........................................................................................................... 80
8.2.3 General Requirements for Pipes ..................................................................................... 81
8.2.4 General Requirements for Pipe Fittings ......................................................................... 81
8.2.5 Rubber Gaskets .............................................................................................................. 81
8.2.6 Laying and Jointing ........................................................................................................ 82
8.2.7 Joints and Lubricants...................................................................................................... 82
8.2.8 Marking .......................................................................................................................... 82
8.2.9 Hydraulic testing and Disinfection ................................................................................. 82
8.3 Installation of pipe by HDD ............................................................................. 84
8.4 Supplying and Laying of MS Pipes ................................................................. 85
8.4.1 Scope of Work ................................................................................................................ 85
8.4.2 Applicable Codes ........................................................................................................... 85
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8.4.3 Grade of Steel ................................................................................................................. 85

8.4.4 Ultrasonic Testing and Chemical Composition of Steel Plates ...................................... 85
8.4.5 Standard Length of Pipes and Tolerance ........................................................................ 85
8.4.6 Sampling and Testing ..................................................................................................... 85
8.4.7 Hydraulic Testing at Works ........................................................................................... 86
8.4.8 Surface preparation ........................................................................................................ 86
8.4.9 Internal and External Epoxy Coating and Lining ........................................................... 86
8.4.10 MS Specials .................................................................................................................... 86
8.4.11 Radiographic / Ultrasonic test ........................................................................................ 87
8.4.12 Transportation of Pipes .................................................................................................. 87
8.4.13 Cutting of Steel Pipes ..................................................................................................... 87
8.4.14 Welding of Pipes ............................................................................................................ 87
8.4.15 Applicable Standards for Welding of Steel Pipes .......................................................... 88
8.4.16 Destructive andNon-destructive Tests on Weld Tests.................................................... 88
8.4.17 Storage of Wires ............................................................................................................. 96
8.4.18 Coating of Joints after Welding...................................................................................... 96
8.4.19 Touch up and repair procedure....................................................................................... 96
8.4.20 Safety in Welding ........................................................................................................... 96
8.4.21 Lighting .......................................................................................................................... 98
8.4.22 Air Supply System ......................................................................................................... 98
8.4.23 Laying of Pipe in Trenches ............................................................................................ 98
8.4.24 Laying of Pipe in Elevated Alignment ........................................................................... 99
8.4.25 Miscellanous Provisions ............................................................................................... 100
8.4.26 Non-Destructive Testing (NDT) .................................................................................. 100
8.4.27 Hydro-testing of Pipes .................................................................................................. 100
8.5 Laying of pipes across River / Canal Crossing ............................................ 101
8.6 Pipe laying below major Roads ..................................................................... 102
8.6.1 General ......................................................................................................................... 102
8.6.2 Topographic Survey ..................................................................................................... 102
8.6.3 Excavation .................................................................................................................... 102
8.6.4 Pipe Jacking Crew ........................................................................................................ 102
8.6.5 Pit Details ..................................................................................................................... 103
8.6.6 Jacking Equipment ....................................................................................................... 103
8.6.7 Safety Measures ........................................................................................................... 103
8.7 Valve Chamber and Flow-meter Chamber .................................................. 103
8.7.1 Type of Chambers ........................................................................................................ 103
8.7.2 Size of Chamber ........................................................................................................... 103
8.7.3 Requirements................................................................................................................ 103
8.7.4 Brick Masonry Chamber .............................................................................................. 104
8.7.5 RCC Chamber .............................................................................................................. 104
8.7.6 Top Slab ....................................................................................................................... 104
8.7.7 Footrests ....................................................................................................................... 104
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1.0 Project Background
1.1 Background to the Project

A large part of India’s population is dependent on groundwater as the major source of
potable water. Contamination of groundwater, especially by naturally elevated inorganic
contaminants like arsenic and fluoride, is a major issue in parts of the country, potentially
leading to serious health hazards for the affected populations. Prolonged exposure to excess
arsenic in drinking water may lead to keratosis, melanosis and cancer, while exposure to
excess fluoride may lead to dental, skeletal and non-skeletal fluorosis. The total population at
risk with respect to Arsenic and Fluoride Contamination in India is estimated at around 21.45
million as of August 20161.
The proposed West Bengal Drinking Water Sector Improvement Project (WBDWSIP) aims to
provide safe, reliable and continuous drinking water as per Government of India’s standard to
about 2.6 million people in the arsenic, fluoride, and salinity affected selected areas of North
24 Parganas, (one district of South 24 Parganas), Bankura and East Medinipur districts in
West Bengal.
The impact of the project will be drinking water security ensured in selected districts of West
Bengal (Vision 2020, PHED2).The outcome will be inclusive, gender-responsive, and
sustainable drinking water service delivered in Project districts.
1.2 Project Output

The Project is expected to have the following outputs:
(a) Output 1: Drinking water infrastructure constructed and upgraded. The project will
provide a minimum 70 liters per capita per day (lpcd) potable water through metered
household connections on a 24/7 basis to each household in the selected rural areas
covered under the project, and potable bulk water at the prescribed national standards to
the en-route habitations. The distribution systems will be designed on district metering
area (DMA) basis, provided up to the household level, including community and
government institutions such as schools and Anganwadis,3complete with district meters
and domestic water meters. Both the bulk as well as distribution systems will be
integrated with state-of-art smart water management and monitoring tools, including
SCADA and GIS. Bulk water supply systems will be inter-connected on a grid-based
supply system where feasible. PHED will be responsible for operating, maintaining and
monitoring the bulk water systems, up to boundary of the Gram Panchayats (GPs),4
whereas the GPs will operate and maintain the respective distribution networks. The
Panchayat Samitis (PS)5 and Zilla Parsishads (ZPs)6will be involved in coordinating,
technical support and monitoring role at the block and district level respectively; and
(b) Output 2: Institutional strengthening, skilling, and capacity building for operational
sustainability achieved. The project will strengthen institutional structures and capacity of
PHED, the bulk water supplier up to the GPs, and project GPs - for efficient and
sustainable drinking water service delivery. It will support and enable them to conduct
web-based water quantity and quality monitoring, electronic billing and collections, meter
1
Data provided by Ministry of Drinking Water and Sanitation, India.
2
Vision Plan – 2020 (To Provide Safe, Sustainable and Adequate Water Supply to All Humans
and Livestock by 2020), Public Health and Engineering Department, August 2011, Government of
West Bengal, available at http://www.wbphed.gov.in/main/index.php/vision-2020).
3
An Anganwadi is a typical health care center in rural India.
4
Village-level administrative authority, the first-tier of the local administrative body of the West
Bengal Government
5
Block-level administrative authority, the second-tier of the local administrative body of the
Government
6
District-level administrative authority, third tier of the local administrative body of the
Government
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reading, and accounting. To ensure long-term asset sustainability and service delivery,
GoWB will issue a government order defining roles and responsibilities of PHED and
project GPs called asset management and service delivery framework (AMSDF) which
each project GPs will endorse prior to commissioning of the system. The project will
introduce innovative practices and high technology for smart water management to
create a model for rural water service delivery and bulk water supply systems for the
state and the country. It will provide skill training, and generate employment for about350
locals, of which 33% minimum are expected to be females. It will support the project GPs
in creating public awareness on water, sanitation and hygiene (WASH), and benefits and
opportunities arising from the project. It will also support the state to strengthen water
and sanitation safety planning, develop regulatory framework and piloting for fecal sludge
(or septage) management in West Bengal.
1.3 Salient features of the Project

The present assignment relates to providing surface water based piped water supply for the
blocks of Mejhia and Gangajalghati in Bankura district. The Durgapur barrage on the
Damodar river is proposed to be raw water source for the 2 blocks. The overall scheme has
been conceived considering a base year of 2020, intermediate design year of 2035 and an
ultimate design year of 2050. The gross water demand for the 2 blocks is estimated at 30.3
Mld in 2035, and 36 Mld in 2050.
Salient features of the project components are as stated below:
1.3.1 Intake, WTP and Primary Transmission Main

Raw water is proposed to be abstracted from river Damodar by construction of an intake at
Durgapur barrage. The raw water shall be pumped to the WTP site, proposed to be located
in Gangajalgati block, near Basudevpur, (approximately 16 Kms from Intake).
The Capacity of WTP is 36 Mld. Treated water from the WTP will be pumped from the clear
water reservoir in WTP to proposed overhead reservoirs in both the blocks.
1.3.2 Overhead reservoirs and Water Supply Distribution Network

Mejhia block has been divided into 9 water supply zones (Proposed 7 overhead reservoirs
and utilising 2 existing reservoirs), while Gangajalghati block is divided into 25 water supply
zones (Proposed 23 overhead reservoirs and utilising 2 existing reservoirs).
The entire water supply to the habitations shall be served from Overhead reservoirs.
Overhead reservoirs have been proposed at suitable location to serve all the habitations
within the block by gravity. The water supply distribution network shall include
comprehensive household service connection and water metering.
1.4 Supplementary information

The present paragraph outlines briefly the prevailing site conditions in the project area. The
site conditions outlined herein are indicative only and that the Contractor is responsible for
determining or verifying the stated conditions.
Mejia block is bounded by Damodar river in the north, Barjora block on the
east, Gangajalghati block on the south and Saltora block on the west. Mejia block has an
area of 162.87 Sq. Kms. It has 1 panchayat samity and 5 gram panchayats namely
Ardhagram, Banjora, Kustora, Mejia and Ramchandrapur.
Gangajalghati block is bounded by Mejia block on the north, Barjora block on the
east, Bankura-II block on the south and Chhatna and Saltora blocks on the west.
Gangajalghati block has an area of 366.47 Sq. km. It has 1 panchayat samity and 10 gram
panchayats (namely Ban Asuria, Barsol, Bhaktabandh, Gangajalghati, Gobindadham,
Kapista, Lachmanpur, Latiabani, Nityandapur and Pirrabani). Gangajalghati block is
characterized by undulating terrain with many hills and ridges.
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The soil is laterite red and hard beds are covered with scrub jungle and Sal wood.
1.4.1 Communication and Accessibility

The blocks of Mejhia and Gangajalghati are connected by motorable road from Bankura
town, as well as Durgapur. There are regular train services between Howrah and Bankura.
1.4.2 Climatic Condition and Annual Rainfall

The project area has a tropical dry climate. Average annual temperature varies from 10o C to
46oC, whereas the annual mean temperature is around 25°C.
Summers are hot and humid and during dry spells the maximum temperatures often exceed
40°C during May and June. Winter tends to last for only about two and a half months, with
seasonal lows dipping to 5°C - 6°C between December and January.
Rains brought by the Bay of Bengal occur between June and September. The average
annual rainfall varies in the district has varied from a low of 917mm in 2010, to a high of
(approximately) 1800mm.
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2.0 General Information
2.1 Scope of Work and Services

This is a single-point responsibility Contract for the design, build and operation of bulk water
supply system for Mejhia and Gangajalghati blocks in Bankura District of West Bengal.
The requirements provided herein are the basic minimum. It is the intent of the Employer to
have a project constructed which utilizes the highest standards for design, construction and
supply of plant and equipment to enable a sustained, reliable system for performance for the
design life of the installed components.
The Contractor is fully responsible for delivering a complete and operational bulk water
supply system as per the scope of work. The Contractor is required to verify the surveys,
investigations, design criteria during the design phase. He may propose upgrades where he
feels that modifications are required to achieve the project objectives, or that he can supply a
comparable or improved system within the ambit of the laid down specifications.
Detailed design and working drawings shall be prepared by the Contractor before
construction and procurement of materials and equipment commences. The Contractor shall
be responsible for ensuring that the works fulfils the objectives for which it has been
designed. Any modifications to the design as described in these specifications and
associated drawings must be acceptable to the Employer's Representative.
The brief scope for the present subject contract comprises of the following components:
Component A: Design, build, supply, install and commission of Raw water intake well
cum pumping station and approach bridge on Durgapur barrage and on shore Subs
Station including all ancillary Civil, Mechanical, Electrical and Instrumentation works and
SCADA all complete.
Component B: Design, build, supply, install and commissioning of 36 Mld WTP
including Clear water reservoir and Pumping station, Electric Sub-station, Admin
building, Chlorine house, Store Building with all ancillary Civil, Mechanical, Electrical and
Instrumentation works and SCADA all complete.
Component C: Design, supply, laying and commissioning of raw and clear water
transmission mains, from raw water Intake well to WTP, and from WTP to all the
overhead storage reservoirs with all ancillary Civil, Mechanical, Electrical and
Instrumentation works and SCADA all complete..
Component D: Operation and Maintenance of the Design-Built Works for a period of 2
years after successful commissioning as per the scope under the contract.
All the Civil works shall be designed and constructed to meet and fulfil the requirements
atleast for the ultimate design year (of 2050) as stated in the specifications. Similarly, all
Electrical, mechanical, Instrumentation components shall be designed and constructed to
fulfil the requirements atleast for the intermediate design year.
It is necessary that Contractor be clear regarding the exact scope and extent of works, which
has been considered within the ambit of the works as outlined in the specifications.
The scope includes all Civil, Mechanical, Electrical and Instrumentation and SCADA works
related to the proposed works. The following activities shall be carried out by the Contractor
for each component of this Contract.
The estimated gross water demand (WTP Output) for the 2 Blocks is estimated as 36 Mld in
2050 (12.0 Mld for Mejhia Block and 24.0 Mld for Gangajalghati Block) and 26.1 Mld in 2022
(8.5 Mld for Mejhia Block and 17.6 Mld for Gangajalghati Block).
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2.2 Brief Description of Specification

The Contract has two key parts: (i) Design and Build; and (ii) Operation Service.
The Scope and requirements for the subject contract shall be guided by the various
provisions and guidelines as spelt out in the Employers requirements (Section-6) of the
document. The Employers Requirements are provided as:
- Particular Requirements (For Civil, Electrical, Mechanical, Instrumentation
and SCADA Works).
− Standard Specification (For Civil Works).
− Requirements for Operation and Maintenance Services
− Quality Assurance, Quality Control Plan
− Personnel and Equipment Requirement
− Tender Drawings and
− Supplementary Information
The Standard Specification provides minimum standards of materials and workmanship to be

achieved by the Contractor in the Works. The overall technical requirements spelt out in the
Standard Specifications are not exhaustive. As, such the Standard Specification (For Civil
Works) shall be read in consonance with:
(a) The technical specification for Building works issued by PWD (GoWB) for General
Civil works and the CPWD Specifications.
(b) The technical specification for Roads and Bridges issued by PWD (GoWB) for Civil
Works related to construction of Roads and Bridges and technical specifications.
(c) The applicable (BIS) Standards and Codes, as applicable, unless mentioned
otherwise.
Where such standards and codes are national, other authoritative standards that ensure
substantial equivalence to the standards and codes specified will be accepted subject to the
Employer’s prior review and written approval.
The Particular Requirements outline the key components of the Works for which the
Contractor will be responsible for the design, supply, installation, commissioning and
operation. In the event of any discrepancy between the provisions of the “Standard
Specifications” and that of “Particular Specifications” the provisions of the “Particular
Specifications” shall prevail.
The Employer has carried out some necessary surveys, investigations and these have been
provided as Supplementary information. These are provided to the Contractor for guidance
only. The Contractor is responsible for checking all such information and incorporating it into
his own Engineering designs appropriately.
The Supplementary information relates to field data and information that has been collected
by the Employer and has been presented as follows:
(1) Annex-1: Initial Environmental Examination Report
(2) Annex-2: Due Diligence Report and
(3) Annex-3: Ensuring Climate Resilience of Assets
(4) Annex-4: Soil Investigation Report
(5) Annex-5: Water Quality Analysis Report
The main parameters and specifications delineated in this document shall form the
framework of the Contractor’s final design and execution of the work. The Specification is
intended to indicate the minimum requirements of the Employer.
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2.3 Details of Activities

2.3.1 Preliminary Activities
Generally the following activities shall be carried out for each component of the Contract:
(a) Necessary field investigation including bathymetric survey, topographical survey,
water quality testing, geotechnical investigations that the Contractor needs to
conduct for a complete design of the water treatment plant.
(b) Preparation of system designs, where required , (e.g. Raw water Intake well, Water
treatment plant, raw water intake well cum pumping station, surge protection
systems, power supply systems, automation, local SCADA systems for monitoring
and control, communications etc.) for approval of the Employer's Representative.
Planning, design and preparation of the working drawings for the proposed facilities
(c) Preparation and submission of the layout plans, sections and details, etc. and all
other drawings at an appropriate scale to be agreed with the Employer’s
Representative and details for planning and construction of all components of the
project.
(d) Preparation of road and drainage layout plan, including wastewater disposal
scheme required. Preparation of interception and diversion of drains within the
vicinity of the system of the Intake and WTP.
(e) Submission of documents (designs, drawings, data sheets, etc) and samples
required according to the Contract for approval by the Employer's Representative of
all designs and drawings, materials to be used, equipment specifications, etc., prior
to delivery of any material and equipment to the site or any construction activities.
(f) Submission of the design, drawings, catalogues and the technical data sheets of all
the equipment, electrical system design of the electrical components and
substations taking into account the interfaces to the other project components .
(g) Preparation and submission of General Arrangement Drawings (GAD) and
Architectural Elevations of all structures proposed to be constructed for approval by
the Employer’s Representative as mentioned elsewhere in the specification
(h) Preparation of the structural design and drawings (including reinforcement detailing)
for all the facilities taking into consideration the functional reliability and structural
safety of the civil structures and buildings with Seismic criteria.
(i) Prior to the preparation and submittal of detailed designs and working drawings, the
Contractor shall submit the designs guidelines and layout plans for approval by the
Employer's Representative.
2.3.2 Activities related to Project implementation

Establishing fully equipped and staffed field offices, for supervision of the works for the
Contractor's staff and the Employer's Representative to carry out the required surveys and
investigations and to prepare the necessary designs and drawings at the start of the
Contract. The design offices shall interact with the Employer's staff to ensure coordination for
timely submission and approval of the detailed design and drawings required.
(a) Development of suitable storage spaces, for construction materials, piping and
equipment for the work. Identification of suitable quarries and other sources for
construction materials and have them approved by the Employer's
Representative,
(b) Establishing and staffing with qualified technicians, the laboratories suitable for
adhering to the Quality Assurance Program/Quality Plan.
(c) Establishing suitable labour camps with all electrical, water and sanitation
facilities required under the relevant Labour laws. Implementation of all the
environmental and relevant social mitigation measures as required, as
described in the document.
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(d) Making arrangements for equipment and materials required for maintaining the
safety of the sites and the workmen at the sites (helmets, boots, jackets, safety
belts, gloves, scaffolding, barricading, etc).
(e) Submittal of an initial work program and schedule and updating the same every
month for approval by the Employer's Representative.
(f) Development and submittal of a Traffic Control Plan prior to the start of pipeline
installation along any route. The plan shall indicate the period of road closure;
identify the detour routes for roads that will be closed where there is not a
second traffic lane and the means of access of residences where the access to
them has been blocked by construction activities. It is the responsibility of the
Contractor to seek approval of the Traffic Control Plan. The Employer will
provide all necessary assistance in getting the approval.
(g) Site clearance and levelling of the work sites.
(h) Layout of the works shall be as per the drawings.
(i) Disposal of surplus soil and construction waste as directed by Employer’s
Representative, and maintaining the construction sites in orderly manner.
(j) Performing tests on materials received and for the finished works and
maintaining complete records and registers required on site as per the QA/QC
Manual.
(k) Participating in weekly progress meetings with the Employer and Employer’s
Representative to review the schedule and other pertinent issues.
(l) Factory and field testing, pre-dispatch inspections, packaging, transportation to
the Project Site, providing transit insurance, storage, handling at the sites,
installation, trial runs and commissioning of all components/elements of the
system including the pipes, fittings, valves, hydrants, etc
(m) Remedying any defects identified during the Contract period.
(n) Site clearance and restoration of the premises after completion of the work.
(o) Submission of 'As Built' drawings and Operation and Maintenance Manuals.
(p) Any other items, as described elsewhere in the document.
2.3.3 Project Sign Board

The Contractor shall erect and maintain notice boards (of minimum 2mx1.2m, size) at each
end of the site (Intake, WTP, and at critical location along the route of the transmission main)
giving details of the Contract in the format and wording to be approved by the Employer’s
Representative. These boards shall be erected within 14 days after the Contractor has been
given the Possession of Site.
The Contractor shall not erect any advertisement sign board on or along the work without the
written approval of the Employer.
All sign boards shall be removed by the Contractor by the end of the Defects Liability Period.
2.3.4 Project Photographs

The Contractor shall undertake, maintain and provide photographic records of the existing
condition and work progress. A complete photographic record of existing site conditions shall
be undertaken by the Contractor before commencing any work on site. The record shall
include existing pavement, drainage, structures and site areas affected by the work in
sufficient detail to clearly portray all existing conditions of structures, finished surfaces. No
work shall be undertaken prior to receiving approval at any work site.
The Contractor shall supply photographs, of such portions of the works in progress and
completed, as may be directed by the Employer’s Representative. The hard and soft copies
of prints shall not be retouched. Each photograph shall be the property of the Employer and
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shall be delivered to the Employer’s Representative with prints. No prints from these shall be
supplied to anyone without the written permission of the Employer.
The submission of photographs shall be as follows:
(a) Progress photographs (each of them shall have 6 colour prints without mounting in
150x100 mm size and the soft copy supplied within first week of each month)
(b) Record photographs (each of them shall have 4 colour prints in 150x100 mm without
mounting and the soft copy supplied within first week of each month)
(c) The Contractor shall supply four prints of each of the photograph which shall be
taken at locations and times determined by the Employer’s Representative.
Both categories of photographs shall be properly referenced to the approval of the
Employer’s Representative and on the back of each print shall be recorded the date of the
photograph and the direction in which the camera was facing, and identifying description of
the subject, and the reference.
Photographs taken for the record purposes as ordered by the Employer’s Representative
shall have on the reverse of one print the signature of the Contractor and the Employer's
Representative's Representative for the purpose of attestation. If required, the Contractor
may at his own expense have an additional print similarly attested for his retention.
2.4 Contractors Submittals

Where submittals are required hereunder, the Contractor shall submit six copies of each
submittal item. All final design and drawing are to be submitted in soft copy also. The
Contractor shall submit the following items to the Employer’s Representative for review:
(a) Survey and Investigation Reports related to but not limited to Bathymetric survey,
Geo-technical Investigations, Water Quality Analysis, Topographic Survey report etc
(b) Detailed designs including detailed structural design and analysis, Process design,
Calculation sheets
(c) General Arrangement Drawings, Architectural drawings including Construction
drawings for all structural components,
(d) Shop Drawings including a respective schedule, Working drawings for Mechanical,
Electrical and Instrumentation and SCADA system
(e) Samples (as required)
(f) Technical details, manufacturer’s drawings, data sheets, performance curves of
materials and equipment
(g) Proposed Substitute ("Or-Equal") submittals listed in the Bid (if required)
(h) A list of all permits and licenses the Contractor shall obtain indicating the agency
required to grant the permit, the expected date of submittal for the permit, and
required date for receipt of the permit.
(i) A detailed layout of the field office required under Field Offices, Equipment, and
Services, including:
(j) Environmental Management Plan
(k) Project Quality Plan
(l) Project Health and Safety Plan
(m) Project Traffic Plan
(n) Fire protection programme
(o) Method statements (as desired and the sections stated)
(p) The Technical Manual (Documentation)
(q) Record Drawings (as-built)
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(r) Detailed spare-part-list

(s) Operation and Maintenance Manual
2.5 Rates of Work Items

In the absence of any directions to the contrary, the rates are to be considered as full
inclusive rates for finished works covering all labour, materials, storage, guarding, wastage,
transportation, temporary work, plant, equipment, testing, overhead charges and profit as
well as the general liabilities, obligations, insurance and risks, taxes and duties like GST etc
and per the scope of works outlined in the specification and as required to complete the
work. The rates quoted by the contractor shall, unless otherwise specified, also include
compliance the activities stated below:
(a) General works such as survey and setting out, clearance of site before setting out
and clearance of works after completion; carrying out soil investigation works,
condition assessment reports etc.;
(b) Preparation and submission of a detailed Work Program for the construction and
completion of the works (using CPM/PERT techniques) giving, in addition to
construction activities, detailed network activities for the submission and approval of
materials, procurement of critical materials and equipment, fabrication of special
products/equipment and their installation and testing, and for all activities of the
Employer that are likely to affect the progress of work, etc., including updating of all
such activities on the basis of the decisions taken at the periodic site review
meetings or as directed by the Engineer;
(c) Tests to ensure that the materials for construction are as per the relevant provisions
contained in the Specifications including carrying out necessary tests at Works on
samples of various materials as proposed to be used on the Work and conducting
tests thereon as required in the provisions of the Contract and or as per typical or
prescribed industry practice;
(d) Design of concrete mixes as per the relevant Clauses of the Specifications giving
proportions of ingredients, sources of aggregates and binder along with
accompanying trial mixes as per the relevant clauses of the Specification to be
submitted to the Engineer for his approval before use on the Works;
(e) Detailed design calculation and drawings for all Permanent Works and Temporary
Works (such as formwork, staging, centring specialized constructional handling and
launching equipment and the like);
(f) Detailed drawings for templates support and end anchorage, bar bending and
cutting schedules for reinforcement, material lists for fabrication of structural steel,
etc.;
(g) Testing of various finished items and materials including cement, concrete, bearings
as required under these Specifications and furnishing test reports/certificates;
(h) Inspection Reports in respect of Pipeline Testing, Valves, form work, staging,
reinforcement, and other items of work as per the relevant Specifications etc. The
cost towards the inspection of materials and plants as per the Category mentioned
are to be borne by the agency and are inclusive in the rate quoted.
(i) Cost of in-built provisions for Quality Control and Quality Assurance activities
including of safeguarding/protection of the environment, as required from time to
time;
(j) All costs related to implementation of occupational Health and safety, public safety,
and EMP implementation, as outlined in the IEE and other relevant sections of the
bidding documents will be borne by the contractor.
(k) Cost of Designs, Documents, drawings including necessary as-built drawings and
other submittals as required under the specifications. Cost for procurement for
necessary software (like Auto-CAD, STAAD, Watergems,) required for preparation /
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updating the water supply network drawings, including finalisation of as-built

drawings shall be considered to be included within quoted rates;
(l) Cost incurred on traffic management plan, including diversion works,
accommodation of traffic, including erecting barricading, caution signs, project sign
boards, and safety tapes to ensure protection at site;
(m) Cost of all taxes, duties and royalties, GST ,site commissioning and all incidental
costs;
(n) Cost of all operations like storing, erection, moving into final position, etc. necessary
to complete and protect the work till handing over to the Employer;
(o) Carrying out various work activities (pipe laying, providing service connection,
installation valves, flow-meters etc) during odd hours or in the night in the densely
congested areas, including costs for lighting, barricading, traffic management etc;
(p) Carrying out preventive maintenance of the equipment and plants installed under
the contract including repairing / rehabilitating / replacing defective / non-functional
tools, plants and equipment’s supplied / installed under the contract;
(q) Cost for storage of tools, plants and equipment’s including office operations, as
required from time to time;
(r) Provision of Office space (for contractor and Employer) including Godown, storage
facilities as maybe required.
(s) Cost for providing progress photograph ,which are to be shared with the Employer
as and when required and along with the weekly progress report in hard or soft
copy as deemed fit are inclusive in the rate quoted.
(t) Any other data which may be required as per these Specifications or the conditions
of Contract or any other annexes/schedules forming part of the contract;
(u) Any other items of works which is not specifically provided in the Schedule of
Quantities but which is necessary for complying with the provisions of the Contract.
(v) Permission for construction, erection or laying work from the statutory authority like,
PWD, I&W, ZilaParisad, Panchayat, WBSEDCL, NHAI, Railway, WBHIDCO, P& T
Department, PMGSY authority etc.are to be taken by the contractor by deploying
their manpower, License Fees or any other fees in these regard will be paid from
the Provisional Sum. The Employer will only assist in getting such permission from
the Authority. Cost of such deployment of manpower for persuasionactivity shall be
inclusive in respective items. No extra payment will be made.
Should there be any detail of construction or materials which have not been referred to in the
specifications or in the bill of quantities and drawings but the necessity for which may be
implied or inferred there from, or which are usual or essential to the completion of the work in
the trades for serving the purpose, the same shall be executed and if such work becomes an
extra item of work, in the opinion of the Engineer, then it shall be analysed by the Engineer
and may be approved by the Employer for payment to the Contractor. The objective of the
contract is to deliver the specified service in totality and hence all expenditure/ cost are to be
considered to achieve the goal.
2.6 CPM / PERT Schedule (Work Programme)

2.6.1 Initial Schedule Submittals
The Contractor shall submit a comprehensive document at a Pre-construction Conference
which shall serve as the Contractor’s initial design and construction schedule identifying the
manner in which the Contractor intends to complete the Works within the Contract Period.
Project Overview Bar Chart: The overview bar chart shall indicate the major components of
work and the sequence relations between major components and subdivisions of major
components, including such activities as: design; site clearance; excavation; procurement of
Page 16
materials for the works; construction of civil works; testing of pipelines and water retaining
structures; major mechanical and electrical work; and other important work for each major
facility within the overall project scope. Planned durations and start dates shall be indicated
for each work item subdivision. Each major component and subdivision component shall be
accurately plotted on time scale sheets not to exceed A1 in size. Not more than four sheets
shall be employed to represent this overview information.
The Employer’s Representative and the Contractor shall meet to review and discuss the
construction schedule within 5 days after submittal to the Employer’s Representative. The
Employer’s Representative’s review and comment on the schedules will be limited to
conformance with the sequencing and any milestone requirements in the Contract
Documents. The Contractor shall make corrections to the schedules necessary to comply
with the requirements and shall adjust the schedules to incorporate any missing information
requested by the Employer’s Representative.
2.6.2 Schedule of Submittal of Work Programme

The Employer’s Representative, within 14 days from the date that the Contractor’ submitted
schedule will either (1) accept the Schedule as submitted, or (2) advise the Contractor in
writing to review any part or parts of the Schedule which either do not meet the Contract
requirements or are unsatisfactory for the Employer’s Representative to monitor the
Contract's progress and status or evaluate scheduled payment requests by the Contractor.
The Employer’s Representative may accept the Schedule with conditions that the first
monthly CPM schedule update be revised to correct deficiencies identified. When the
schedule is accepted, it shall be considered as the "Original CPM Construction Schedule"
until an updated schedule has been submitted.
Acceptance of the Contractor’s Schedule by the Employer’s Representative will be based
solely upon compliance with the requirements of the Contract. By way of the Contractor
assigning activity durations and proposing the sequence of the work, the Contractor agrees
to utilize sufficient and necessary management and other resources to perform the work in
accordance with the Schedule.
Submission of the Contractor’s CPM Schedule to the Employer’s Representative shall not
relieve the Contractor of total responsibility for scheduling, sequencing, and pursuing the
work to comply with the requirements of the Contract Documents, including adverse effects
such as delays resulting from ill-timed work.
A detailed Schedule for the design and construction and completion of the works (using
CPM/PERT techniques) shall be presented by the Contractor within 28 days after the
Commencement Date giving, in addition to construction activities, detailed network activities
for the submission and approval of materials, procurement of critical materials and
equipment, fabrication of special products/equipment and their installation and testing, and
for all activities that are likely to affect the progress of work etc.
The Contractor is supposed to take all necessary measures to maintain the CPM schedule
programme. The schedule shall be updated during the progress of the work and based on
the decisions taken at the periodic site review meetings.
2.6.3 Contractors Monthly Progess Report

The Contractor shall furnish monthly project status to the Employers Representative in
triplicate in conjunction with the CPM Schedules, which shall include:
A bar chart schedule of the major project components, which shall be a summary of the CPM
A written narrative report of the status of the project which shall include:
(a) The status of major project components (percent complete, amount of time
ahead or behind schedule) and an explanation of how the project will be
brought back on schedule if delays have occurred:
(b) The progress made on critical activities indicated on the CPM Schedule.
Page 17
(c) Explanations for any lack of work on critical path activities planned to be
performed during the last month.
(d) Explanations for any schedule changes, including changes to the logic or to
activity durations.
(e) A list of the critical activities scheduled to be performed in the next two month
period.
(f) The status of major material and equipment procurement.
(g) The status of the Environmental Management Plan
(h) The value of materials and equipment properly stored at the Site but not yet
incorporated into the Works.
(i) Any delays encountered during the reporting period.
(j) An assessment of inclement weather delays and impacts to the progress of the
work.
The Contractor may include any other information pertinent to the status of the project and
shall include additional status information requested by the Employer’s Representative.
2.7 Operation and Maintenance of the “As Built” Components

The Contractor shall operate and maintain the as-built components. Immediately after
completion of the Construction, the Contractor shall
• Prepare and submit of as built drawings
• Prepare and submit the list of warranties
• Establishment of the maintenance inventory
The O&M services in short shall include the following basic minimum services:
• Preparation of O&M Manual, Training and Capacity Building Plan
• Establishing bench marks for Key Performance Indicators including monitoring and
reporting for the Performance measurement system
• Monitoring of the Performance measurement system including reporting
• Adhering to Customer Service Health and Safety requirements including performance
benchmarks
• Providing Training and Capacity Building to Employer’s representative including GP
personnel
• O&M services of “As Built” components as per requirements.
2.8 Battery Limits of the Work

The battery limits for the proposed works shall unless specified otherwise and or directed by
the Engineer, shall commence from the raw water intake well and upto to the inlet of the
Overhead storage reservoirs under Mejhia and Gangajalghati block.
2.9 Interfacing of works

The Contractor will carry-out the works in a co-ordinated and planned manner in consultation
with the Employer, Engineer to meet the requirements of the project. The Contractor must
note that the works for Construction of Overhead reservoirs including laying of water supply
distribution network will be carried out under a separate contract.
The Contractor shall provide space, requisite access and facilities to the personnel /
workmen engaged in the works of the other contract with due instruction of the Engineer to
facilitate the works to be executed smoothly.
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2.10 Safety Measures

2.10.1 Safety Plan
A Safety Plan shall be submitted by the Contractor indicating Safety Management and
application and monitoring for the Engineer’s approval within 28 days of Date of
Commencement. Notwithstanding such a Plan, the Contractor shall take all required safety
measures.
The Contractor shall observe a comprehensive Safety Plan at all stages of the construction
work. Such safety plan shall cover:
− Maintaining safe work sites and work places and have in place safe work procedures
and method statements (including training and work site inductions) to protect the
health and safety of the Contractor’s personnel and subcontractors, the community
and public, and any visitors to the Contractor’s sites and workplaces
− Safety measures taken to protect against damages to the buildings, boundary walls
or any structure adjoining any of the contractor’s worksites
− Safe use of vehicles, plant, machinery, equipment and tools
− Safety of the pedestrians
− Protection of underground utilities as well as overhead fixtures
− All site personnel must wear the appropriate personal protection equipment
− Safety of other related matters under statutory requirements
At various stages of the excavation and shoring work upto the stage of complete backfilling
and consolidation thereof for the excavated portion/ trenches is to be kept under constant
surveillance. The Contractor shall maintain exigency plan to take prompt preventive action in
case of any eventuality. Labourers of the Contractor engaged in excavation and shoring work
shall be provided with personal safety equipment.
The Contractor shall be well versed with safety requirements corresponding to respective
local bodies/ authorities for underground utilities like electric cables of WBSEB, telephone
cable and water line etc and also disposition of conservancy materials etc. The Contractor
shall provide a permanent Safety Officer throughout the period of contract to monitor the
degree of compliance with safety requirements and provide safety training.
2.10.2 Project Sign Board

The Contractor shall erect and maintain notice boards (of minimum 2mx1.2m, size) at each
of the construction sites giving details of the Contract in the format and wording to be
approved by the Engineer. These boards shall be erected within 14 days after the Contractor
has been given the Possession of Site.
The Contractor shall not erect any advertisement sign board on or along the work without the
written approval of the Employer.
All sign boards shall be removed by the Contractor as and when directed by the Engineer.
2.11 Applicable Standards and Codes

Wherever reference is made in the Contract to specific standards and codes to be met by the
materials and other supplies to be furnished, and work performed or tested, the edition or the
revised version of such codes and standards current at the date twenty-eight (28) days prior
to the date of bid submission shall apply, unless otherwise expressly stated in the Contract.
Where such standards and codes are national, other authoritative standards that ensure
substantial equivalence to the standards and codes specified will be accepted subject to the
Engineers prior review and written approval.
Differences between the standards specified (in the contract / codes) and the proposed
alternative standards must be fully described in writing by the Contractor and submitted to
the Engineer at least 28 days prior to the date when the Contractor desires the Engineers
Page 19
approval. In the event the Engineer determines that such proposed deviations do not ensure
substantially equal performance, the Contractor shall comply with the standards specified in
the contract documents (or relevant codes as mentioned in the contract documents and or as
decided by the Engineer).
2.12 Protection and Maintaining Utility services during Construction

2.12.1 General
Services like water pipes, sewers, cables owned by Public or Private Entities, and Local
Authorities shall be identified prior to the commencement of work by the Contractor
If any government, publicly and privately-owned service for drinking water, electricity,
drainage, irrigation channels, sewers, telecommunication and OFC cables/lines and other
services and structures, passing through the site is affected by the works, the Contractor
shall provide a satisfactory alternative service in full working condition to the satisfaction of
the owner of the services and of the Engineer before terminating the existing service. Any
damages resulting from the activities by the contractor have to indemnify.
The Contractor must also allow for shifting of these services and alternations upon the works
and for arranging regular meetings with the various bodies at the commencement of the
contract and throughout the period of the works in order to maintain the required co-
ordination.
Any services affected by the works shall be restored immediately by the Contractor who must
also take all measures reasonably required by the various bodies to protect their services
and property during the progress of the works.
The Contractor may be required to carry out the permanent removal or shifting or diversion of
certain services/utilities on specific orders from the Engineer for which payment shall be
made to him. Such works shall be taken up by the Contractor only after obtaining clearance
from the Engineer and ensuring adequate safety measures.
In case of shifting of any utilities, prior permission shall be taken from the Engineer and the
same shall be carried out by the Contractor only after written approval from the Engineer and
the cost so incurred shall be reimbursed under Provisional Sum. The necessary deposit shall
be paid by the Contractor to the concerned department or line agency in case the shifting/ re-
fixing of utility has to be carried out by the line agency. All expenses as approved by the
Engineer shall be reimbursed to the Contractor including Contractor’s premium as stipulated
in the bid document. Payment shall be made under Provisional Sum.
2.12.2 Safeguarding Public Utility

Drawings scheduling the affected services like water pipes, sewers, cables ducts etc. owned
by various authorities including Public Undertakings and Local Authorities shall be collected
by the Contractor for information prior to the commencement of any work.
Notwithstanding the fact that the information on affected services may not be exhaustive, the
final position of these services within the Works shall be supposed to have been indicated
based on the information furnished by different bodies and to the extent the bodies are
familiar with the final proposals.
No clearance or alterations to the utility shall be carried out unless specially ordered by the
Engineer.
The Contractor may be required to carry out certain Works for and on behalf of the various
bodies and he shall also provide, with the prior approval of the Engineer such assistance to
the various bodies as may be authorized by the Engineer.
2.12.3 Temporary protection of Utility Services

Any services affected by the Works must be temporarily supported by the Contractor who
must also take all measures reasonably required by the various bodies to protect their
services and property during the progress of the Works.
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The work of temporarily supporting and protecting the public utility services during execution
of the Works shall be deemed to be part of the Contract and no extra payment shall be made
for the same.
The Contractor may be required to carry out certain works for and on behalf of the various
bodies and he shall also provide such assistance to the various bodies as may be authorised
by the Engineer.
2.12.4 Removal / Shifting of Utilities

The Contractor shall be required to carry out the removal or shifting of certain
services/utilities on specific orders from the Engineer for which payment shall be made to
him. Such works shall be taken up by the Contractor only after obtaining clearance from the
Engineer and ensuring adequate safety measures.
2.12.5 Temporary diversion of Utilities and drains

All arrangement for providing temporary cross drainage structures including maintenance,
cleaning debris where necessary, shall be considered as incidental to the works.
Any services affected by the works must be temporarily supported by the Contractor who
must also take all measures reasonably required by the various bodies to protect their
services and property during the progress of the Works.
The Contractor may be required to carry out certain Works for and on behalf of the various
bodies and he shall also provide such assistance to the various bodies as may be authorised
by the Engineer.
There shall be no separate payment for this item. Cost for this item shall be deemed to be
included in other items.
2.13 Work Program and Methodology

2.13.1 Work Program
Prior to start of the construction activities at site, the Contractor shall, within 28 days after the
date of the Letter of Acceptance, submit to the Engineer for approval, a detailed work
program showing the general methods, arrangement, order and timing for all activities and
obtain approval prior to commencement of construction. The submittal shall also include
construction methodology including mechanical equipment proposed to be used.
Acceptance of the Contractor’s Schedule by the Engineer will be based solely upon
compliance with the requirements of the Contract. By way of the Contractor assigning activity
durations and proposing the sequence of the work, the Contractor agrees to utilize sufficient
and necessary management and other resources to perform the work in accordance with the
Schedule.
The Contractor shall make corrections to the schedules necessary to comply with the
requirements and shall adjust the schedules to incorporate any missing information
requested by the Engineer.
The Contractor shall prepare detail work program using Project Management software,
showing the sequence of various activities and schedule from start to end of the project.
Submission of the Contractor’s CPM Schedule to the Engineer shall not relieve the
Contractor of total responsibility for scheduling, sequencing, and pursuing the work to comply
with the requirements of the Contract Documents, including adverse effects such as delays
resulting from ill-timed work.
2.13.2 Contractor’s Monthly Progress Report

The Contractor shall furnish monthly project status to the Engineer in triplicate in conjunction
with the CPM Schedules, which shall include:
A bar chart schedule of the major project components, which shall be a summary of the CPM
Page 21
A written narrative report of the status of the project which shall include:
(k) The status of major project components (percent complete, amount of time ahead or
behind schedule) and an explanation of how the project will be brought back on
schedule if delays have occurred:
(l) The progress made on critical activities indicated on the CPM Schedule.
(m) Explanations for any lack of work on critical path activities planned to be performed
during the last month.
(n) Explanations for any schedule changes, including changes to the logic or to activity
durations.
(o) A list of the critical activities scheduled to be performed in the next two month period.
(p) The status of major material and equipment procurement.
(q) The status of the IEE / EMP
(r) The value of materials and equipment properly stored at the Site but not yet
incorporated into the Works.
(s) Any delays encountered during the reporting period.
(t) An assessment of inclement weather delays and impacts to the progress of the work.
The Contractor may include any other information pertinent to the status of the project and
shall include additional status information requested by the Engineer.
2.13.3 Submission of Project Progress Photographs

The Contractor shall undertake, maintain and provide photographic records of the work
progress. A complete photographic record of the site conditions shall be undertaken by the
Contractor before commencing any work on site. The record shall include existing site areas
in sufficient detail to clearly portray all existing conditions.
The Contractor shall supply photographs, of such portions of the works in progress and
completed, as may be directed by the Engineer. Each photograph shall be the property of the
Employer. No prints from these shall be supplied to anyone without the written permission of
the Employer / Engineer.
Project progress photographs shall be provided with the Monthly Progress Photographs.
Contractor shall shoot video of each activity for the components of works, as per direction of
the Engineer during execution of works and submit on a DVD / Pen Stick along with the
monthly progress report.
2.13.4 Obtaining Permission and approvals

The Contractor shall assist the Employer in obtaining all permissions for railway line/ road
crossing / Canal crossing/river crossing and/ or laying pipeline along the road from respective
authorities such as State Highway Authority, State PWD, Forest Department, Irrigation &
Waterways Directorate, Municipal Bodies, Gram Panchayat, Zilla Parishad and any other
agency.
Apart from the permission for laying or construction permission, data required for designing
and other calculation shall have to be obtained by the contractor from the competent
authority.
For cutting of trees for the purpose of construction at any site, required permission has to be
taken from the Forest Department / appropriate authorities and necessary fees in this regard
are to be submitted along with new plantation plan as required.
The Employer shall provide endorsing letter(s) to relevant authorities. The Contractor shall
pay all fee, charges, levies in relation to permission for laying of pipeline for getting statutory
clearances etc, which shall be reimbursed to the Contractor as per actual against proof of
such payment from Provisional Sum.
If the rules/ guidelines/ directions of concerned authorities do not permit Contractor to restore
the roads then the Contractor shall deposit such road restoration cost to the relevant
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authorities at his own. Same shall be reimbursed to the Contractor as per actual against
proof of such payment from Provisional Sum.
2.14 Establishment of Site Office, Laboratory, Testing facilities

2.14.1 Establising Project Site Office
The Contractor shall erect or hire buildings to house Site / field offices near the work sites for
the exclusive use of the Employer and the Engineer / Engineer’s Representative and staff
during project duration. The location of the office shall be as approved by the Engineer.
Unless, specified otherwise, atleast one project site offices shall be erected and maintained
as project field offices within each of the block.
The field office, equipped as indicated herein, shall be provided, ready for exclusive use by
the Engineer and the Engineer’s Representative and staff within 28 days after the
Commencement Date, unless otherwise agreed by the Engineer in writing.
The Contractor' shall be responsible for providing 24 hours electricity supply including the
costs of installation and maintenance, and payment for all official telephone calls, facsimile,
e-mail and internet charges..
Each field office required hereunder shall be provided with sufficient lighting at each desk
location. Exterior lighting shall be provided over the entrance door. A minimum of four 220-
VAC duplex electric convenience outlets shall be provided in each office and in the
conference room and common area. At least one such outlet shall be located on each wall.
The electric distribution panel shall service not less than two 220-VAC circuits.
The field offices shall have the following minimum provisions:
1. One container of 25 m2 (min.) floor space equipped with
(a) Split air-conditioning unit(s)
(b) One telephone line
(c) Four writing desks with arm chairs
(d) One table approx. 1500 x 800 x 750 mm high
(e) One lockable drawing cabinet and one lockable filing cabinet
2. One container site meeting room of 20 m2 (min.) floor space equipped with
(a) Split air-conditioning unit(s)
(b) One large table with 8 wooden chairs
3. Two toilets (separate provision for female and male employees).
Where inside toilet facilities are not connected to outside plumbing, a flush-type chemical
toilet with a holding tank shall be provided. All such sanitary waste material shall be regularly
pumped out and the chemicals recharged. Toilet paper and paper towels shall be furnished
for each toilet facility.
Regular daily janitorial services shall be furnished during working hours each day. Offices
shall be swept, dusted, and waste receptacles emptied. Toilet facilities shall be sanitized and
cleaned daily.
2.14.2 Facilities to be provided at Site

The Contractor shall provide parking areas at the field office, with adequate space for atleast
two (2) vehicles for the Engineer and/or Engineer’s Representative
Traffic and parking areas shall be maintained in a sound condition, free of excavated
material, construction equipment, mud, and construction materials. The Contractor shall
repair breaks, potholes, low areas which collect standing water, and other deficiencies in the
field office area.
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2.14.3 Establishment of Testing facilities and Laboratory

The Contractor shall establish, in the campus of site office, an on-site fully furnished and
adequately equipped field laboratory staffed by qualified personnel suitable for construction
material testing except cement and steel etc. He will make the facility to test other material in
the approved independent material testing laboratory. The name and qualifications of
independent testing laboratories shall be submitted to Engineer for approval no less than
thirty calendar days prior to the date the laboratories are to be used. Once approved,
dismissal and replacement of the approved independent testing laboratory shall require
written authorization by the Engineer. The site laboratory shall be functional till the works are
completed. Laboratory and equipment shall become the property of the Contractor upon
completion of the Contract
If in the opinion of the Engineer, the Laboratory arranged by the Contractor is not being
maintained properly then the Engineer shall reserve the right to deduct a reasonable amount
from the payment. The calibration of the laboratory equipment and instruments shall at the
initial stage to be certified by approved agencies.
The Laboratory equipment shall be properly maintained and calibrated throughout the period
of the Contract by the Contractor at his own expense. The Contractor shall notify the
Engineer in sufficient advance prior to conducting any tests for the materials and work.
The Engineer / Engineer’s Representative will also inspect the laboratory and the contractor
shall provide adequate facilities to the Engineer / Engineer’s Representative for his
independent verification of the accuracy and adequacy of the facilities. The Contractor shall
be responsible for the sampling, and transport to the laboratories of all materials for testing,
and all testing costs including laboratory fees, and/or all costs in running the on-site
laboratory, i.e., chemicals, reagents, and other test consumables, staff, and utilities. No
separate payment shall be made for establishment of the Laboratory and testing facilities at
the site.
2.15 Contractors Project Facilities

2.15.1 Storage Facilities and Labour Camp
Space allocated for storage of materials such as pipe, pipe specials, fittings, cement,
reinforcement, gabion wire, reinforcing wire, pipes etc. shall in general be damp-free, rain-
proof and away from petroleum products storage. Permission may be granted by the
Engineer to erect temporary suitable camps if such establishments do not cause obstructions
to traffic, nuisance to works execution and adverse effect to the environment.
To prevent disturbance to nearby communities the labour camps must be located at least
500 m away from the nearest settlement, unless otherwise agreed in writing by the Employer.
Rent is to be paid if land is provided by the state Government or other authority (State
Government undertaking).
2.15.2 Electricity Provisions in the Camps

The Contractor shall make his own arrangement for the supply of electrical power that will be
required for the Works throughout the contract period. Standby generators shall have to be
provided wherever the public electricity supply is unreliable.
2.15.3 Water Supply and Sanitary Provisions

The Contractor shall so far is reasonable, having regard to local conditions, provide on the
Site and at his expense an adequate supply of drinking water for the use of Contractor’s staff
and work people, together with sanitary facilities (portable toilets or latrines), to the
satisfaction of the Employer. Piped water for drinking use shall be supplied to the office and
camps together with sufficient tank storage to provide continuous running water for 24 hours.
The Contractor shall also provide any additional treatment or equipment (such as electric
water filter) necessary for the provision of drinking water. The Contractor shall ensure that
proper drinking water, waste disposal and toilet facilities are provided to the camps. This
arrangement shall be enforced to avoid proliferation and generation of various water borne
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diseases. The Contractor shall inform the Engineer regarding sources, installation and
operation of supply of potable water within a week after the supply is commenced.
Provision of toilets for labour and employees shall be made to avoid public nuisance as well
as pollution of water courses and air. Toilets shall not be located near streams or rivers. The
Contractor shall construct suitable septic tanks and/or soak pits along with room of pit-type
latrines. Sufficient water must be provided and maintained in the toilets. Proper methods of
sanitation and hygiene should be employed during the whole project duration. The Contractor
shall provide waste disposal facilities such as dustbins and waste disposal pits.
2.15.4 Maintenance of Camps and Offices

Various works defined under this item are related to provision and maintenance of camps for
Contractor’s workmen and employees, Contractor's site offices, stores, equipment yards and
workshops. These camps must be adequate, rain-proof, spacious, airy and hygienic with
proper lighting and materials storage facilities. The area shall be kept neat and clean.
Written information must be given to and approval be taken from the Engineer regarding
proper establishment and maintenance of such camps.
2.15.5 Removal of Camps

On completion of the works the Contractor shall remove those facilities. At the end of
Contract Period the Contractor shall remove the remaining facilities from site in accordance
with the Conditions of Contract.
The Contractor shall take down and remove all structures connected with this camp, and
shall take out all pipes, drains and culverts, backfill trenches, fill up all latrine pits, soak ways
and other sewage disposal excavations, and shall restore the site as far as practicable to its
original conditions and leave it neat and tidy to the satisfaction of the Engineer.
During shifting of the camp all trash and unwanted material must be burnt or disposed of
properly. Pit latrines must be adequately covered. Areas without any vegetation must be re-
vegetated carrying out appropriate bio-Engineering works.
2.16 Confidentiality of data, documents and information

The Contractor shall keep confidential and shall not, without the written consent of the
Employer/Employers Representative, divulge to any Third Party any documents, data or
other information arising directly or indirectly under the Contract, whether such information
has been furnished prior to, during or following termination of the Contract.
Notwithstanding relevant Clause to the General Conditions of Contract, the Contractor may
furnish to its Sub-Contractors such documents, data and other information to the extent
required for the Sub-Contractors to perform their work under the Contract, in which event the
Contractor shall obtain from such Sub-Contractors an undertaking of confidentiality similar to
that imposed on the Contractor.
The Contractor shall not use such documents, data and other information received from the
Employer/Employers Representative for any purpose other than the Services as are required
for the performance of the Contract. The Contractor shall not publish, permit to be published,
or disclose any particulars of the Services, Site or the Works in any trade or technical paper
or advertising materials without the prior written consent of the Employer/Employers
Representative.
3.0 Survey and Investigation
3.1 Scope of Works

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The details of Survey and Investigation carried out for reference are appended for
information. However, the Contractor is required to carry out independent survey and
investigation activities to ascertain the ground realities.
The minimum requirements for the survey and investigation activities are stated herein. It is
the responsibility of the Contractor to carry out the survey and investigation in details based
on the assessed scope of the work and overall requirements as deemed fit based on site
condition and design requirements.
3.2 Bathymetric Survey

The Contractor shall carry out the Bathymetric survey to assess the bed profile of the
Duragpur barrage in the suggestive location of the raw water intake well and along proposed
approach bridge.
The survey shall be carried out for a minimum area of 0.10 Sq. km. The Contractor shall
establish a bench mark onshore prior to commencement of the Bathymetric survey. An
outline of the survey works and methodology to be adopted shall be submitted to the
Employer for approval.
Ground Control Points (GCPs) shall be established within the study area and the co-
ordinates recorded with GPS and river bed level through echo sounder. The detailed
bathymetric survey conducted shall be submitted in a report format with clear maps, showing
the bed profile (with respect to the GCPs), isopleths showing the bed level and bed profile of
the river bed along the suggestive alignment of the raw water main. The distance between
any two GCPs, should not exceed 50m.
3.3 Geo-technical investigation

3.3.1 Scope of Works
Geotechnical investigation report carried by the Employer at various locations is appended
with the bid document. The report is suggestive and the Contractor shall carry out necessary
geotechnical investigation to confirm the soil properties and safe bearing capacity.
The Contractor shall carry out Geo-Technical Investigation work at each of the work sites to
assess the safe bearing capacity of soil and design the components for the piped water
supply schemes. Unless, specified otherwise, geotechnical investigation shall be carried out
by drilling bore-holes upto a minimum depth of 30m below average ground level in soil or
refusal layer, whichever is encountered earlier.
The number of boreholes shall be guided by the following minimum requirements:
(a) For the raw water intake well cum pump house and Approach Bridge at Durgapur
barrage, a minimum of 3 bore holes shall be drilled.
(b) For the proposed WTP Site, at Basudevpur a minimum of 4 boreholes shall be drilled
spatially distributed in the area.
Geo-technical investigation must also be carried out along the alignment of the transmission
(raw and clear water transmission main), where pipe main is proposed to laid over pipe
bridges and or pipe is proposed to be laid by trenchless methods. A minimum of one
borehole shall be drilled at each of the location, where pipe bridges are proposed and or pipe
is to be laid by trenchless methods to assess the suitability of soil and foundation
requirements.
The Contractor shall also carry out necessary Soil Investigation by carrying out trial trenches
upto a depth of 2.5 from the existing ground level and or 0.3m below the bed level of the
pipe, whichever is lower to ascertain the type of soil (and or presence of rock).
This apart geo-investigation may be desired at various locations as per site requirement,
based on ground conditions. The same shall be carried out by the Contractor in his own
interest.
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3.3.2 Exploratory Borehole

The location of bore holes is to be finalized in consultation and approval of the Engineer. For
all borings, necessary information as detailed below shall be given. A site plan showing the
location of the bore holes shall also be attached. Following information shall be included:
− Location with reference map
− Pit/ borehole number and dimensions
− Reduced level (RL) of ground surface or other reference point (the RL shall be with
respect to GTS datum)
− Dates of starting and completion
− Scales of plans and sections
− General description of strata met with and RLs at which they are met
− The level at which the sub-soil water is met
− Visual description of strata and soil classification
− Any other information and remarks
− Standard Penetration Test value
− Tests on disturbed and undisturbed samples
Upon removal of sampling tube, the length of the sample in the tube and the length between
the top of the tube and the top of the sample in the tube shall be measured and recorded.
The bore log exploration will be carried out upto a depth of 30m below average Ground Level
at the location and or upto the refusal strata (N>100). The available information after bore
logging shall be submitted to the Engineer in Six (6) hard copies and one soft copy.
The investigation results shall be used to establish the soil parameters that are to be adopted
for the designing the treatment units as per relevant IS codes:
− The soil investigation is necessary for finalization of the type of foundation of the
structure and hence all necessary parameters like SBC, N-Value etc. are required to be
determined for design purpose.
− All the Soil Test Reports are to be submitted in a separate booklet (soft copy as well as
hard copy) containing details of soil characteristics, testing details and results, foundation
design and recommendations.
The geo-technical investigation works shall be carried out by reputed agencies, acceptable to
the Engineer. The geo-technical investigation report shall include specific recommendations
for the safe bearing capacity of the soil at various depths. Agency engaged by the contractor
for geo technical investigation may be asked for removal if found not suitable in the opinion of
the Employers representative.
3.3.3 Plate Load Test

Plate load test shall be conducted to determine the bearing capacity and load/settlement
characteristics of soil at shallow depth by loading a plate and levelled steel plate kept at the
desired depth and measuring the settlement under different loads until a desired settlement
takes place or failure occurs. The specification for equipment and accessories required for
conducting the test, the test procedure, field observations and reporting of results etc shall
conform to IS: 1888. The location and depth of the test shall be as given in the drawing or as
indicated by the Engineer.
Undisturbed tube samples shall be collected at 1m and 2.5m depths from the ground level for
carrying out laboratory tests. The size of pit shall not be less than five times the plate size
and the depth shall be as specified.
Unless otherwise specified the reaction method of loading shall be adopted. Settlement shall
be recorded from dial gauges placed at four diametrically opposite ends of the test plate. The
test plate shall be of 600mm x 600mm size and atleast 25mm thick. The bottom of the pit
shall be levelled before placing the plate in position for conducting the test.
A seating load of 7kN/sqm shall be applied and after the dial gauge readings are stabilized,
the load shall be released and the initial readings of the dial gauges be recorded after they
indicate constant reading. The load shall be increased in stages.
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In case of cohesive soils, each load increment shall be maintained until the settlement is less
than 0.02mm/minute or 6 hours whichever is later. Dial gauge readings for settlement shall
generally be taken at 1, 2.25, 4, 6.25, 9, 16, 25, 60, 90 and 120 minutes from the start of
each stage of loading. Thereafter the readings shall be taken at hourly interval upto a further
4 hours and at two hours interval thereafter for another 6 hours.
Other than cohesive soils, each stage loading shall be maintained for a minimum duration of
one hour or till the settlement rate reduces to 0.02mm/minute whichever is later. No
extrapolation of settlement rate from periods less than one hour shall be permitted. The final
loading shall be maintained for 24 hours. During unloading, reading of dial gauge shall be
recorded for each stage of unloading.
Loading shall be carried out in stages as specified above till one of the following conditions
occurs:
(1) Failure of soil under the plate i.e. the settlement of the plate at constant load becomes
progressive and reaches a value of 50 mm.
(2) Load intensity of 40 Tons/sqm is reached without failure of the soil.
Backfilling of the pit shall be carried out as per the directions of the Engineer. Unless
otherwise specified the excavated soil shall be used for this purpose.
3.3.4 Resistivity Survey

Resistivity survey along the pipe line route shall have to be undertaken for finalizing the
degree of protective measure to be adopted for MS pipes. Detailed resistivity survey analysis
along the stretches of pipeline to be laid by transmission mains shall be conducted and
submitted by the Contractor, prior to commencement of works.
3.3.5 Report and Recommendations

On completion of all the field and laboratory works, the contractor shall submit a draft report
containing geological information of the region, procedure adopted for investigation, field
observations, summarized test data, conclusion and recommendations. The report shall
include detailed bore logs, sub-soil sections, field test results, laboratory observations and
test results in both tabular as well as graphical forms, practical and theoretical considerations
for the interpretation of test results, the supporting calculations for the conclusions drawn etc.
for comments/approval.
The results of the laboratory tests and the calculations for safe bearing capacity have to be
presented in a report. The execution of the foundations shall be started only after approval of
the Engineer. The Contractor shall be responsible for design of the foundation and
(associated) structures based on these investigations and the investigations drawn.
The Contractor shall submit the geo-technical investigation report, including the bore-log
data, laboratory test results and the calculations (for safe bearing capacity) and
recommendations to the Engineer in 6(Six) hard copies and one soft copy (pdf format)after
obtaining approval. In case there is a discrepancy between the inferences drawn from the
(3) bore holes (and or plate load tests), the lower of the values of the safe bearing capacity
shall be considered for the design.
Recommendations shall be given duly considering the type of soil/rock, structure, foundation
type and ground water table etc in the area. The recommendations shall include but not be
limited to the following.
− Type of foundation to be adopted for various structures duly considering the sub
strata characteristics, water table, total settlement permissible for the structures and
equipments, minimum depth and width of foundation etc
For shallow foundations, the following shall be indicated with comprehensive supporting
calculations.
− Net safe bearing pressure for isolated square/rectangular footings and continuous
strip footings at different founding depths below ground level considering both shear
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failure and settlement criteria giving reasons for the type of shear failure adopted in
the calculation.
− Net safe bearing pressure for raft foundation of widths greater than 6m at various
depths below ground level considering both shear failure and settlement criteria.
− Modulus of sub-grade reaction and modulus of elasticity from plate load test results
along with time-settlement curves and load settlement curves in both natural and log-
log graph.
The report shall also outline recommendation of increasing the safe bearing capacity by filling
with coarse sand and other soil strengthening / stabilizing options.
If piling is envisaged the following shall be furnished with comprehensive supporting

calculations.
− Type of pile and reasons for recommending the same duly considering the sub strata
characteristics.
− Suitable founding strata for the pile.
− Estimated length of pile. End bearing and frictional resistance shall be indicated
separately. Safe lateral and tensile load carrying capacities of pile with supporting
calculations.
− Magnitude of negative skin friction if any.
3.4 Topographic Survey and Levelling

3.4.1 Survey Work Program
The Contractor shall submit a detailed survey program providing timelines for completing the
works within a stipulated time period as agreed with the Engineer. It is the responsibility of
the Contractor to ensure that all the works carried out under the proposed scheme are with
respect to a common reference bench mark.
The survey drawings shall be complete with grid markings and coordinates. All data should
be submitted in hard and soft copy (AutoCAD). The survey drawings shall be coloured
including list of layers for each component provided separately.
3.4.2 Equipments for Survey

The following minimum equipment in required numbers as deemed fit by the Contractor to
complete the survey activity in time shall be deployed.
• Differential GPS equipment
• Electronic total stations with angular accuracy of ± 1 sec.
• Auto level having accuracy of ± 2.5 mm/km
• Other items like measuring tapes, ranging rods, leveling staff etc., as required
3.4.3 Establishment of Bench-marks

The Contractor shall establish permanent bench marks (BM) value tied with the reference
bench mark (shown by the Engineer) using DGPS equipment within the project area
including all major pipe bridge sites and other locations as maybe required soon after taking
possession of the site.
The Contractor shall transfer bench mark (BM) value from identified place to proposed work
site and establish the same at nearby location for regular use for construction purpose.
BM level value shall be inscribed in 15 mm thick, 300mmx300mm square granite plaque
etched suitably to show level with its centre point and the same shall be anchored on a 300
mm square concrete pillar (Nominal mix, 1:1.5:3, with plaster of 12mm thick in cement mortar
1:4, with a floating coat of neat cement) of height 500 mm from ground with suitable
foundation in a safe place to the approval of the Engineer’s Representative.
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The reference bench mark for the area shall be obtained by the Contractor from the
Engineer’s Representative. The working bench marks/ level shall be approved by the
Engineer’s Representative. Checks must be made on these bench marks once in every
month and adjustments, if any, agreed with the Engineer’s Representative and recorded.
An up-to-date record of the DGPS bench marks including approved adjustments, if any, shall
be maintained by the Contractor and also a copy supplied to the Engineer’s Representative
for his record. These bench marks shall be on a permanent structure.
3.4.4 Contour / Area Survey

The Contractor will carry out the topography survey work by using Total station equipment.
Traverse and Grid Contour Survey within the area earmarked for the:
− Area around electric sub-station near Intake
− Water Treatment Plant, near Basudebpur.
− Other locations (like pipe bridges, pipe supporting structures across rivers, canals,
drainage channels, waterways etc) and also across pipeline stretches to be laid by
trenchless methods, as instructed by the Engineer.
Available topographic survey data (in AutoCAD/ GIS) will be shared by the Contractor.
Topographic / Contour survey will only be carried out as per the instruction of the Engineer.
The Contractor will transfer the bench mark to be provided by the Engineer and a permanent
bench mark will be established at all the major construction sites (Intake, WTP and along the
alignment of the pipe mains).
The survey works shall include collection of details for all features such as utilities, existing
roads, electric and telephone poles, huts, adjacent buildings, or any other structure, fencing
and trees (with girth greater than 0.3 m) etc., falling within the extent of survey. All the data
shall be digitized in standard software like Auto-CAD.
The work will include taking spot levels at 5.0 m x 5.0m grid or at intervals as necessary and
contour plotted at 0.25m intervals (minor contour) and 1.0m intervals (major contour).
Area mapping details and level survey data shall be plotted by the Contractor in a map for
submission to the Engineer within 15 days of completion of the field survey. The number of
hard copies to be submitted shall be four. The survey drawings shall be in Auto-CAD format
and the soft copies shall be submitted on memory sticks.
3.4.5 Survey along Roads, pathways for pipeline works

The Contractor will be provided with the available Topographic survey data (in AutoCAD /
GIS format) for the proposed Transmission main showing the length, pipe diameter and
alignment of the pipeline.
The survey data however shall be updated to provide for pipeline networks in all roads /
pathways to provide accessibility to all the properties and provide for service connections.
The Topographic survey shall be carried out only after the instruction of Engineer.
Topographical survey shall be carried along existing road network / pathways as maybe
required for detail design of the pipe network beyond the surveyed length. The survey shall
update all objects/ roads / steps / drains/ gully pits/ culverts etc., on both sides of the road
(black bituminous top or concrete or brick) edges including road portion. Type and width of
road and offset distance of important structures within or adjacent to road, from a fixed point
shall be shown in the map. Topographic survey, unless otherwise stated shall commence
from the DGPS control points in the OHR locations.
Spot level survey of road, drain, and culvert, shall be carried out by the Contractor as per
direction of the Engineer. Level survey on roads shall be carried out generally at 15m interval
and at change of grades / strategic locations. Level information shall be collected at regular
interval as stated earlier as well as at road intersections, road curves and invert level of drain,
culverts. Any other level essentially required shall be recorded as per direction of the
Engineer.
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The entire topographic survey shall be carried out by Total Station having facility of
transferring data to computer. All traverse stations shall be recorded with X, Y and Z
coordinates and shall be checked to eliminate any error. However the Z values obtained from
this should not be used for any survey work. The BMs shall be connected for X and Y
coordinates by Total Stations with closing at intervals. In case of closing error being outside
the permissible limit, survey to be repeated for proper closing.
Levels of all temporary BMs shall be obtained by Auto levels only. Levels shall be closed to
eliminate any error.
Location of traverse stations for carrying out Total Station survey shall be selected on the
following basis:
• It should be located on the edge of the road so that traffic is not disturbed while the survey
is in progress.
• It should be triangulated properly with respect to existing permanent features (as far as
possible).
• It should as far as possible be near to a permanent structure so that it can be identified
easily on field.
Traverse stations should be located such that last station signal bottom and next station
signal bottom are clearly visible from the occupied station.
3.4.6 Submission Pattern

All topographic data should be submitted in hard and soft copy in memory sticks.
All hard copies shall be submitted in A1 sheets properly numbered and indexed with
reference to index map included at the corner of each sheet. The drawings shall preferably
be coloured. All drawings shall be prepared in AutoCAD only. A list of layer details shall be
submitted separately.
3.4.7 Underground services

Trial trench/ pit excavations shall be conducted at least up to 2m below existing GL/ road top
to ascertain the presence of all existing buried services/ utilities along the water supply pipe
route. The buried services data shall be recorded and incorporated in the survey drawings to
enable the Employer’s Representative to approve the alignment of pumping mains proposed
by the Contractor. All safety precautions shall be ensured by the Contractor.
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3.5 Water Quality Analysis

The tentative values of raw water quality parameters are appended with the report. The
Contractor may use the following raw water quality data for preliminary assessment.
Parameter Unit Indicative Design
Value
Turbidity NTU 850
pH - 8.25
TDS mg/L 201
Alkalinity mg/L 118
Total Hardness (CaCO3) mg/L 118
Conductivity Micro-Siemens/cm 340
The monthly raw water quality data tested at Durgapur barrage as available will be provided
to the successful bidder.
Detailed raw water quality analysis of the Durgapur barrage shall be carried out by the
contractor prior to commencement of the process design. The raw water should be sampled
and analysed for parameters as per IS: 10500. The Contractor shall consider jar test, as
necessary to desire the output water quality.
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4.0 Design Norms and Criteria
4.1 General Requirements

The design standards adopted shall follow the best/ modern Engineering practice in the field.
The BIS standards shall be followed. Wherever there is no specific guidelines given in the
Indian Standards, same may be adopted based on any other international standard or
specialist literature subject to such standard reference or extract of such literature in the
English language being supplied to and approved by the Employer's Representative.
In case of any variation or contradiction between the provisions of the IS Standards or Codes
and the specifications given along with this bid document, the provision given in this
specification shall be followed.
4.2 Design Standards to be adopted for General Civil Works

All designs shall be based on the latest Indian Standard (BIS) Specifications or Codes of
Practice published 28 (twenty eight) days prior to the last date of submission of bid.
4.2.1 Indian Standard Specifications / Codes of Practice

The structural design and construction of all components of the work shall conform to the
recommendations made in the following latest publications of the Bureau of Indian Standards
(BIS) including all applicable official amendments and revisions or any other Indian Standard
Specifications and Codes of Practice, in addition to the books of reference listed here. Other
IS codes not specifically mentioned here, but pertaining to work form part of these
specifications.
IS:456 Code of practice for plain and reinforced concrete
IS:800 Code of practice for general construction in steel
IS:806 Code of Practice for use of steel tubes in general building construction
IS:875 Code of practice for design loads for buildings and structures
IS:1786 High strength deformed steel bars and wires for concrete reinforcement -
specification
IS:1793 Criteria for earthquake resistant design of structures
IS:1893 Criteria for earthquake resistant design of structures
IS:2062 Hot rolled low, medium and high tensile structural steel
IS:2911 Code of practice for design and construction of pile foundations
IS:2974 Code of practice for design and construction of machine foundations
IS:3370 Code of practice for concrete structures for the storage of liquid
IS:6403 Code of practice for determination of bearing capacity of shallow foundations
IS:8009 Code of practice for calculation of settlements of foundations
IS:10262 Recommended guidelines for concrete mix design
IS: 13920 Ductile detailing of RCC structures subject to seismic loading
4.2.2 Design Life

The minimum design life of all civil structures and buildings shall be 30 years.
The design life of the electromechanical equipment shall be minimum 15 years.
The design life of instrumentation/ SCADA equipment shall be minimum 10 years.
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4.2.3 Design Loads

The design of various components of all the structures shall generally be carried out in
accordance with the technical specifications and relevant IS codes. All buildings and
structures shall be designed to resist the worst combination of the loads/ stresses under test
and working conditions; which include dead load, live load, wind load, seismic load, stresses
due to temperature changes, shrinkage & creep in materials and dynamic loads.
4.2.4 Dead Load

This shall comprise of loads arising due to all permanent construction including walls, floors,
roofs, partitions, stairways, fixed service equipment and other items of machinery. In
estimating the loads of process equipment, all fixtures and attached piping shall be included.
The following minimum loads shall be considered in design of structures:
Weight of water : 9.81 kN/m3
Weight of soil : 19.00 kN/m3
(Irrespective of strata available at site and type of soil used for filling etc.
However, for checking stability against uplift, actual weight of soil as determined
by field test shall be considered)
Weight of plain concrete : 22.00 kN/m3
Weight of reinforced concrete : 25.00 kN/m3
Weight of steel : 78.00 kN/m3
Weight of brickwork (exclusive of : 22.00 N/m2 per mm thickness of
plaster) brickwork
Weight of plaster to masonry surface : 17.00 N/m2 per mm thickness
Weight of granolithic terrazzo finish or : 24.00 N/m2 per mm thickness
rendering screed etc.
Weight of sand (filter media) : 16.0 kN/m3
4.2.5 Live Load

Live loads shall be in general as per IS: 875 (Part 2) and the load from the equipment as is
necessary based on manufacturer’s recommendation. However, the following minimum loads
shall be considered in the design of structures:
Live load on roofs : 1.50 kN/m2
Live load on floors supporting equipment such as pumps, : 10.00 kN/m2
blowers, compressors, valves etc.
Live load on all other floors, walkways, stairways and : 5.00 kN/m2
platforms
In absence of any suitable provisions for live loads in IS Codes or as given above for any
particular type of floor or structure, any assumptions made must receive the approval of
Employer’s Representative prior to starting of the design work. Apart from the specified live
loads or any other load due to storage of materials, any other equipment load or possible
overloading during maintenance or erection/ construction in part or full shall also be taken
into account. Most critical condition shall be considered in the design.
4.2.6 Wind Load

The wind load shall be calculated as per IS: 875 (Part 3).
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4.2.7 Effect of Temperature

For temperature loading, the total temperature variation shall be considered as 2/3 of the
average maximum annual variation in temperature. The structure shall be designed to
withstand stresses due to 50% of the total temperature variation.
Suitable expansion joints shall be provided in the longitudinal direction whenever necessary
with provision of twin columns. The maximum distance of expansion joint shall be as per
provision of IS: 800 and IS: 456 for steel and concrete structure respectively.
4.2.8 Seismic Load

For design of all structures the seismic loads shall be considered and structure designed as
per the provisions of IS-1893 (latest draft code) and detailing of reinforcement shall be done
as per the provisions of IS-13920 (latest). The various design parameters, as defined in IS:
1893 (Part 1), to be adopted for the project site shall be as follows:
a) Zone-IV (As per IS)
b) Zone factor = As per table given in IS:1893 (Part 1)
c) Importance factor = 1.5
d) Response reduction factor = 3.0
e) Average response acceleration co-efficient as per site condition and building
configuration
4.2.9 Earth Pressure

The active earth pressure, passive pressure, dynamic augmentation in active earth pressure
and dynamic decrement in passive earth pressure in designing the underground structures
and foundation shall be considered as given in the IS code.
4.2.10 Dynamic Load

Dynamic loads due to working of plant items such as pumps, blowers, compressors, switch
gears, travelling cranes, etc. shall be considered in the design of structures.
4.2.11 Load Combination

Structures shall be designed with the following load combinations:
− Combination I : Dead load (DL) + Live load (LL) + Equipment load (Dynamic load)
− Combination II : Combination I + Wind load (WL)
− Combination III : Combination I + Seismic force on DL + 50% LL in transverse
direction/ seismic force on DL only in longitudinal direction + 50% Braking/ Tractive
force in longitudinal direction (for bridge structure)
4.2.12 Joints
Movement joints such as expansion joints, complete contraction joints, partial contraction
joints and sliding joints shall be designed to suit the requirements. However, contraction
joints shall be provided at specified locations spaced not more than 7.5m in both directions at
right angles to each other for walls and rafts.
Suitable gap at the location of expansion joints placed at a suitable interval, not more than
30m shall be provided in walls, floors and roof slabs of all structures.
Construction joints shall be provided at right angles to the general direction of the member.
The locations of construction joints shall be decided as per convenience of construction. To
avoid segregation of concrete in walls, horizontal construction joints are normally to be
provided at every 2m height. Approved PVC water stops of 150 mm width shall be used for
walls and 230 mm width for base slabs.
Expansion joints for non-liquid retaining structures shall be provided as per IS: 3411.
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4.2.13 Partly / Fully Underground Liquid Retaining Structures

All underground or partly underground liquid retaining structures shall be designed for the
following conditions:
Liquid depth upto full height of wall and free board: no relief due to lateral soil pressure from
outside to be considered.
Reservoir empty (i.e. no liquid or any material inside the storage area): full lateral earth
pressure at rest due to surrounding saturated soil and surcharge pressure as applicable,
shall be considered.
Partition wall between two compartments to be designed as one compartment empty and
other full.
Structures shall be designed for uplift in empty conditions considering the depth of the
highest water table recorded in the area.
Walls shall be designed under operating conditions to resist earthquake forces developed
due to mobilization of earth and dynamic water loads.
Underground or partially underground structures shall also be checked against stresses
developed due to any combination of full and empty compartments with appropriate ground/
uplift pressures on the base slab. A minimum safety factor of 1.2 shall be ensured against
uplift or floatation. The structure shall be designed as an un-cracked section.
4.2.14 Foundations
The minimum depth of foundations for all structures, equipment, buildings and frame
foundations and load bearing walls shall be as per IS: 1804. However, it shall not be less
than 1.5m from the GL at that location in case of ordinary soil. It shall be reviewed by the
Employer’s Representative in case hard stratum is encountered within that depth.
Care shall be taken to avoid the interference of the foundations or any other component of
the new building with the foundations of adjacent buildings or structure. Suitable adjustments
in depth, location and size may have to be made depending on site conditions.
Special attention is drawn to the danger of uplift being caused by the ground water table. A
base raft or piling for underground structures shall be designed for uplift forces that are likely
to be developed.
Where the level of foundation is above or near the natural/ existing ground level, this
difference shall be filled up in the following ways:
− In case of non-liquid retaining structures, the natural top soil shall be removed till a
firm stratum is reached (minimum depth of soil removed shall be 500 mm) and the
elevation difference shall be made up by compacted backfill as per specifications.
However, the thickness of each layer of the backfill shall not exceed 150 mm. The
area of backfilling for floor slabs shall be confined to prevent soil from slipping out
during compaction. The safe bearing capacity of this well compacted backfilled soil
shall not be considered more than 100 KN/m2 in the design. Pitching shall be
provided to maintain slope.
− In case of liquid retaining structures, the natural top soil shall be removed and the
elevation difference shall be made up with plain cement concrete.
4.3 General Requirements for Construction

The Contractor along shall submit the construction methodology to be adopted for the works.
From all major concrete works, concrete shall be brought from a batching plant. Concrete
shall be brought to site in transit truck / mixers.
The following are the design requirements for all reinforced or plain concrete structures:
(a) All binding and levelling concrete shall be a minimum 100 mm thick in concrete M15
grade.
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(b) The minimum grade of concrete to be used for water retaining structures shall be
M30 grade having minimum cement content of 320 kg/m3 with maximum 20 mm size
coarse aggregates. The quantity of the admixture shall be as per mix design.
(c) All other structural reinforced concrete shall be at least of M25 grade having minimum
cement content of 300 kg/m3 with maximum 20 mm size coarse aggregates. The
quantity of the admixture shall be as per mix design.
(d) All design for liquid retaining structures shall be done as per IS: 3370. For walls and
base slabs of liquid retaining structures, the following shall be considered:
1 Minimum reinforcement shall be as per IS: 3370 (Part II). This reinforcement
shall be placed closer to the concrete faces and the minimum specified clear
cover as per IS: 3370 and clause (v) above.
2 The maximum length of panel to be concreted, sequence of pouring and
height of pour shall be as per specifications, IS: 456 and IS: 3370 (Part I) as
applicable.
(e) Approved quality waterproofing compound (chloride free) shall be added during
concreting of all liquid retaining structures in the proportion specified by the
Manufacturer or 2% by weight of cement, whichever is higher.
The minimum cover to all reinforcement including stirrups and links shall be as per IS: 456.
However the minimum clear cover shall not be less than the following:
Table 1: Minimum Clear Cover requirement for structures
Location Minimum Clear Cover (in mm)
At each end of reinforcing bar Maximum of 25 mm and twice the
diameter of bar
Column longitudinal bar 40 mm
Beam main bar Maximum of 25 mm and the diameter
of bar
Slab Maximum of 15 mm and diameter of
bar
Wall 25 mm
Footing and base slab 50 mm
Liquid retaining structures (for all 40 mm
structural members including roof above)
Sludge retaining structures (for all 50 mm
structural members including roof above)
All buildings shall have minimum 1.0m wide, 100 mm thick plinth protection paving in M15
grade concrete or stone slabs/ tiles. All plinth protection shall be supported on well
compacted stratum.
The following minimum thickness shall be used for different reinforced concrete members,
irrespective of design concrete grade used:
Table 2: Minimum Thickness of Structural Elements
Structural Component Minimum Thickness
Walls for liquid retaining structures 200
Roof slabs for liquid retaining structures 150
Bottom slabs for liquid retaining structures 200
Floor slabs including roof slabs, walkways, canopy slabs 125
Walls of cables/ pipe trenches, underground pits etc. 125
Column footings 300
Parapets, chajja 100
Precast trench cover 100
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4.3.1 Concrete Pouring

For all major concrete works (and concrete works exceeding 5 Cum by volume), concrete
shall be brought from batching plant. Concrete shall be brought to site in transit truck mixers.
Concrete pouring shall be carried out by either discharging through concrete pumps of
adequate capacity. Manual pouring of concrete shall not be permitted.
However, for minor concreting works, manual pouring of concrete may be permitted with
specific approval of the Employer.
4.3.1 Batching Plant and Equipment

The batching plant shall include minimum four bins, weighing hoppers, and scales for the fine
aggregates and for each size of coarse aggregate. If cement is used in bulk, a separate scale
for cement shall be included. The weighing hoppers shall be properly sealed and vented to
preclude dust during operation. Approved safety devices shall be provided and maintained
for the protection of all personnel engaged in plant operation, inspection and testing. The
batch plant shall be equipped with a suitable non-resettable batch counter which will correctly
indicate the number of batches proportioned. A continuous type of mixing plant can also be
used provided the ingredients are weighed through electronic sensors before feeding.
Automatic weighing devices: Batching plant shall be equipped to proportion aggregates and
bulk cement by means of automatic weighing devices using load cells. The weighing devices
shall have accuracy within ±1 % in respect of quantity of cement, admixtures and water and
±2% in respect of aggregates and the accuracy shall be checked at least once a month.
Mixer: Mixers shall be pan type, reversible type or any other mixer capable of combining the
aggregates, cement, and water into a thoroughly mixed and uniform mass within the
specified mixing period, and of discharging the mix, without segregation. Each stationary
mixer shall be equipped with an approved timing device which will automatically lock the
discharge lever when the drum has been charged and release it at the end of the mixing
period. The device shall be equipped with a bell or other suitable warning device adjusted to
give a clearly audible signal each time the lock is released. In case of failure of the timing
device, the mixer may be used for the balance of the day while it is being repaired, provided
that each batch is mixed in 90 seconds or as per the manufacturer's recommendation. The
mixer shall be equipped with a suitable non-resettable batch counter which shall correctly
indicate the number of batches mixed.
The mixer shall be cleaned at suitable intervals. Batching Plant shall be calibrated in the
beginning of the works (immediately after installation) and thereafter at suitable interval not
exceeding 3 months.
Control cabin: An air-conditioned centralized computer control cabin shall be provided for
automatic operation of the equipment. The design features of the batching plant should be
such that it can be shifted quickly.
4.3.2 Design Mix Concrete

The Contractor may carry out laboratory trials of design mix with the materials from the
approved sources. Trial mixes shall be made in presence of the Employer or his
representative and the design mix shall be subject to the approval of the Employer’s
representative.
Alternatively, Mix design shall be tried and the mix proportions checked on the basis of tests
conducted at a recognized laboratory duly approved.
All concrete proportions for various grades of concrete shall be designed separately and the
mix proportions established keeping in view the workability for various structural elements,
methods of placing and compacting. Mix proportions shall be designed to ensure that the
workability of fresh concrete is suitable for conditions of handling and placing, so that after
compaction it surrounds all reinforcements and completely fills the formwork. When concrete
is hardened, it shall have the stipulated strength, durability, and impermeability.
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The mix design shall be done according to provisions of SP: 23 (Reference may also be
made to ACI 211.1-77 for guidance).
For any change in quality/quantity in the ingredients of a particular concrete, for which mix
has been designed earlier and approved, the mix has to be redesigned and approval
obtained again.
4.3.3 Design of Formwork

Forms shall be constructed with Mild Steel, unless specified otherwise. Ply forms may be
used in specific cases with prior permission of the Employer.
Staging (propping and centering) should be either of steel tubes with extension pieces or built
up sections of rolled steel. Structural steel tubes used as support for forms shall have a
minimum wall thickness of 4 mm. Ballies shall not be used as staging. Staging must have
cross bracings and diagonal bracings in both directions. Staging shall be provided with an
appropriately designed base plate resting on firm strata.
Where metal forms are used, all bolts and rivets shall be countersunk and well ground to
provide a smooth, plane surface. Where timber is used it shall be well seasoned, free from
loose knots, projecting nails, splits or other defects that may mar the surface of concrete.
Design and Drawing of Staging and Formwork: The Contractor shall furnish the design and
drawing of complete formwork (i.e. the forms as well as their supports) for approval before
any erection is taken up. Notwithstanding any approval or review of drawing and design, the
Contractor shall be entirely responsible for the adequacy and safety of formwork.
Chamfers and Fillets to formwork: Unless otherwise specified, or directed, chamfers or fillets
of size 25 mm x 25 mm shall be provided at all angles of the formwork to avoid sharp
corners. The chamfers, bevelled edges and mouldings shall be made in the form work itself.
Opening for fixtures and other fittings shall be provided in the shuttering required.
Lining of Formwork: The formwork shall be lined with approved material so as to provide a
smooth finish of uniform texture and appearance. This material shall leave no stain on the
concrete and shall be so fixed to its backing as not to impart any blemishes. It shall be of the
same type and obtained from only one source throughout for the construction of any one
structure. Internal ties and embedded metal parts shall be carefully detailed and their use
shall be subject to the approval of the Employer.
Inspection for Formwork: The Contractor shall give due notice before placing any concrete in
the forms to permit him to inspect and approve the formwork. However, such inspection shall
not relieve the contractor of his responsibility for safety of formwork, men, machinery,
materials and finish or tolerances of concrete.
Removal of Formwork: The scheme for removal of formwork (i.e. de-shuttering and de-
centering) shall be planned and furnished for scrutiny and approval. No formwork or any part
thereof shall be removed without prior approval. The formwork shall be so removed as not to
cause any damage to concrete. Centering shall be gradually and uniformly lowered in such a
manner as to permit the concrete to take stresses due to its own weight uniformly and
gradually to avoid any shock or vibration.
4.3.4 Setting Out and Leveling

The Contractor is to set out and level the works and will be responsible for the accuracy of
the same. He is to provide all instruments and proper qualified staff required for checking the
Contractor’s work.
4.3.5 Grade of Concrete

The minimum Grade of Concrete shall be M-30 for water retaining structure or structures in
direct contact with water. The minimum Grade of Concrete shall be M-25 for all other
structural buildings / works, unless specified otherwise.
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4.3.6 Placement of Reinforcement

All Reinforcement shall be High Yield Strength Deformed bars (HYSD) confirming to IS:1786,
of Grade Fe-415 / Fe-500. All reinforcement steel shall be procured from original producers;
no re-rolled steel shall be incorporated in the work. Only new steel shall be delivered to the
site. Each delivery shall be inspected (and samples collected for testing) before assembling
on the work and defective, brittle or burnt bar shall be discarded. Cracked ends of bars shall
be discarded.
Reinforcement laid and tied shall be inspected by the Engineer, prior to commencement of
concreting.
4.4 Design Requirements and Submittals

The Contractor will be required to submit the necessary designs (including design
calculations) and drawings for approval to the Employer's Representative.
4.4.1 Detailed Design and Drawings

The detailed design of all the items of work comprising of hydraulic, architectural and
structural design has to be prepared by the Contractor in close coordination with the
The outline dimensional drawings submitted by the Contractor shall include the following
parameters of equipment in addition to overall dimensions:
− Load details
− Support details
− Foundation pocket details
Note: For submittals related to Electrical, Mechanical and Instrumentation Works and SCADA
refer to the Particular Requirements for Electrical, Mechanical and Instrumentation Works
and SCADA.
The drawings and documents related to Civil Works to be provided by the Contractor shall
include the following, but not be limited to those listed:
Sl. Description To be submitted
No. with Tender after Contract award
1.0 Methodology of construction of raw water intake √ √
well - cum - pumping station and approach
bridge including GA drawings
2.0 General WTP layout showing all proposed √ √
treatment units and all buildings including
components
3.0 Construction methodology for all other √
components of the work
4.0 Structural drawing showing reinforcement √
details of all the components as specified by
Employer's Representative
5.0 Plan and sections of all the buildings showing √
layout of Plumbing and Sanitary work on scale
as specified by Employer's Representative
6.0 Structural drawing showing member sizes and √
their fixing details, foundation details, etc.
Detailed design calculations and working drawings shall be prepared and shall have to be
submitted by Contractor for scrutiny.
The submittals shall include but not limited to:
− Architectural drawing and General Arrangement drawing for each structural unit
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− Structural Design for each of the building units / structure (pump house and storage
reservoir)
− Detailed RCC drawings including reinforcement details
− Plumbing and Sanitary Drawings
− Mechanical drawings (Ventilation arrangement, ACs, as applicable for the building
units, Pumps, Cranes, piping layout etc for the pump house)
− Electrical drawings (as applicable) and
With reference to the drawings, the contractor shall submit the Bar bending schedule for all
RCC Structures (element-wise) for review and approval. Reinforcement checking at site shall
be based on approved drawings and approved BBS.
For works related to Steel structures, the Contractor shall provide detailed Bill of Materials for
review and approval.
Detailed quantity estimates for items for plumbing and sanitary works for each building unit
and structures shall also be submitted for approval.
The contractor shall submit the detailed design and analysis (Calculations, Spreadsheets,
Input and Output files of the designs, where specific Design Software is used) and submit the
report in six (6) sets including soft copy for approval. Design input and Output files in original
format should be made available to the Engineer in required formats that can be viewed and
edited, if required.
The contractor shall submit six (6) sets of working drawings including design including soft
copy for approval.
4.4.2 Preparation of detailed layout plan

The Contractor shall prepare detailed layout plan for Intake, Electric Sub-station and WTP
Site. The preparation of the layout plan shall outline the:
(1) Proposed location for carrying out geotechnical investigation to confirm the safe bearing
capacity at the sites.
(2) Location of minimum 3 nos. TBM established at site with RL and co-ordinates.
(3) Civil structures and ancillary components within the premises.
(4) Alignment of the inlet pipe, outlet pipes, wash-out and overflow pipes including pipeline
interconnectivity as per requirements, location of valve chambers, flow-meter chambers
etc as required.
(5) Layout of internal road and pathways, including details of approach road including
culvert, as required.
(6) Detailed internal drainage network, including sizing of the drains, location of culverts (as
required) including drainage outfall.
(7) Yard lighting including cable / cable trenches as required.
(8) Provide detail design of formwork and staging, for the reservoirs.
(9) Provide Bar Bending Schedule for each component of the reservoirs.
The works at site shall be carried out based on the detailed layout plan, duly approved by the
Employer / Engineer. The construction of all installation works / utilities (like cable, drains,
piping arrangement etc) shall commence only after approval of the detailed layout plan.
4.4.1 Working drawings and Completion drawings

The contractor shall submit six (6) sets of working drawings, designs including soft copy for
approval. The contractor shall submit six (6) sets of as built completion drawings after
completion of the work including soft copies, after completing the works.
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4.4.2 Submission and Approval of Drawings after award of contract

The Contractor shall submit six copies of each drawing/ document along with a CD for
approval to the Employer's Representative.
All drawings provided by the Contractor shall be on standard A1 size sheets, unless
otherwise directed by the Employer's Representative, prepared using latest version of
AutoCAD software and shall show the following particulars in a title block located in the lower
right hand corner : the project name, name of the Employer, Employer's Representative,
Contractor, Designer and Equipment Manufacturer, date, scale, drawing number, revision
number (R0 for drawings submitted initially, R1, R2, etc. for drawings submitted
subsequently). The title block of the drawing is to be finalized in consultation with the
The drawings shall also include adequate space for the Employer's Representative’s
approval stamp and provision shall be made for details of revisions to be recorded.
All drawings submitted by the Contractor shall use the English language and dimensions
should be preferably in SI units. All drawings shall be clearly and fully cross referenced to the
other drawings as relevant.
The Contractor shall ensure that the contents on copies of drawings are legible and are
complete. Drawings that are not legible or are incomplete will not be reviewed.
After tests on completion, the Contractor shall submit the conclusion of the tests within 15
days and ‘As Built Drawings’ within three months of actual completion to the Employer's
Representative. These drawings shall be accurate and accepted only on acceptance of the
Completion drawings shall be supplied by the Contractor in six prints along with three soft
copies in CD/ DVD to the Employer's Representative. These drawings shall be developed
using latest version of AutoCAD.
4.4.3 Detailed Drawings / Documents

The Contractor shall submit to the Employer's Representative, all working drawings,
equipment data and detailed drawings, as applicable. These shall include general
arrangement, plan - profile drawings for pipeline, structural details, details of equipment,
foundations, installation details for cabling, earthing and lighting systems, wiring diagrams,
cable schedules, etc. necessary for erection of the plant.
These drawings/ data having been corrected or amended as necessary based on the
Employer's Representative's comments shall become the 'Approved' drawings/ data to be
used for manufacture, installation of the system and erection of plant.
4.4.4 Approval of Sample

Sample of materials to be supplied and used by the Contractor in the works shall have prior
approval of the Employer's Representative. For this purpose, the Contractor shall furnish in
advance representative sample in quantities and in the manner as directed by the Employer's
Representative for his approval.
4.4.5 Ground Conditions

The Contractor is to visit the site and ascertain local conditions, soil conditions, accessibility
to the site, traffic restrictions and obstruction in the area and his quoted price is deemed to be
inclusive of any extra expenses likely to be incurred in due to any limitation whatsoever. No
additional claims will be allowed on the ground of difficult site conditions, poor approachability
or any other issues not foreseen.
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4.5 First Aid Kit

The first aid kit shall consist of all materials, medicines necessary for treatment of cuts,
wounds, burns bad effects of inhalation of chlorine, bad effects on skin due to contact of
chemicals acids etc. Following materials in general in sufficient quantities shall be provided.
(a) Medical cotton, sterile cotton pads
(b) Cotton Bandages, elastic bandages
(c) Pair of scissors, packet of new shaving blades
(d) Sticking plaster for medical use.
(e) Band aid stripes
Following chemicals/medicines shall be provided in sufficient quantities:
(a) Tinctures iodine and mercury chrome
(b) Burnol ointment
(c) Bottles of spirit and of Dettol
(d) Toilet soaps
To be procured under medical advice
(e) Tablets for bad-effects of chlorine inhalation
(f) Skin lotions and ointments for burns, acid effects
(g) Eye drops for soothing effects
First Aid Kits shall be provided in the Raw Water Intake well, Clear Water Pump House,
Administrative building, Laboratory room and SCADA Control room.
4.6 Specific Requirements

Unless otherwise specified elsewhere all works, where Contractor shall submit the designs,
the following requirements shall hold good.
(a) Building designs shall confirm to National Building Code. The buildings and
structures shall be constructed considering “Good Engineering” practices.
(b) All buildings shall have reinforced concrete framework with column and beam
arrangement. The building plinth shall be minimum 600 mm above average finished
ground level.
(c) Minimum 75 mm thick RCC Damp Proofing Course in M15 shall be provided to all
building. Minimum 75mm BFS to be provided below all shallow foundations.
(d) All buildings shall have a minimum 1.0 m wide, 100 mm thick plinth protection paving
in M15 grade concrete finished with stone slabs/ tiles. All plinth protection shall be
supported on well-compacted stratum (300mm sand filling).
(e) The base or floor, unless specified otherwise shall be filled with minimum 900mm
thick sand layer, topped with 75mm thick brick flat soling (n 2 layers) and 50mm
screed concrete (1:2:4).
(f) All brick walls shall be in 250 mm thick brick masonry built in cement mortar in (1:4).
Toilet partition walls shall be in 125 mm thick brick masonry built in cement mortar
1:4. Brickworks below ground level shall have flush pointing to both faces in 1: 6
cement and sand mortar.
(a) Outside plaster shall be 20mm thick (1:6), while inside plaster shall be 12mm thick
(1:6). Ceiling plaster shall be 6mm thick (1:4) with Plaster of Paris punning. For
outside plaster, waterproofing compound of approved make and quality shall be
added to the cement mortar in proportions as specified by the manufacturer.
(g) All the internal walls and ceiling of the building units (including pump house) shall be
provided with 2 coats of Interior grade acrylic emulsion (Standard quality) of
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approved quality and brand over acrylic primer on plastered or concrete surface,
unless stated otherwise.
(h) The external surfaces of the buildings shall have two coats of acrylic primer and paint
(2 coats), of approved quality and shade over a coat of primer.
(b) Anti-termite treatment shall be provided for all structure / building units as per IS:
6313 with injection of chloropyrious emulsifiable concrete (1%) timber care ground
treatment chemically emulsion 1:3 and creating a chemical barrier under and around
the column pits, wall trenches, basement excavation, top surface of plinth filling,
junction of wall and floor along the external perimeter of building, expansion joints,
surrounding of pipes and conduits etc.
(c) Provision of water supply and sanitation facilities shall be provided for Administrative
building, Staff quarters cum laboratory and Store cum Operators room. Such
arrangements shall be made as required to meet the demand for the building units.
(d) The building units shall be provided with potable water supply from minimum one
overhead tank (minimum 2000Litre Capacity) placed on the roof of the building.
Tanks shall be PUF Insulated Tank with PE.
(e) Bathroom/ W.C. floor slab shall be provided with anti-skid tiles (300mmx300mm). The
walls shall tiles upto a height of 1.2m above the Floor level. The finished floor level in
Bathroom / W.C. areas shall be normally 12 mm below the finished floor level on the
outer side. All toilet blocks shall have the following minimum facilities:
o One (1) No. anglo-Indian Water Closet in white glazed vitreous china ware of
approved make complete in position with necessary bolts, nuts, with “S” trap.
o 1 No. Urinal of sizes 600 mm x 400 mm x 300 mm flat back type in white
porcelain separated by a kota stone partition of size 680 mm x 300 mm shall be
provided outside toilet.
o 1 No. Wash basin of size 510 mm x 400 mm in white Porcelain with inlet, outlet
with bottle trap.
o 1 No. Mirror of size 400 mm x 600 mm PVC moulding wall mounted type fitted
over washbasins.
o 1 No. Plastic liquid soap bottle.
o 1 No. Chromium plated brass towel rails minimum 750 mm long.
o The stopcocks, valves and pillar cocks shall be of chromium-plated brass,
heavy duty.
o All fittings such as `P’ or `S’ traps, floor traps, pipes, down-take pipes etc.
Each Toilet block shall be provided with 2 numbers of Steel Buckets (20 Litres) and 2 Steel
mugs.
The waste-water from toilet blocks shall be led to a septic tank with soak pit. The Contractor,
at a suitable location, shall provide a septic tank (minimum 20 Users) and a soak pit.
Construction of septic tank shall be done with 1st class brick work in cement mortar (1:4)
including two 560 mm dia. R.C.C. manhole cover (heavy type) of approved make supplied,
fitted and fixed in the 100mm thick R.C.C (1:1.5:3) top slab with necessary fittings, 20mm
thick cement plaster (4 : 1) with neat cement finish to the internal surfaces and 15 mm thick
cement plaster (4 : 1) to outside wall upto 200 mm below G.L floor finished with 25 mm thick
grey artificial stone over 100 mm thick R.C.C (1:1.5:3) bottom slab including supplying, fitting
and fixing all necessary specials, fittings, S.W. tees, C.I. foot rest etc. including excavation
earth in all sorts of soil, shoring, bailing out and pumping out water as necessary, ramming,
dressing the bed and refilling the sides of the tanks with earth, removing spoils, filling up the
chamber with clear water, removing foreign materials from the chamber and including
constructing attached inspection pit and connecting all necessary pipes, joints etc. with
internal plaster work and artificial stone flooring is to be done with admixture of water
proofing compound. After completion of the tank, the tank shall have to be filled up with clear
water after removing any foreign materials from the inside of the tank, if any.
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Circular soak well shall be 2.5 metre deep with dry brick work upto 1.6 metre from the ottom
having 150 mm intermediate cement brick work (1:4) band all round and cement brick work
(1:4) upto 0.90 metre from top with 20mm thick cement plastering (1:4) to inside face upto
the depth of cement brick work, 15mm thick cement plaster (1:4) on outer face from top of
the well upto G.L. and 6 mm thick cement plaster (1:4) on top of the R.C.C. cover slab
including filling bottom 1.00 metre of inside of the well with brick metal (50 mm to 63 mm
size) including R.C.C. cover slab of 100 mm thick with cement conc (1:1.5:3) with stone chips
with necessary reinforcement and shuttering including one 560 mm dia. R.C.C. manhole
cover (heavy type)of approved make supplied, fitted and fixed in the cover slab with
necessary fittings, making necessary arrangements for pipe connections, excavation of well
including shoring, dewatering and removing the excess earth from the premises complete in
all respect with all costs of labour and materials.
Suitable drainage arrangement shall be provided for conveyance of the grey water.
(f) All building including rooms under the project shall be provided with appropriate
signboards indicating the function of the rooms involved. The name of the structural /
building units shall be clearly written for easy identification. The letters and figures
shall be such that these are easily read from a distance. These shall be stencilled or
drawn in pencil and got approved before painting. They shall be of uniform size and
finished neatly. The edges shall be straight or in pleasant smooth curves.
(g) All office floors shall have vitrified tiles. Staircase in the administrative building shall
be laid with Marble stone flooring with 18 mm thick marble stone over 20 mm thick
cement mortar (1:4).
(h) The passage area, stair blocks in the building units shall be finished with minimum 25
mm thick Kota Stone treads and 20 mm thick Kota Stone skirting. The rise of stairs
shall not exceed 170 mm and minimum width of the tread shall not be less than
275mm. All steps shall have 20mm nosing.
(a) The pump rooms and store rooms shall have 52 mm thick cement concrete flooring
with concrete hardener topping, under layer 40 mm thick cement concrete 1:2:4 (1
cement : 2 coarse and : 4 graded stone aggregate 20 mm nominal size) and top layer
12 mm thick cement hardener/ Ironite consisting of mix 1:2 (1 cement hardener mix :
2 graded stone aggregate 6 mm nominal size) by volume, hardening compound
mixed @ 2 litre per 50 kg of cement or as per manufacturer’s specifications.
(b) All roof tops shall be made accessible with concrete stairs. Provision for MS vertical
ladders fitted with landing point extensions will be permitted where considered
appropriate by the Engineer to access areas not frequently visited.
(c) All floor cut-outs and cable ducts, etc. shall be covered with pre-cast concrete covers
in outdoor areas and G.I. chequered plates of adequate thickness in indoor areas. All
uncovered openings shall be protected with hand railing (minimum 1.0m). All hand
railings outside shall be of mild steel (painted with epoxy) and inside the buildings
shall be of stainless steel. Vertical posts (minimum 1.0m) shall be spaced not more
than 1.5m, while horizontal rails shall be at 2 layers. Vertical posts shall be 65mm,
while railing shall be of 50mm diameter.
(d) The design of buildings shall reflect the climatic conditions. All the building units shall
as far as possible permit the entry of natural light. Emergency exit doorways shall be
provided from all buildings in order to comply with local and international regulations.
Stairways and paved areas shall be provided at the exit points. All types of opening
such as doors, windows and ventilators shall be minimum 25% of the floor area.
(e) The reinforced concrete roofs shall be made waterproof by application guaranteed for
10 years. The finished roof surface shall have adequate slope to drain quickly the
rainwater to Rain Water (RW) down-take points.
(f) All the exterior doors and windows shall be provided with R.C.C. chajja of approved
design. Top surfaces of chajjas and canopies shall be made waterproof by providing
a screed layer of adequate slope or application of an approved roof membrane and
sloped to drain the rainwater.
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(g) Kerbs to be provided below the hand railing on the catwalks/pathways should be as
per relevant sections of the Factory Act. Wherever equipment and machinery is
required to be moved for inspection, servicing, replacement etc., suitable movable
gantry of required capacity shall be provided. All chequered plates shall be hot dip
galvanized.
(h) Suitable access ladder, platform, staircase, walkways (minimum 1.2m wide), hand
railing etc. (all structural steel) shall be provided for approach to all the equipment on
and inside the unit as well as for easy accessibility of different subsystems of the
plant supplied under this specification. Hand railings provided in pump house /
reservoirs shall be minimum 1.0 m height.
(i) All Windows / Ventilators of mild steel (IS:1038), shall be with bubble free float glass
6mm thick tinted / coloured / clear glass (as approved) as per IS: 2835. All steel
windows and ventilators shall be provided with (15kg/sqm) M.S grill of approved
design joints continuously welded with M.S, Flats and bars of windows, railing etc.
fitted and fixed with necessary screws and lugs. The design of the grills shall be duly
approved by the Engineer.
(j) Rolling shutter shall be provided for all pump houses, store rooms and Electric Sub-
station buildings, and in location and dimension as shown in the drawings. Rolling
shutter shall be of steel rolling grills link type with 18 B.G .of approved type steel to
the section 75mm wide, fitted with coil wire spring to necessitate the fitting of required
Nos. of C.I. Pulleys on heavy type solid drawn seamless steel tube complete with
locking arrangements both inside and outside specially built-up side guide channels
including providing a hood for the steel rolling shutter in the room. The rolling shutter
shall be painted with two coats of approved aluminium paint over a coat of red lead
primer.
(k) All buildings shall be provided with furniture and facilities for regular use. Wooden
furniture as considered shall be of best quality teak wood. Executive chairs (minimum
4 nos.), Tables, Steel Almirah shall be provided for all office rooms.
(l) Provision of air conditioning arrangements shall be provided in the Meeting room,
SCADA control room, office room(s) in the Administrative building and Laboratory
room. Doors and windows in these locations shall be of aluminium frame with sliding
arrangement. Anodized brass screws / chromium brass screws shall be used for
fixing. Fittings shall be got approved by the Engineer before fixing. Aluminium
windows /ventilators shall confirm to IS: 1948. The windows shall have 8mm thick
bubble free float glass (tinted / coloured) of approved make and brand conforming to
IS: 2835. All windows and ventilators/skylights shall be of heavy duty aluminum
extruded section of approved design.
(a) The rooms shall be finished 2 coats of acrylic emulsion paint (luxury paint) of
approved make and brand on walls and ceiling including sand papering in
intermediate coats including putty.
(b) The pump house, guard room, operators room shall be provided with MS sheet door.
(c) Wooden doors shall be flush type doors of deluxe decorative (both side) quality,
conforming to I:S 2202 timber frame consisting of top and bottom rail and side styles
of well seasoned timber 65mm wide each and the entire frame fitted with 27.5mm
wide battens places both ways in order to made the door of solid core and internal
lipping with teak, mahogony or rose wood as approved decorative veneers using
phenol formaldehyde as glue.
(d) Door for toilet block shall be of 30 mm thick both side pre-laminated factory made
solid Panel PVC Door Shutter consisting of outer frame (covered with 5 mm thick
heat moulded PVC “C” channel) made out of M.S. tubes of (19 gauge thickness).
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5.0 Raw water Intake well and allied works
5.1 Design of Raw Water Intake Well

The intake structure shall be circular in shape. The capacity / size of the same shall also be
determined by the following conditions:
− The depth of the Intake is to be considered taking into consideration the minimum
water depth required up to minimum WL to satisfy NPSHR for Pumps to avoid air
entry during drawdown.
− Provision for prevention of vortex formation.
− Provision for obtaining uniform distribution of the in-flow to all the operating pumps
and to prevent starvation of any pump.
5.1.1 Construction of Raw water Intake Well

The construction of intake well shall be done with respect to Good Engineering practices.
The technical specifications of MoRTH will be followed in this regard.
5.1.2 Inlet arrangement

The entrance of large objects into the intake well shall be prevented by coarse screen. Fine
screen for exclusion of small fish and other objects shall be placed at the accessible point.
The area of the opening in the intake well shall be sufficient to ensure an entrance velocity
greater than 1 meter per second. Submerged ports in the intake well shall be provided in
such a way that the rate of flow of inlet water through the port hole is greater than the rate of
maximum discharge from the well at the lowest level of water.
The size of port opening shall be provided carefully, so that the rate of inflow of raw water
through the port openings must be greater than the rate of discharge from the well ensuring
adequate supply in the ultimate design year.
To prevent river wildlife and debris from entering the intakes, suction lines with wedge wire
screens shall be fastened to the suction pipes. Proper flushing arrangement of the screens
with water or air jet shall be kept.
There will be a minimum of 3 inlet isolation gates, (manually operated non-rising spindle
type). The spindle of the sluice gate shall be of stainless steel and additional length of
Stainless Steel spindle shall also be provided with intermediate line support bearing of
phosphor bronze sleeve in CI casing at a regular interval of maximum 1.5 m shall be
provided for operation of the sluice gate from top at the pump floor level. Diameter of the
spindle shall be sized such that tensional deflection is restricted below 0.25 degree/m length.
Operational arrangement shall be essentially be made with bevel gear and head stock
assembly for easy operation by one person.
5.2 Raw water Pumping Station

5.2.1 General Requirements
The raw water pump station will be an RCC framed structure square in shape constructed
over the raw water intake well. The dimensions of the raw water intake pumping station shall
be based on Contractor’s own design (the dimensions of raw water intake pumping station).
The floor of Pump House and discharge pipe floor with RCC beams shall be constructed to
withstand the load of Pumps, Motors, Column Pipes, Delivery Pipes, Valves and other
electrical accessories, E.O.T. crane etc. as well as part of the load coming from the approach
steel bridge which shall rest on the floor at one end.
The height of the pump house shall be 10.5m.
The walls of the Pump House shall be 250 mm thick 1st class brickwork with 1:4 cement
mortar (1 cement and 4 sand). Adequate numbers of RCC columns along the centre line of
periphery of the square brick wall shall be provided and equally spaced for the support of 2
Page 47
nos. of Rolled Steel Joists (RSJ) and RCC Roof beams. The columns shall be constructed to
support the RSJs over which crane shall be fixed for lifting the Pumps, Motors, Pipes, Valves,
and Electrical Accessories as well as to support RCC roof beams.
The area of the pump station should be sufficient space to locate all the Working and
Standby units of pump, motor along with associated valves, piping, control panels and cable
trays in a rational manner with easy access and with sufficient space around each equipment
for the maintenance and repairs.
Provision of a head room and material handling tackle with adequate clearance to lift the
motor clear off the face of the coupling and also carry the motor to the service bay without
interference with any other apparatus including adequate clearance to dismantle and lift the
largest column assembly.
5.2.2 Layout of the Pump House

The layout of the pump station should be done to allow:
− Sufficient space between two adjoining pumps/motors
− Provision of sufficient space for the control panels as per the Indian Electricity (I.E.)
Rules
− Provision of service bay in the station with space to accommodate overhauling and
repairs of the largest equipment
− Provision of loading and unloading bay to facilitate attending to major repairs and
overhauling.
5.2.3 Rolling Shutter

Rolling shutter shall be link type, shutter with 18 B.G .of approved type steel to the section
75mm wide, fitted with coil wire spring to necessitate the fitting of required Nos. of C.I.
Pulleys on heavy type solid drawn seamless steel tube complete with locking arrangements
both inside and outside specially built-up side guide channels including providing a hood for
the steel rolling shutter in the room, painting two coats of approved aluminium paint over a
coat of red lead primer complete.
Unless specified otherwise, the rolling shutter shall be of size 3.0mx3.5m.
5.2.4 Windows and Ventilators

Steel windows shall be openable type with integrated grills (@ minimum 12 Kg/Sqm)
conforming to IS 1038 and manufactured from rolled steel sections conforming to IS 7452
with non-friction projecting type, box type hinges, glazing clips, lugs locking bracket, handle
plate etc.
Ventilators shall be openable type (Centre hung) of 580mm.
The windows / ventilators shall be provided with bubble free float glass 6mm thick tinted /
coloured / clear glass (as approved) as per IS: 2835. M.S grill shall be of approved design
joints continuously welded with M.S, Flats and bars of windows, railing etc. fitted and fixed
with necessary screws and lugs. The design of the grills shall be duly approved by the
Engineer.
5.2.5 Flooring
Unless, specified otherwise, the pump rooms shall have 52 mm thick cement concrete
flooring with concrete hardener topping, under layer 40 mm thick cement concrete 1:2:4 (1
cement : 2 coarse and : 4 graded stone aggregate 20 mm nominal size) and top layer 12 mm
thick cement hardener/ Ironite consisting of mix 1:2 (1 cement hardener mix : 2 graded stone
aggregate 6 mm nominal size) by volume, hardening compound mixed @ 2 litre per 50 kg of
cement or as per manufacturer’s specifications.
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5.2.6 Finishing
Outside plaster shall be 20mm thick (1:6), while inside plaster shall be 12mm thick (1:6).
Ceiling plaster shall be 6mm thick (1:4) with Plaster of Paris punning. For outside plaster,
waterproofing compound of approved make and quality shall be added to the cement mortar
in proportions as specified by the manufacturer.
All the internal walls and ceiling shall be provided with 2 coats of Interior grade acrylic
emulsion (Standard quality) of approved quality and brand over acrylic primer on plastered or
concrete surface, unless stated otherwise. The external surfaces of the buildings shall have
two coats of acrylic primer and paint (2 coats), of approved quality and shade over a coat of
primer.
5.3 Approach Bridge

5.3.1 General Requirement
The minimum grade of concrete to be used for raw water intake well and approach bridge
structure shall be M30 grade (With maximum 20 mm size coarse aggregates). The quantity
of the admixture shall be as per mix design.
The approach bridge shall be designed to take motorable vehicular load. The hand railing
shall be made of mild steel pipe of minimum 65mm diameter, of minimum 1.2m height.
5.3.2 Length and Width of Approach Bridge

The approach bridge shall be of adequate width to allow for the raw water main to be laid. The
minimum width of approach bridge shall not be less than 5.0m.
5.4 Electrical Sub-station Building

The electrical sub-station should be well ventilated and generally accommodate the following
equipments:
(a) H.V. switchgear and metering arrangement as per requirements of Licensee in
accordance with Rule 64 (I) (a) of I.E. Rules
(b) Consumers H.V. panel boards
(c) Transformers
(d) M.V. Panels in accordance with Rule 64 (I) (a) of I.E. Rules
(e) Cable trenches / Cable trays / Bus ducts
(f) Inter-connecting cables and auxiliary equipments
Unless, specified otherwise, the sub-station building shall consist of:

− Supplier H.T. Breaker room
− Consumer H.T. Breaker room
− Transformer room
− L.T. Panel room
− Store room and Office room
The substation building height should be minimum 4.5m. Fire brick barrier wall shall be
provided as per requirements.
The supplier H.T. Breaker room shall have no ventilation and no windows, only rolling
shutter, while the Consumer H.T. Breaker room shall have provision of exhaust fan for
ventilation, no windows, louvers at lower side and rolling shutter. The L.T. Panel room shall
have provision of exhaust fan for ventilation, and shutter height of minimum 3.5m.
The Transformer room shall have provision for exhaust fan and rolling shutter and shall have
adequate dimensions for installation of dual transformer.
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5.4.2 Doors, Windows and Ventilators

All doors and windows shall be steel for fire protection. Ventilators (minimum 750mmx
500mm) shall be made of steel frame with heavy wire mesh, 50cms below the ceiling.
Windows shall be with integrated grills conforming to IS 1038 and manufactured from rolled
steel sections conforming to IS 7452 with non-friction projecting type, box type hinges,
glazing clips, lugs locking bracket, handle plate as per direction of the Engineer.
Windows shall be with bubble free float glass 4mm thick tinted / coloured / clear glass (as
approved) as per IS: 2835. Steel windows shall be provided with (15kg/sqm) M.S grill of
approved design joints continuously welded with M.S, Flats and bars of windows, railing etc.
The ventilation arrangement shall be complete with tube axial supply air fans with all
accessories including ducting arrangement for supplying air and exhaust fans. The same
shall be supplied in adequate quantities to ensure minimum 12 air changes per hour.
The door shall be of MS sheet of relevant IS (Heavy duty).
5.4.3 Flooring
Flooring shall be cement concrete flooring with high performance non-metallic floor hardener
containing specially graded non-metallic hard wearing natural aggregates imparting floor
hardness in the range of mohr scale 8-9 & capable of achieving 28 days compressive
strength of 25 MPa with air content less than 3% applied as a dry shake @ 5Kg/sgm
sprinkled to provide durable, non-slip monolithic floor for application of the topping over
freshly laid concrete with under layer of 40 mm. thick cement concrete (1:2:4) (1 cement : 2
coarse sand : 4 graded stone aggregate 20 mm nominal size) as per specification of the
manufacturer and as per direction of Engineer-in-Charge.
5.4.4 Furniture
The following furniture’s shall be provided:
o Two (2) number of wooden size 1200x600x740
o Four (4) number wooden Chairs 525x630x815
o Two (2) number Steel almirah
The table shall have 18mm thick particle board laminated with veneer top (shade to be
approved by Engineer) and back panel having teal wood beading all around on top. Drawers
(minimum 3 nos.) to be provided with suitable locking arrangement and handle with glass top
(5 mm thick) shall be provided).
Steel almirah shall be fabricated from high quality CRCA steel of 20 gauge having anti rust
treatment equipped with precision lock and four adjustable shelves with powder coated finish
of Size (minimum): 1980mmx915mmx485mm.
5.4.5 Toilet Block

The finished floor level in toilet block shall be 12 mm below the finished floor level on the
outer side. The toilet blocks shall have the following minimum facilities:
o One (1) No. anglo-Indian Water Closet in white glazed vitreous china ware of
o 1 No. Urinal of sizes 600 mm x 400 mm x 300 mm flat back type in white porcelain
separated by a kota stone partition of size 680 mm x 300 mm shall be provided
outside toilet.
o 1 No. Wash basin of size 510 mm x 400 mm in white Porcelain with inlet, outlet with
bottle trap.
o 1 No. Mirror of size 400 mm x 600 mm PVC moulding wall mounted type fitted over
washbasins.
o 1 No. Plastic liquid soap bottle.
o 1 No. Chromium plated brass towel rails minimum 750 mm long.
Page 50
o The stopcocks, valves and pillar cocks shall be of chromium-plated brass, heavy
duty.
o All fittings such as `P’ or `S’ traps, floor traps, pipes, down-take pipes etc.
The toilet block shall be provided with 2 numbers of Steel Buckets (20 Litres) and 2 Steel
mugs. The waste-water from toilet blocks shall be led to a septic tank with soak pit. The
Contractor, at a suitable location, shall provide a septic tank (minimum 20 Users) and a soak
pit. The floor slab shall be provided with anti-skid tiles (300mmx300mm). The walls shall tiles
upto a height of 1.2m above the finished floor level.
Page 51
6.0 Design and Construction: Water Treatment Plant
6.1 Scope of Works

The Scope of work involves Survey, Investigation, Design and Construction of Water
Treatment Plant comprising of the following basic units:
(a) Stilling Chamber, Inlet Channel and Parshall Flume,
(b) Flash Mixer and Distribution Chamber
(c) Flocculators and inclined plate clarifiers with sludge breeding arrangement,
(d) Rapid Gravity Filter (With provision of Elevated Service cum Backwash reservoir for
backwashing of Filter and other utilities and water supply to different units of plant
and staff quarters within the WTP premises)
(e) Clear Water Reservoir (cum Pump house for pumping to the intermediate ground
level storage reservoir and pumping to elevated service reservoir within the WTP)
(f) Sludge / backwash waste-water collection in sumps and partial re-circulation of
backwash waste-water into the treatment system ahead of the Parshall flume
(g) Sludge lagoon
(h) Chemical House (With provision of alum, chlorine and Poly-electrolyte dozing system
for coagulation and disinfection) and
(i) Chlorination building
The hydraulics of the WTP shall be such that raw water will flow from the Stilling chamber to
the clear water reservoir by gravity.
The list of buildings which are proposed to be constructed within the WTP premises shall
include but not limited to:
o Administrative Building (Three Storied)
o Staff Quarters
o Store room and
o Guard Room
This apart, provision for Electrical Sub-station (and Switch Yard) with open space for main
and auxiliary transformer. The scope also includes:
− Area grading, final dressing and Levelling including Landscaping (With Gardens,
Lawns, Tree Guards etc)
− Peripheral road access road including in-plant road including pathways
− Secured boundary wall (with fencing) and Gate
− Plant and Road Illumination
All complete as per drawings, documents, technical requirements as stated in the bid
document. The scope and requirements shall be read in conjunction with Particular
specification for Mechanical Works, Electrical and Instrumentation and SCADA works.
6.2 Requirements of Pump House

The layout of the pump station shall be designed to allow:
− Sufficient space between two adjoining pumps/motors
− Provision of sufficient space for the control panels as per the Indian Electricity (I.E.)
Rules
− Provision of service bay in the station with space to accommodate overhauling and
repairs of the largest equipment
Page 52
− Provision of loading and unloading bay to facilitate attending to major repairs and
overhauling.
The minimum area of the pump house shall be not less than as indicated in the tender
drawings.
Design of the entire pump house shall be taken care such that no columns come in the
long and cross travel of EOT crane. The travel of crane in longitudinal and transverse
direction shall ensure maximum floor coverage including unloading bay.
For operation of valves at suction & delivery side, necessary RCC walkway shall be
provided at suitable levels.
Foundation system for support of Rotary machines such as Horizontal Pumps shall strictly
comply with the requirements of Code IS: 2974 (Part-IV)-latest edition. The Rotary Machine
support system require careful study of the foundation system with due consideration of
vibration characteristics. For satisfactory design and construction, the following precautions
need be taken with careful dynamic analysis of machine foundation and its supporting
structures:
(a) The natural frequency of the Foundation System shall be analysed and the mass of
the Foundation System shall be considerably larger than the mass of the whole
machine.
(b) Dynamic Analysis due to insufficient clearance between impeller and casing of
Pumps shall be checked and frequency arising out of this type of vibration need to
be made as per relevant IS Code.
(c) Dynamic Response check of the block foundation may be carried out as per
relevant IS Code.
(d) Permissible amplitude of Vibration of displacement as per IS Code 2974 (Part-IV),
is to be calculated and the design shall be checked accordingly.
(e) Permissible stresses in Soil / Concrete be suitably reduced/increased as per IS
Code.
(f) Natural frequency of Foundation System shall be such as shall avoid resonance
with the Operating Speed of the Machine. The natural frequency of the foundation
system shall not be within ±20% of the operating speed of the machine.
(g) The foundation system shall be so dimensioned that the resultant force due to mass
of the machine and mass of the Foundation passes through the Centre of gravity of
the base area of the Foundation.
The successful Bidder is required to submit a “Technical Write-up” with relevant details of
Foundation System. This shall help the Employer / Engineer to fix up the accepted
Parametric Norms of the foundation System that shall finally be adopted in the design and
construction of the Building and Structures after award of the contract.
All exposed Mild Steel parts shall be coated with red oxide primer, zinc chromate primer of
approved brand and manufacture overlaid with epoxy based coal tar paint giving a total dry
film thickness of at least 275 microns, unless specified otherwise.
Ceiling plaster shall be 6mm thick (1:4) with Plaster of Paris punning.
The internal walls and ceiling shall be provided with 2 coats of Interior grade acrylic emulsion
(Standard quality) of approved quality and brand over acrylic primer on plastered or concrete
surface. The building outside shall be provided with 2 coats of protective and decorative
acrylic exterior emulsion paint of approved quality, over acrylic primer.
The hand railing inside the pump house shall be of stainless steel of minimum 50mm
diameter. The height of hand railing shall not be less than 1.0m. Vertical posts shall be
placed at a minimum distance of 1.5m centre to centre. Horizontal hand rails shall provided
at two levels.
Doors shall MS framed with metal sheet (Heavy duty) as per IS.
Page 53
All Windows / Ventilators of mild steel (IS:1038), shall be with bubble free float glass 4mm
thick tinted / coloured / clear glass (as approved) as per IS: 2835. All steel windows and
ventilators shall be provided with (15kg/sqm) M.S grill of approved design joints continuously
welded with M.S, Flats and bars of windows, railing etc. fitted and fixed with necessary
screws and lugs. The design of the grills shall be duly approved by the Engineer.
The pump house shall have 40mm of cement concrete flooring with high performance non-
metallic floor hardener containing specially graded non-metallic hard wearing natural
aggregates imparting floor hardness in the range of mohr scale 8-9 & capable of achieving
28 days compressive strength of 25 MPa with air content less than 3% applied as a dry
shake @ 5Kg/sgm sprinkled to provide durable, non-slip monolithic floor for application of the
topping over freshly laid concrete with under layer of 40 mm. thick cement concrete (1:2:4) (1
cement : 2 coarse sand : 4 graded stone aggregate 20 mm nominal size) as per specification
of the manufacturer & as per direction of Engineer-in-Charge.
The Contractor shall submit to the equipment data as applicable. These shall include general
arrangement, plan – profile, drawings for pipeline, structural details, details of pump /
equipment, foundations, installation details for cabling, earthing and lighting systems, wiring
diagrams, cable schedules, etc.
Rolling shutter shall consist of steel rolling grills link type, shutter with 18 B.G .of approved
type steel to the section 75mm wide, fitted with coil wire spring to necessitate the fitting of
required Nos. of C.I. Pulleys on heavy type solid drawn seamless steel tube complete with
locking arrangements both inside and outside specially built-up side guide channels including
providing a hood for the steel rolling shutter in the room, painting two coats of approved
aluminium paint over a coat of red lead primer complete.
Rolling shutter shall be with locking and gear arrangement.
The water supply service connection, internal and external plumbing arrangements,
arranging of water from the proposed delivery / pumping pipe main (from the booster
pumping station) shall be included within the scope of the works of the building. The cost of
such arrangements for water supply facilities shall be included within the quoted rates for
subject work.
6.3 Requirements Administrative Building

The size and dimension of the building and the various facilities are as shown in the tender
drawing. The contractor shall prepare a conceptual layout plan of the civil works together with
architectural elevations of the facilities to be included shall be submitted to the Engineer for
approval.
The building shall be an RCC framed structure, with brick masonry work for external walls.
The plinth level shall be 600mm above the finished ground level.
6.3.1 Finishing
The inside walls and ceiling shall be rendered with White Cement base “Water Proof” wall
putty of approved make & brand(1.5 mm thick), overlaid with acrylic emulsion paint of
approved make and brand on walls and ceiling (luxury quality).
Outside walls shall be provided with weather coat emulsion paint (2 coats) over a coat of
primer (Cement paint).
All bathrooms shall be provided with anti-skid tiles (300mmx300mm).
Page 54
6.3.2 Lightening Arrestor

Lightening arresters shall be fixed on the top of the building and the arrangements should
conform to IS: 2307(latest edition). The building shall have proper earthing arrangement as
per IS: 3043 confirming to IE rules.
6.3.3 SCADA Control room

The SCADA control room shall be housed on first floor of the Administrative building. The
SCADA control room shall be provided with air conditioner (AC) of sufficient capacity to keep the
room cool (approx. 18o-21oC) with relative humidity from 40% to 65%.
For the SCADA control room, the Contractor shall submit conceptual designs and 3-d model for
visual understanding, with appropriate internal surfaces. Ceiling materials should offer moderate
to high reflectance of 0.8 or higher to improve light distribution throughout the room and reduce
energy cost. The ideal walls in a control room feature an off-white matte or flat finish with a
reflectance range of 0.5 to 0.6. Floor materials should have a lower reflectance of 0.2 to 0.3 for
carpet or 0.25 to 0.45 for floor tiles.
6.3.4 Air Condition arrangement

Provision for air condition shall be provided in the SCADA control room, meeting room and all the
office rooms and rest rooms. The provision of the Air Conditioners shall be done to keep the
temperature between 18o-21oC.
For all other rooms, adequate ventilation arrangement shall be kept.
6.3.5 Water Supply facilities

The building shall be provided with potable water supply from an overhead tank (Two number
2000litre Capacity) placed on the roof of the building. Tanks shall be PUF Insulated Tank
with PE.
The service connection shall be provided from the existing pipe main. The overhead tank
shall have provision for automatic level controller, which shall regulate the flow of water to the
tank. The water supply service connection, internal and external plumbing arrangements,
pumping station) shall be included within the scope of the works of the building.
The cost of such arrangements for water supply facilities shall be included within the quoted
rates for subject work.
6.3.6 Sanitary and Drainage facilities

The waste-water from toilet blocks shall be led to a septic tank with soak pit. The Contractor,
at a suitable location, shall provide a septic tank (minimum 20 Users) and a soak pit.
6.4 Design and Construction of Staff quarters

6.4.1 Scope of Work
The size and dimension of the building and the various facilities are as shown in the tender
drawing. The contractor shall prepare a conceptual layout plan together with architectural
elevations of the facilities to the Engineer for approval. The plinth level shall be 600mm
above the finished ground level.
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6.4.2 Platering and Painting

Ceiling plaster shall be 6mm thick (1:4) with Plaster of Paris punning. For outside plaster,
waterproofing compound of approved make and quality shall be added to the cement mortar
in proportions as specified by the manufacturer.
The internal faces of the building shall be finished 2 coats of acrylic emulsion paint (luxury
paint) of approved make and brand on walls and ceiling including sand papering in
intermediate coats including putty. The external surfaces of the buildings shall have two
coats of acrylic primer and paint (2 coats), of approved quality and shade over a coat of
primer.
6.4.3 Doors and windows

The windows for staff quarters and laboratory room shall be of aluminium frame with sliding
arrangement. Anodized brass screws / chromium brass screws shall be used for fixing.
Fittings shall be got approved by the Engineer before fixing. Aluminium windows /ventilators
shall confirm to IS: 1948. The windows shall have 8mm thick bubble free float glass (tinted /
coloured) of approved make and brand conforming to IS: 2835.
The main door form the staff quarter shall have metal flush door (heavy duty) as per IS. The
other doors shall be flush type wooden doors of deluxe decorative (both side) quality,
conforming to I:S 2202 timber frame consisting of top and bottom rail and side styles of well
seasoned timber 65mm wide each and the entire frame fitted with 27.5mm wide battens
places both ways in order to made the door of solid core and internal lipping with teak,
mahogony or rose wood as approved decorative veneers using phenol formaldehyde as
glue.
6.4.4 Water Supply facilities

The building shall be provided with potable water supply from an overhead tank (Two number
2000litre Capacity) placed on the roof of the building. Tanks shall be PUF Insulated Tank
with PE.
The service connection shall be provided from the existing pipe main. The overhead tank
shall have provision for automatic level controller, which shall regulate the flow of water to the
tank.
The water supply service connection, internal and external plumbing arrangements,
pumping station) shall be included within the scope of the works of the building. The cost of
such arrangements for water supply facilities shall be included within the quoted rates for
subject work.
6.4.5 Sanitary and Drainage arrangement

The toilet block shall have provision of:
− One (1) No. anglo-Indian Water Closet in white glazed vitreous china ware of
− 1 No. Urinal
− 1 No. Wash basin of size 510 mm x 400 mm in white Porcelain with inlet, outlet with
bottle trap.
− 1 No. Mirror of size 400 mm x 600 mm PVC moulding wall mounted type fitted over
washbasins.
− 1 No. Plastic liquid soap bottles
− 1 No. Chromium plated brass towel rails minimum 750 mm long.
− The stopcocks, valves and pillar cocks shall be of chromium-plated brass, heavy
duty.
− All fittings such as `P’ or `S’ traps, floor traps, pipes, down-take pipes etc.
The waste-water from toilet blocks shall be led to a septic tank (20 Users) with soak pit.
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6.4.6 Furniture
Provision of four (4) nos. 1131x 2060x930 Wrought Iron Cot and two (2) nos. steel wardrobe
in the Staff quarters shall be made.
In the laboratory room following facilities shall be provided:
o Two (2) Nos. Storage Based Laboratory Table
o Two (2) Nos. Chemical / Reagent / Glassware /Plastic ware storage racks.
o Four (4) Nos. 525 x 630 x 815 Size steel office chair (made of steel frame of 25 mm x 11
gauge pipe duly powder coated epoxy finish. Cushion shall be 75 mm thick in seat and
50 mm thick in back.
o Two (2) Nos. wooden stool.
o One (1) Nos. Computer table (16 gauge ERW MS pipes 'C' frame designed with sliding
keyboard on nylon rollers. Table top and sliding board of 18mm pre-laminated particle
board with PVC lipping)
o One (1) Nos. 1200x600x740 wooden working table with drawers and
o One (1) Steel almirah fabricated from high quality CRCA steel of 20 gauge having anti
rust treatment equipped with precision lock and four adjustable shelves with powder
coated finish.
6.5 Laboratory Room and Equipment

6.5.1 Laboratory Room
The contractor shall arrange, fully furnished and equip a complete water testing laboratory of
as per CPHEEO manual for overall process control, monitoring chemical solutions,
treatment, testing general water quality analysis and routine quantity monitoring instruments
maintenance. Air conditioners shall be installed in the laboratory.
Equipment shall be provided for chemical analysis and physical routine examinations. The
laboratory installations by the contractor include the supply of benching, plumbing, internal
water supply and waste drainage, electric power and lighting installations, fume cupboards
etc. Waste water drainage from the laboratory area shall be provided under the civil works
and shall be connected to sludge drainage line.
Approximately 40% of the carpet area of the laboratory is to be covered by tables, fitted with
necessary drawers and sinks. The height and top width of the tables should be 900mm and
750mm respectively. All the furniture should have a decorative finish. The wooden furniture
shall be of best quality teak wood of approved quality and the top of the tables shall be
acid/alkali & heat resistant and the drawer units shall be provided with laminate sheets. The
laboratory sinks shall be of stainless steel.
The laboratory room shall be provided with adequate number of R.C.C. shelves with terrazzo
finish for placing the laboratory equipments, 2(two) number of sinks and wardrobe.
Two (2) number 3000litre capacity R.C.C. overhead water tank shall be provided on the roof
of chemical house for water supply to the laboratory. Plumbing arrangements shall be with GI
heavy duty GI pipes.
6.5.2 Sampling Equipment

The Contractor shall provide and install one sampling table with granite top. The sampling
table shall be provided with three clarity bowls to indicate the clarity of raw water, clarified
water and filtered water, a stainless steel sink and three faucets with swan necks to give
independently samples of raw water, clarified water and final filtered and chlorinated water.
Individual supply lines of the sampling table shall be marked distinctively as “raw”, “clarified”
and “filtered water”.
This arrangement is to be provided in the laboratory room.
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6.5.3 Laboratory Equipment

The laboratory shall be fully equipped with bacteriological unit, physical and chemical test
unit including jar test apparatus, turbidity meter, total chlorine demand testing apparatus,
residual chlorine measuring device and PH meter.
All the laboratory equipment shall be of reputed and approved make. All the equipment are
to be installed in position and commissioned including supply of all accessories, stands,
tables with complete air conditioning arrangement including glass apparatus and chemical
reagents.
The list of equipments and apparatus shall include:
(1) One set of Electrical mono-pan balance of 100gm. capacity, having sensitivity of
1/100 mg complete with weight box and digital display.
(2) One single pan electronic balance, capacity 200gm. and of sensitivity 0.01mg
(3) One Distilling Apparatus, electrically heated, with low water cut off and automatic
shut off complete.
(4) One Autoclave, vertical type electrically operated at 220/230 volt AC main,
operated under steam pressure made of heavy gauge rolled steel brass sheet
inside heavily lined with working pressure 25 psi hydraulically tested, provided
with necessary gauges, valves, cocks fitted with gun metal lid and ring mounted
on painted steel outer jacket complete with immersion heaters and other electrical
fittings, boiling dry with automatic cut- off device.
(5) Two Muffle Furnace made of high sillimanite Muffle and sillimanite bricks. The
outer body is made of heavy gauge mild steel sheet finished in heat proof and rust
proof silver ash hammer stone painting fitted with swing type hinged door with
peep holes, temperature upto 1200o C provided with excess temperature
protection and accessories for direct connection to laboratory A.C. mains 220/230
volt, single phase, 50 cycles. Size of Muffle Chamber 150mm x 150mm x 300mm
or close to this size.
(6) One Incubator suitable for operation on 220/230 V, AC, single phase, operating
temperature being 0 to 66o C with thermostatic control fitted with dial thermometer
and provided with three removable trays – complete.
(7) One pH Meter of digital display type with range 0 to 14 in 0.1 pH subdivisions. It
should be compact direct reading type with a built-in voltage stabilizer, a
temperature compensator and an anti-parallax mirror. Electrode assemblers shall
comprise a glass electrode, calomel reference electrode and a resistance
thermometer for temperature compensation housed in an immersion type housing.
Operation should preferably be push button type and the instrument shall be
suitable for operating in a temperature range of 0 to 66o C -complete.
(8) Two Jar Test Apparatus. It should be provided with six transparent glass jars,
each containing a paddle mixer hanging from a long horizontal shaft through a
bevel gear. The horizontal shaft shall be run by a variable speed motor with the
provision of measuring rpm of paddle mixer. RPM of paddle should be in the
range of 0 to 150 rpm. Jars shall be provided with suitable sampling points to
determine PH and turbidity.
(9) Two Hot plates, operating on 230V, single phase 50 cycles, AC, capable of
adjusting at different range of 750, 1000 and 1200 Watt, complete with heating
elements.
(10) One compound Microscope with Huygenion binocular eye pieces, Ocular
micrometer, provision for oil-immersion objective and mechanical stage is to be
provided. The magnification with a chromatic immersion objective and 20 x
compensating eye piece should be 1940 times.
(11) One Hot Air Sterilizer (oven) of (0 to 3500 C) temperature range.
(12) One Magnetic Stirrer - complete.
(13) One Dissolved Oxygen Meter - complete with necessary electrode.
(14) Two Frost free Refrigerator, 290 liters capacity (approx.).
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(15) Twelve Crucibles, Gooch F, 30 ml and Three Crucible Holders, Gooch (B).
(16) One Water Bath with 8 nos. of hole, electrically operated SS made – complete.
(17) Two Thermometers, general lab engraved stem 10o to 260o C, 1o subdivision.
(18) One Thermometer, precision: 1o to 101o C, 1/10o subdivision
(19) One Interval Timer, Spring wound.
(20) One stop watch.
(21) One chloroscope for measurement of residual chlorine with necessary reagents -
complete.
(22) One atomic absorption spectrophotometer with the provision of Zeeman
background/ Smith Hieftje background correction suitable for determination, traces
of metals and non- metals like As, Cd, Cr, Hg, CN, Cu, Co, Ni, Pb, etc. including
installation with supply of all accessories including Computer, printer etc.
(23) One Photo meter (SQ – 118) with computer printer and other accessories all
complete.
(24) One Ion Analyser – complete.
(25) One Conductivity meter – complete
(26) One electrical turbidity meter (Nephelomatric method) capable of measuring
turbidity in the range of 0 – 2000 NTU- complete.
(27) One BOD Incubator –complete
(28) One Double Walled Oven for operation at temperatures up to 400o C. It should be
provided with at least three trays and suitable temperature indicators, temperature
deviation being ±0.5oC. It will be electrically heated with thermostatic control,
power supply being 230 V, single phase, 50 cycles, AC.
(29) One Demineralizer –complete.
(30) One Turbidity meter, Jackson
(31) Two Turbidity meter Tube, 75 cm, white
(32) One Centrifuge, International Clinical model - complete.
(33) One Centrifuge head, 4 place, 50 ml
(34) Twelve Centrifuge tubes, 50 ml
(35) Membrane filters assembly –complete.
6.6 General Requirements of Electric Substation Building

The electrical sub-station should be well ventilated and generally accommodate the following
equipments:
(g) H.V. switchgear and metering arrangement as per requirements of Licensee in
accordance with Rule 64 (I) (a) of I.E. Rules
(h) Consumers H.V. panel boards
(i) Transformers
(j) M.V. Panels in accordance with Rule 64 (I) (a) of I.E. Rules
(k) Cable trenches / Cable trays / Bus ducts
(l) Inter-connecting cables and auxiliary equipments
Unless, specified otherwise, the sub-station building shall consist of:

− Supplier H.T. Breaker room
− Consumer H.T. Breaker room
− Transformer room
− L.T. Panel room
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− Store room and Office room
The substation building height should be 4.5m. Typical layout drawing is appended. Fire brick
barrier wall shall be provided as shown and marked in the drawings.
The supplier H.T. Breaker room shall have no ventilation and no windows, only rolling
shutter, while the Consumer H.T. Breaker room shall have provision of exhaust fan for
ventilation, no windows, louvers at lower side and rolling shutter.
The L.T. Panel room shall have provision of exhaust fan for ventilation, and shutter height of
3.5m.
The Transformer room shall have provision for exhaust fan and rolling shutter and shall have
adequate dimensions for installation of dual transformer.
6.6.2 Doors, Windows and Ventilators

All doors and windows shall be steel for fire protection. Ventilators (minimum 750mmx
500mm) shall be made of steel frame with heavy wire mesh, 50cms below the ceiling.
6.6.3 Flooring
Flooring shall be cement concrete flooring with high performance non-metallic floor hardener
containing specially graded non-metallic hard wearing natural aggregates imparting floor
hardness in the range of mohr scale 8-9 & capable of achieving 28 days compressive
strength of 25 MPa with air content less than 3% applied as a dry shake @ 5Kg/sgm
sprinkled to provide durable, non-slip monolithic floor for application of the topping over
freshly laid concrete with under layer of 40 mm. thick cement concrete (1:2:4) (1 cement : 2
coarse sand : 4 graded stone aggregate 20 mm nominal size) as per specification of the
manufacturer and as per direction of Engineer-in-Charge.
6.6.4 Furniture
Provision of 1 no. 1200x600x740 wooden working table, 4 nos. 525x630x815 size office chair
and one (1) No. steel almirah shall be made.
The table shall have 18mm thick particle board laminated with veneer top (shade to be
approved by Engineer) and back panel having teal wood beading all around on top. Drawers
(minimum 3 nos.) to be provided with suitable locking arrangement and handle with glass top
(5 mm thick) shall be provided).
Steel almirah shall be fabricated from high quality CRCA steel of 20 gauge having anti rust
treatment equipped with precision lock and four adjustable shelves with powder coated finish
of Size (minimum): 1980mmx915mmx485mm.
6.7 Requirements of Guard Room

The scope includes carrying out design, drawings including construction of the Guard room
all complete. The work shall be executed as per the design, drawings prepared by the
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contractor and approved by the Engineer. The dimension of the building shall be as outlined
in the tender drawing.
The Contractor shall submit detail structural design of the building for approval of the
Engineer. The Contractor shall also prepare the working drawings, showing the foundation
details, details of fixing of doors, windows, reinforcement details, plumbing and sanitary
arrangement, and electrical drawings including detailed Bill of Materials and Quantities for
approval of the Engineer.
The building shall be an RCC framed structure, with 250mm thick brick masonry work for
external walls. 75 mm thick RCC Damp Proofing Course in M15 shall be provided to all
building walls. Plinth protection shall be laid for a width of 1.2m from the external wall. The
plinth level shall be 600mm above the Finished Ground level.
The flooring for the Guard room shall be 40mm thick Cement concrete flooring 1:2:4 (1
cement: 2 coarse sand: 4 graded stone aggregate) finished with a floating coat of neat
cement.
The internal walls and ceiling shall be provided with 2 coats of Interior grade acrylic emulsion
(Standard quality) of approved quality and brand over acrylic primer on plastered or concrete
surface. The building outside shall be provided with 2 coats of protective and decorative
acrylic exterior emulsion paint of approved quality, over acrylic primer.
The guard room shall be provided with one wooden table (of size 1200mm x 600mm
x740mm) and 2 number plastic chairs of reputed make.
6.8 Requirements of Back-wash reservoir

All inside surfaces of the reservoirs in contact with water should be finished with 20mm
Cement Plaster (1:3) and 3mm Neat Cement Punning with suitable water proofing
compound. The external surfaces of the reservoirs shall be 10mm thick cement plaster (1:4).
The bottom of the reservoir shall be finished with paver block over 100 mm thick PCC and
150 mm thick sand. The periphery of the bottom shall be provided with 250mm x 250 mm
drain connecting with the main drain.
The external surface of the backwash reservoirs shall be painted with protective and
Decorative 100% acrylic exterior emulsion paint (Weather resistant type) of approved quality.
The painting shall be done over one coat of acrylic primer. The colour proposed for the
reservoirs shall be got approved by the Engineer by preparing appropriate colour scheme.
Cement based polymer modified waterproofing slurry coating of thickness as recommended
by approved IS or ISO/9001 and supplied from recognized manufacturer on all concrete
surfaces exposed to water/water vapours i.e. inside surface of reservoir wall, bottom and top
slab after testing the reservoir proper shall be applied for leakage/seepage.
The location and capacity of each of the backwash reservoir constructed shall be clearly
written on the reservoir portion.
The letters and figures shall be to the heights and width as ordered by the Engineer. These
shall be stencilled or drawn in pencil and got approved before painting. They shall be of
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uniform size and finished neatly. The edges shall be straight or in pleasant smooth curves.
The thickness and height of the lettering shall be as approved by the Engineer. Lettering
shall be vertical or slanting as required. Two or more coats of paint shall be applied till
uniform colour and glossy finish are obtained.
Black Japan paint (conforming to IS: 341) or ready mixed paint as ordered by the Engineer
shall be used. The paint shall be of approved brand and manufacture. Ordinary ready mixed
paint shall be of the shade required by the Engineer.
The backwash reservoirs shall be provided with Lightning Arrestor.
Lightning conductor shall be provided with Copper bar of 25 mm diameter and 3 m height,
fixed at the center of roof and connected by Aluminium strip of 25mm width and 3mm
thickness. The strip shall be connected to a 600x600x6mm thick copper plate embedded
below ground, 3 m away from the structure, with 40mm diameter GI pipe in earthing etc.
complete. The Aluminium strip for horizontal length below ground and 3 m height above
ground shall be covered by 40 mm diameter GI pipe which shall be fixed with one of the
columns of the reservoirs. Earthing shall comply to IS: 3043.
Aluminium ladder, 0.50 m wide with hand railing, shall be provided inside the container from
roof level to the container bottom with adequate slope for entering into the container. The
reservoir opening shall be covered with heavy duty Cast Iron cover of adequate size.
6.9 Scaled Model of the WS System

The Contractor shall supply scaled (1:200) model of the entire treatment plant which shall be
displayed at a suitable place in the entrance hall of the main administrative building. The
models shall be mounted on suitably designed stands fitted with trolley wheels.
Adequate illuminations shall be provided for this display. In addition, an animated flow
diagram of the process showing the colour of the water during the different stage of the
treatment shall be provided. The flow diagram shall be in a wooden cabinet with glass cover
suitable for hanging on the wall of the entrance hall. The switch buttons shall be located at
the bottom of the frame.
6.10 Infrastructure arrangement inside WTP

6.10.1 Levelling, Landscaping and Horticulture
Horticulture and Landscaping shall be done according to the topography of the area and
should be planned so as to have a pleasing appearance. The WTP area must be provided
with gardens, with seasonal flowerbeds and decorative plants. Horticulture operations shall
be started on ground previously leveled and dressed to require formation levels and slopes.
In case where unsuitable soil is met with, it shall be either removed or replaced or it shall be
covered over to a thickness decided by Employer’s Representative with good earth. All the
vacant spaces other than different units in the Water Treatment Plant is to be developed,
upgraded & beautified by proper landscaped gardens, trees and pathways.
A proposal in this regard with detailed landscape of the WTP area shall be submitted by the
Contractor.
The landscaped gardens shall be planted with trees and other suitable trees & herbs. The
road side plantation shall be taken up just after the completion of carpeting and shoulders.
Shadow trees such as Shisum, Neem, Pipal, Gulmohara and trees like betel-nut, dwarf
variety of mango trees like “Amrapali” & “Mallika” etc as approved by the Employer’s
Representative shall be planted on either side of the road. The height of saplings should be
at least 1.5m. Suitable flowering plants shall be proposed with tree guards for beautification.
Plants should be implanted as soon as possible and at the time of taking over all plants
should be growing. The work includes (a) Preparation of soil including cleaning and removing
of unwanted shrubs and removal of stone and garbage, (b) Digging of pits of at least 60 cm
depth and including removal of stones, manuring, applicable insecticides and watering plant
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after planting, (c) Procurement of required plants and planting and (d) Safety and security of
plants and fencing etc.
The site shall be properly graded and levelled in consultation and to the satisfaction of the
Employer’s Representative.
6.10.2 Construction of Approach Road

The Construction of approach road is within the scope of the contract. The scope includes
construction of minimum 7m wide carriageway with suitable drainage arrangement from the
black top road (Barjora-Purulia Road) upto the WTP area.
The road / pavement structure unless specified otherwise shall comprise of 900mm coarse
sand as sub-grade followed by 150mm thick granular sub-base (Grade-I/II) in 2 layers, base
course of water bound macadam, 150mm thick topped with bituminous macadam, 100mm
thick followed by Dense Bituminous concrete, 40mm thick as the weathering course.
6.10.3 Internal Road Layout

A comprehensive road network shall be provided to provide appropriate connectivity of the
buildings and utilities, to permit vehicular access to each unit of the plant for necessary
maintenance, delivery of consumables and personnel access. The internal roads shall be
made as specified in the relevant subsection. Along the road, pre-cast cement concrete
kerbs of approved shape and size shall be provided.
The road layout shall have due consideration to the storm water drainage system so as to
prevent standing water in the plant area and erosion due to storm runoff.
Paved pedestrian access ways shall be constructed to provide a network of logical routes
interlinking plant areas. Hard standing areas shall be provided to permit the parking of
vehicles involved in the delivery of consumables from blocking site roadways during
unloading or loading. The road system shall be designed such that vehicles involved in the
delivery of consumables can follow a continuous route through the plant area and leave
again without going in reverse or carryout complicated maneuvers in order to exit the plant.
Roads of required width and alignment for accessing the different units of the plants shall be
constructed as required.
The pavement structure shall consist of 600 mm coarse sand filled and compacted with water
over rolled sub base and minimum 75 mm thick paver block with cement concrete curb
stone. The road surface shall be provided with suitable camber and super elevation etc. The
top level of the road should be in accordance with the nearby formation level.
The space interconnecting different structures of Treatment Plant would be covered with
80mm thick concrete block of approved design & make, over a layer of 150 mm thick water
bound macadam, over 150mm granular sub-base, over compacted sub-grade.
6.10.4 Plant Drainage

All buildings and paved areas in the plant area shall be provided with catch drains for
collecting the roof top and surface water. All the drains and catch pits shall be covered with
factory made precast perforated RCC slabs. Wherever the drains have to cross the road
way, cross drainage such as slab or pipe culverts should be provided. All drains having depth
less than 0.75 m shall be in brick work and greater than 0.75m shall be constructed in RCC.
The contractor shall carryout structural designing of the drains and shall submit design and
drawings to the Employer’s Representative for approval.
6.10.5 Waste-water Disposal from Plant

The plant shall be provided with drainage Necessary arrangement shall be made for the
disposal of rain water by gravity into nearby natural drainage system. For this purpose, the
water disposal system shall be designed to make the discharge of the wastewater into the
drainage outlet by gravity alone.
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6.10.6 Boundary wall

The Contract envisages construction of boundary wall covering the periphery of the WTP
site. The boundary wall shall be 250mm x 250mm concrete pillars constructed of RCC
(M25) pillars, spaced minimum 3.0m centre to centre, with tie beams, placed on isolated
footing (minimum 1.2m below the existing ground level).
The panels shall be filled up with 1st class brick work, 125mm thick (Cement-Mortar: 1:4).
Both sides of the wall shall be suitably plastered (12mm thick, Cement-Mortar: 1:4) and shall
be provided with 2 coats of weather coat paint.
Barbed wire fencing shall be provided on top of the boundary wall, and suitably painted.
6.10.7 Requirements of Gate

An ornamental gate of Mild Steel (of Size 4.5m x 2.1m) shall be installed at the entrance
Sites including wicket gate of size 1.0 m x 2.1 m with channels joints, angles, flats, plates,
pipes and sheets including stiffeners, bracing, fabricated links, locking arrangement,
tempered steel pivots, guide track of MS tee, ball bearing arrangement, casters wills etc. all
complete.
The design of the gate shall be got approved by the Employer’ representative prior to
installation.
The frame and stiffener size will be 40mm x 40mm M.S. bar and 40mm x 10mm M.S. bar.
The upper portion of gate shall be provided with 40mm x 10mm M.S. bar @ 100 C/C and the
bars to be welded with the frame bar of 40 mm square. MS Sheets provided shall be not less
than 14 gauge. Adequate locking arrangement (Both inside and outside), M.S. wheel
arrangement and hinges shall be provided. All steel work shall be painted with one coat of
red oxide paint before erection and two coats of synthetic enamel painting after erection. A
cattle trap shall be provided in front of each gate.
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7.0 Design and Laying of Transmission main system
7.1 Design and Drawing of Transmission Mains

7.1.1 Scope of Work
The scope of the work includes preparation of design, drawings of the Transmission main
system from:
(a) Raw water Intake Well to the WTP at Basudebpur
(b) Clear Water reservoir at WTP to Overhead reservoirs in Mejhia and Gangajalghati
block.
It is the responsibility of the Contractor to prepare detailed working drawings for the
Transmission main based on the survey data and design of the Transmission main system,
showing:
(1) Pipe diameters and material along each segment.
(2) Stretches of the pipeline proposed to be laid:
a. Over Steel bridge and
b. By trenchless methods.
(3) The type and location of valves (Sluice valve, Butterfly Valve, Air valve, Wash-out
valve, Control Valve etc), thrust blocks and pipeline appurtenances based on the
design requirements.
(4) The location of surge protection devices, as applicable including flow-meters,
pressure transmitters etc.
The design of the Transmission main shall also include surge analysis and proposals for
surge protection devices. The designs shall also include design of thrust block and anchor
blocks for the various pipe diameters and range of pressures in the system. The rising mains
shall be commissioned with a complete programme of pressure-testing, flushing and
disinfection.
The tender drawings showing the tentative alignment and pipe diameters of the Transmission
main have been issued for guidance to the Contractor. It is the responsibility of the contractor
to design and validate the design of the Transmission main to meet the demand
requirements for each water supply zone / reservoir and fulfil the requirements of the
contract.

The hydraulic design of the clear water transmission (pumping) main shall be primarily based
on economic sizing over its design life (30 years). The hydraulic design shall duly consider
the water demand for each of the zones being served from the reservoirs, the head loss in
transmission and flow velocities and the effect of surge, including surge protection devices as
maybe necessary to ensure smooth functioning over the design life of the transmission main.
The following considerations shall be adopted for hydraulic design and analysis of the
transmission main system:
− Design of the Transmission main system shall be based on the ultimate design year
of 2050. The duration of pumping operation of the system shall not be more than 20
hours/day in the ultimate scenario.
− The analysis for optimum pipe diameter shall be based on the peak water demand for
each of the water zones / reservoirs.
− Minimum residual head to be maintained at the inlet of the over head reservoirs: 3m
(approx.).
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− The use of nominal pipe diameters for design and analysis is subject to the discretion
of the Engineer.
− The Contractor may propose suitable Control valves to regulate the flow to the
reservoirs. Flow setting for the Control Valves shall be specified and detailed
specification submitted to the Engineer for approval. The flow setting proposed for
the control valve shall be done in consultation with valve manufacturer and shall be
realised in practice.
− Design of the transmission main shall be carried out for an extended period
simulation of minimum 72 hours. In and during the extended period simulation, the
overhead reservoirs which shall get filled up will be closed, sequentially. The
timelines, through which each of the reservoirs get filled up and is required to be
closed, shall be clearly provided.
− The design may opt for simultaneous filling up of all the overhead reservoirs or batch-
wise phased filling up of the overhead reservoirs. The daily water demand pattern for
the water supply zones for the overhead reservoirs shall also be proposed, based on
which the EPS shall be carried out.
An initial design of the Transmission main system shall be provided to the Contractor. The
design of the Transmission main system shall be re-designed based on the design
requirements to fulfil the water demand for each zone / reservoir.
The design of the transmission main shall be validated and calibrated with the as laid / built
Transmission main network during commissioning and continuously monitored during the
Operation and Maintenance period.
7.1.3 Resistivity Survey

Resistivity survey along the pipe line route shall have to be undertaken for finalizing the
degree of protective measure to be adopted for MS pipes. Detailed resistivity survey along
the stretches of pipeline to be laid by Mild Steel pipes shall be conducted and submitted by
the Contractor, prior to commencement of works.
7.1.4 Pipe material for Transmission mains

Pipe material for Transmission main to be laid underground shall be Ductile Iron (Class K9)
confirming to IS: 8329.
For stretches of the transmission main to be laid by trenchless methods or pipe supporting
structures, including river, stream, canal and or drainage courses, spirally welded mild steel
(MS) shall be preferred.
The thickness of Mild Steel pipes shall be worked out as per IS: 5822, with adequate
allowance for corrosion resistance. The minimum thicknesses of Mild Steel pipe to be laid /
installed by open cut method corresponding to different pipe sizes shall however be limited to
the following:
Pipe Size (mm) Minimum thickness (mm) Pipe Size (mm) Minimum thickness (mm)
219.1 6.3 406.4 8.0
273.0 6.3 457.0 8.0
323.9 8.0 508.0 8.0
355.6 8.0 610.0 8.0
MS pipes used shall be coated as per Annex-B/ Annex-C (as per the requirement of
Engineer), of IS: 3589, unless specified otherwise. The work of installing piping shall be
carried out carefully so as not to damage it during handling, storage, installation and back
filling. The work shall be executed in a safe and efficient manner under the direction of the
Engineer.
Mild Steel Pipes laid by trenchless methods shall be suitably designed.
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7.1.5 Head loss in Pressure Pipes

The head loss computation through pipes shall be determined either by using Hazen
William’s formula. To account for the head losses due to pipe fittings, valves, bends etc,
provision for head loss not less than 10% of the dynamic head loss shall be considered.
In calculating the head loss due to fittings, specials and other appurtenances, the Contractor
shall reasonably assess the number of different types of specials (fittings), valves etc. to
ascertain the expected head loss on account of pipe fittings etc. The resistance coefficient ‘K’
shall be adopted based on the values as given in the CPHEEO Manual for Water Supply and
Treatment.
7.1.6 Provision of valves and pipeline appurtenances

The class or pressure rating of the valves (i.e. sluice valve, butterfly valve as line valve,
sluice valve as washout valve and air valves) shall be suitable for the maximum pressure
encountered including uncontrolled surge pressure. Precise location of each valve shall be
carried out as per approval of the Engineer. Unless specified otherwise, the pressure rating
of valves in the Transmission system (Pumping) shall be of Class PN 1.6.
All valves shall be in accordance with the specification. The Contractor shall use uniform
types and from single manufacturer for each type of valve, throughout the works.
7.1.7 Provision of Isolation Valves

Sluice valve shall be provided in transmission main system for isolating pipeline sections to
avoid the necessity of emptying the entire pipeline in the event of repair or for routine
maintenance.
Sluice valves shall in general be provided at the following locations:
1 Wherever there is a branching from the main transmission line, sluice valve shall be
provided both on the transmission line (on the downstream side) and branch line.
2 For ease in repairing in the extreme event, isolation valves (sluice valves) shall be
provided. The interval of isolation valves shall be:
− For pipe size 600 mm and above : 1.5 km (approx.)
− For pipe size less than 600 mm : 1.0 km (approx.)
Scour (sluice) valves in general shall be provided at an interval of minimum 1000m and at
locations where the pipe line goes for a steep rise.
The locations of the scour valves need to be so selected that these are at the lowest point in
the route, so that in the event of any repairs, the water can be emptied from the particular
pipeline stretch easily. Careful consideration also needs to be given to the fact that the
proposed location of the scour valves is near the pipe culverts, streams, water-bodies, low
lands etc. whereby the water from the pipeline can be quickly disposed off (and avoid
incidence of flooding). The locations of the scour valves shall be marked in the pipeline
profile drawing prepared by the Contractor.
The Contractor shall ensure that the drained water flows smoothly to the natural drainage
areas without scouring or eroding the natural formation. Where required, the Contractor shall
provide appropriate protections to the formations as approved by the Engineer.
The size of the scour valves to be provided shall be as follows:
− For pipe size 450 mm to 600mm : 250 mm
− For pipe size 450 mm to 300mm : 200 mm
− For pipe size less than 300mm : 150mm
All valves (sluice/ butterfly / scour/ non-return) are proposed to be housed inside valve
chambers.
Dismantling joints shall be provided with all Isolation Valves for easy removal / replacement.
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7.1.8 Provision of Air Valve

Air valves shall be installed at all peak points and major grade changes to expel accumulated
air. Air Valves shall be double ball Kinetic air valves.
The locations of the air valves shall be marked in the pipeline profile drawing prepared by the
Contractor. Air valves installed on pipes shall be situated above ground level, with isolation
sluice valves.
7.1.9 Provision of Control Valves

Control Valves shall be proposed to regulate the flow at the inlet of each of the overhead
reservoirs. The location of the Control Valve shall be done to achieve smooth operation.
7.1.10 Thrust block and Anchor block

The Contractor shall submit detailed design calculations to work out the sizes of thrust blocks
at bends, tees and dead ends and anchor blocks. The design pressures including
uncontrolled surge pressures and available restrained lengths shall be clearly stated in the
detailed design calculations by the Contractor.
The Contractor shall submit the entire design calculations in the form of a report with the
remedial measures and detailed drawings for thrust blocks and anchor blocks at specific
locations in order to obtain the approval from the Engineer.
7.1.11 Design submittals

The design submittals shall include:
− Design guideline report, based on which the design of the Transmission main has
been carried out (including flow / demand patterns, design considerations etc)
− Detailed Output showing pipe diameter, length from the Intake and WTP
− Details of pipe parameters (velocity, unit head loss) and pressure at the nodes with
hourly variations, considering EPS (Extended period simulation)
− Timelines, in which the (overhead storage) reservoirs get filled up and valve is to be
closed
− Pressure profile of the pipeline under various critical conditions including design of
thrust block, anchor blocks suitably.
− The effects of surge in the Transmission main due to pump failure / pump shutdown
condition with no surge protection devices.
− Transient analysis considering proposal for surge protection devices.
− Based on the design and analysis, provide calculations regarding the unavoidable
annual real losses (UARL) in the system and the Infrastructure Leakage Index (ILI) to
be maintained.
The design submittals shall suitably indicate the flow and pressure measurement points
along the length of the Transmission main. The flow and pressure measurement points shall
be calibrated during the trial run stage and monitored subsequently during the O&M period.
7.1.12 Preparation of Working Drawings

Once the designs are approved, the Contractor shall prepare detailed working drawings for
the Transmission main alignment and submit the same to the Engineer for approval.
The drawings should clearly demarcate the:
− Stretches pipe main to be laid by open cut method, (including pipe diameter and
length).
− Stretches of the pipe-main (including length and pipe diameter) to be laid by
trenchless methods (with Co-ordinates and offset lengths) including location of
jacking / receiving pit details, as appropriate.
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− Stretches of pipe-main to be laid on pipe supporting structures (pipe bridges, trestle

etc).
− Location of thrust block / anchor blocks as necessary including flow and pressure
monitoring points.
Detailed drawings for thrust block and anchor block shall be submitted to the Engineer for
approval.
The pipeline alignment shall be clearly marked with GPS points (and chainage, if required),
at suitable intervals to identify the distance of the pipeline from the Carriage-way, Right-of-
Way (RoW).
Wherever required, cross sectional drawings shall be generated to show the offset of the
pipeline from the main carriage-way / road and right of way. Wherever road crossing / cutting
is envisaged the details of the same shall be prepared as per direction of Engineer for
receiving approval from the respective authorities (NHAI, PWD, Panchayet etc).
The details of valves (Control valves, Isolation valves, air valves etc), pressure loggers and
the location should be clearly marked on the drawings.
The contractor shall submit six (6) sets of working drawings including one soft copy for
approval of the Engineer.
7.1.13 Completion Drawings

After tests on completion, the Contractor shall submit the ‘As Built Drawings’ for approval of
the Engineer. The “As Built”, completion drawings shall be supplied by the Contractor in six
hard copies along with one soft copy to the Engineer. These drawings shall be developed
using latest version of AutoCAD.
The drawings shall incorporate all necessary features (diameter wise pipe-main alignment,
valves, pipeline appurtenances etc as per direction of Engineer) and should be done with
GIS coordinate system.
7.1.14 Trial run and Commissioning

Once the transmission main is laid, the Contractor shall carryout trial run and commissioning
of the Transmission main, by pumping from the Clear Water reservoir. Trial run shall
commence only after satisfactory pressure testing of the pipe mains and disinfection.
During the trial run, the Contractor shall establish the flows to each of the overhead
reservoirs, timelines in which the reservoirs are filled in duly to allow for continuous 24x7
pressurized water supply downstream of the overhead reservoirs. Based on the flow
conditions, a detailed program for pumping from the Clear Water reservoir (At WTP) to the
overhead storage reservoirs will be proposed, to be adhered during the O&M services period.
The Contractor shall also calibrate his design of the Transmission main with respect to the
flow and pressure conditions actually achieved in the field.
The Contractor shall note the effects of surge in the transmission main, due to closing of
valves at the OHR end and or pump stoppage and ensure adequate surge protection devices
to dampen the effect of surge.
Based on a flow conditions established during the trial run, the contractor shall evaluate the
baseline ILI for the Transmission main system, which will be maintained during the O&M
period.
7.1.15 Outcome of the Work

The scope shall include carrying out the designs, preparation of necessary working drawings,
and calibration of the Transmission main during Trial run stage including providing the
completion drawings, all to the requirements spelt out and to the satisfaction of the Engineer.
The outcome of the work shall include, but not limited:
1. Design basis report
2. Detail Designs including:
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a. Proposed pipe diameters and lengths.

b. Analysis of the Transmission main network system showing flow conditions
and pressure under Extended period simulation
c. Design of thrust block /anchor block as necessary along the alignment of the
transmission main.
d. Surge Analysis (With and without Surge Protection Devices) and
requirements for surge protection devices.
e. Assessment of Unavoidable Annual Real Loss (UARL) and
f. Infrastructure Leakage Index (ILI) for the Transmission main that is to be
maintained
3. Working Drawings of the Transmission main as per requirements (Showing
Alignment, RoW, Location of Valves, flow-meters, pressure measuring points, thrust
blocks, anchor blocks, pipes laid on pipe supporting bridges, pipe laid by trenchless
methods etc)
4. Traffic Management Plan, as required from time to time
5. Carrying out Calibration of the model during the Trial run period including successful
commissioning of the system
6. Completion Drawings
The works shall include preparation of design, preparation of drawings all complete as per
specifications.
7.2 Surge Control System

7.2.1 Design of Surge Control System
The Contractor shall be responsible for carrying out detailed surge analysis based on his
design of raw and clear water transmission main systems. The surge control system shall be
so designed that the maximum operating pressure (sum of working pressure and residual
surge pressure) at any point in the pipeline is not more than 1.2 times the working pressure.
The surge analysis shall be carried out using standard surge analysis software acceptable to
the Employer's Representative. The surge control equipment, as might be required shall be
capable to withstand the total working pressure and the expected residual surge pressure at
the point of installation. Adequate care must be taken to ensure that the equipment installed
will not affect the general hydraulic condition of the system as designed. The Contractor shall
be responsible for carrying out the analysis, design, manufacture and construction and
installation of surge protection devices.
The detailed designs and drawings related to surge analysis shall be submitted to the
Employer's Representative for approval. If specifically asked for, the Contractor shall give
access to the Employer's Representative the surge analysis software used to facilitate the
Employer's Representative in reviewing and get himself satisfied with the analysis done prior
to approval. If asked for by the Employer's Representative, the surge analysis may have to
be vetted through a reputed institute, with prior approval from the Employer's Representative,
at no extra cost to the Employer.
The approval shall not relieve the Contractor from the responsibility of safety of the entire
system
7.2.2 Surge Analysis

The surge analysis shall contain two parts:
(a) Analysis of the surge in pipeline for different pump failure/shutdown condition
(b) Analysis with proposed surge arresting /control devices in place.
The basic objective of carrying out surge analysis is to have a purpose-designed, economical
and dependable surge control device(s) as necessary to ensure the following:
− Sub-atmospheric pressures are avoided over entire length of the transmission
(pumping) main system.
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− Maximum positive pressure is restricted to safe level such that sum of working
pressure and controlled surge pressure is within safe design pressure of the pumping
mains.
The Contractor shall carry out surge analysis from the reputed Consultant/ Institution for all
the possible flow scenarios and install the devices required to prevent surge for the worst
scenario. Detailed hydraulic transient analysis based on the method characteristics shall be
carried out for the piping system based on the following:
• Pump discharge valve closing time and pump stopping sequence
• Conditions arising due to stopping/ tripping of pumps
• Type, size and number of air release valves in the pumping mains shall be decided
based on the analysis
• Pump discharge valve opening time during start-up condition and pump starting
sequence
• The report of transient analysis shall consist of methodology adopted, characteristic
curve/ data for boundary conditions, complete input data used for execution of
software for various events, result of the programme and concluding remarks of the
analysis.
• There should not be any occurrence of negative pressure (vacuum pressure) in the
pipeline.
• The pipeline profile to be considered for surge analysis shall be based on the results
of topographical survey being carried out by the Contractor.
7.2.3 Surge Protection using Air Vessel

The surge protection system must be procured from the manufacturer who has proven
previous experience of manufacturing such systems.
Air vessels have been proposed as the preferred choice for surge protection. For air vessels,
the manufacturer must produce test results on at least two schemes with volume of the
vessel at least 50% of the volume of vessel recommended by the Contractor for the present
case.
Alternative surge protection system if proposed shall be considered only at the discretion of
the Employer. Detailed technical specifications including proposed surge protection system
with necessary calculation shall be submitted, to the Employer including relative merits (and
de-merits) in comparison to the other available methods (including Air vessel).

Air vessel shall be suitable to take care of the surge occurring in the pipeline system of raw/
treated water mains on which they are proposed. The air vessel shall be manufactured out of
MS plates as per IS: 2002 or equivalent. The design and fabrication shall be carried out as
per latest version of IS: 2825. Air vessel shall be provided with manhole and water outlet at
the bottom, which shall be connected to the rising main along with an isolating valve and a
differential orifice.
Suitable drain shall be provided for maintenance. Air vessel shall have standard fittings such
as pressure relief valve, visual level indicator, control circuit inlet and outlet etc. with isolating
valve.
Two numbers air compressors shall be supplied along with the vessel. The compressor shall
be operating at slightly higher pressure than the line pressure, and compressed air shall be
stored in the receiver from which requisite supply shall be made to air vessel.
The air vessel and air receiver shall be painted internally and externally with zinc rich food
grade epoxy paint.
The following additional equipment shall be supplied as standard accessories to the air
vessel:
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− Receiver with compressor, with automatic on/ off system

− Visual water level indicator, covering full height or length of the air vessel
− Isolating and drain valves for maintenance purpose
7.2.5 Working of Automatic Level Control System

To maintain the level in the vessel between the working limits, electrical/ electronic level
control system shall be provided. The system shall basically consist of the following:
1. Level Sensors. The level of water shall be sensed at the following five levels, as
detailed below:
(a) Upper emergency level : In case, due to faulty operation or otherwise, water level
rises further to level (b) and reaches level (a), then both the solenoid valves for
entry of air shall open to pass on more air in the vessel. Simultaneously, an alarm
shall start to alert the operator. Operator shall attend the same by pressing ‘reset’
and starting manual inlet. When water level reaches mean level both the solenoid
valves are off along with indicator lamps for same.
(b) Upper working level: Due to dissolution of air, water level rises in the vessel. When
the water level reaches this level, one solenoid valve is on and air is passed from
receiver to air vessel, corresponding indicator lamp is on. When sufficient air is
passed and water level reaches ‘mean’ level then solenoid valve is off and all lamps
are off.
(c) Mean working level : Water level in the vessel is required to be maintained around
this level and between levels (b) & (d). At this level all control solenoid valves are in
off position.
(d) Lower working level : In case of drop in the pressure or excess of air in the vessel,
the level in the vessel drops down, one solenoid valve for exhaust of air is on along
with indicator lamp and air from vessel is let out. When water level reaches the
mean working level then solenoid valve along with indicator lamp is put off.
(e) Lower emergency level : In case of faulty operation or otherwise, the level in vessel
drops down then the second solenoid valve along with indicator lamp is put on to
discharge more air from blow off valve provided on the vessel. When water level
reaches ‘mean’ level, both the solenoid valves are off with indicator lamps.
2. Solenoid Valves with Indicator Lamps
7.2.6 General Requirement for Air Compressor

A compressor with receiver shall be provided to get compressed air in receiver. Compressed
air is stored at a pressure higher than working pressure of pumps to avoid frequent ‘on’/ ‘off’
of compressor. The standards for Air Compressor shall be based on the following codal
requirements:
Standard Title
IS:10431 Measurement of air flow of compressors and exhausters by nozzles
IS:9242 Rated pressures of air compressors
IS:7938 Specification for air receivers for compressed air installation
IS:2062 Steel for general structural purposes
IS:2041 Steel plates for pressure vessels used at moderate & low temperature
IS:11461 Code of practice for compressor safety
IS:11465 Technical supply conditions for reciprocating air compressors for power
upto 25 kW
The compressors shall be reciprocating type air cooled, electric motor driven through belt
drive. The compressor and motor shall be mounted on common fabricated steel base plate
with suitable belt guard.
The crank shaft shall be of precision balance type. Bearing shall be adequately sized for
heavy duty. Crank pin bushing shall be replaceable and precision ground.
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Inter cooler shall be made of finned copper tube and provided with safety valves to prevent
over pressurization.
Connecting rod shall be made in one piece with solid end construction with integral splash
lubrication.
Cylinder shall have large number of radial fins to dissipate heat. Cylinder bore shall be
smoothly machined. Cylinder head shall be easily accessible for inspection.
Pistons shall be designed for smooth running and fitted with compression rings and oil
control rings suitable for high pressure and minimum wear. Valves shall be made of stainless
steel for wear resistance and longer life.
Piston displacement As per design/ recommendations of Contractor
Maximum working As per design/ recommendations of Contractor
pressure
Method of starting Auto start - stop with DOL starter set to : as per design/
recommendations of Contractor
Number of Compressors 2 base mounted compressors with one receiver of 1 m3 at
each site
The compressor unit must be equipped with following safety equipment:

− Safety valve
− Automatic shut down for high discharge air temperature
The compressor unit shall have following instruments:
− Air discharge temperature gauge
− Air discharge pressure gauge
The compressor shall be capable of delivering free air at rated discharge and pressure
measured in accordance with IS: 5456 with modification that the performance be given at the
outlet of air receiver.
7.3 Arrangement of Traffic during Construction

7.3.1 General
The Contractor shall at all-time carry out work on the roads in a manner creating the least
interference to the flow of traffic while consistent with the satisfactory and safe execution of
the same. For all works, the Contractor shall, in accordance with the directives of the
Engineer, provide and maintain, during execution of the work, a passage for traffic either
along a part of the existing carriageway under improvement, or along a temporary diversion
constructed close to the road.
The Contractor shall be responsible for removal of excavated spoils/ silt and other debris
without dumping/ stacking the same in huge heaps adjacent to the trench to enable traffic of
any form to ply in the area and to enable people to walk on the sides of the trench outside the
barricade. The Contractor shall also barricade the trench as directed by Engineer. Deck
slabs/ walkway shall be placed at suitable locations across the trench for easy accessibility to
adjoining premises as directed by the Engineer.
Each site must be made safe prior to the end of each workday.
No separate payment shall be made on the above heads. The Contractor shall be deemed to
have included such cost within his quoted price.
7.3.2 Passage of traffic along a part of existing carriageway

Where part width of the existing carriageway is proposed to be used for passage of traffic,
treated shoulders shall be provided on the side on which work is not in progress. The
treatment to the shoulder shall be as per instruction of the Engineer. The continuous length,
in which such a work shall be carried out, would be limited to available space at site and
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instructions of the Engineer. After completion of pipe laying work the carriageway shall be
permanently restored and made useable by traffic. Excavated surplus and debris shall be
removed from site. All barricades shall be removed. Blockade in carriage way fully or partly
are to be done with prior permission from the concerned authority.
7.3.3 Passage of traffic along a Temporary diversion

In stretches where it is not possible to pass the traffic on part of the carriageway, a temporary
diversion shall be constructed of adequate width and in accordance with instruction of the
Engineer. Such diversion shall be requested by Contractor to Engineer with drawings for
approval before commencement of work. Temporary diversion is to be made with prior
permission from the concerned authority.
7.3.4 Traffic Management Plan

A Traffic Management Plan(s) shall be submitted to the Engineer in obtaining permissions
from the concerned authorities, as required when traffic is to be diverted and or part of the
existing carriage-way is used. The Contractor shall render necessary assistance in seeking
necessary permissions from the concerned authorities. The plans shall be submitted well in
advance of the scheduled date for commencement of pipe laying as specified in the
Contractor’s approved work programme.
7.3.5 Traffic Safety and Control

The Contractor shall take all necessary measures for the safety of traffic during construction
and provide, erect and maintain such barricades, including signs, markings, flags, lights,
flagmen and temporary gates as may be instructed by the Engineer for the information and
protection of traffic approaching or passing through the section of the road under which the
sewer shall be laid. Before taking up any construction, an agreed phased programme for the
diversion of traffic shall be drawn up in consultation with the Engineer.
(1) The barricades shall be erected on either side of the trench/ excavation closed to
traffic. Red lanterns or warning lights of similar type shall be mounted on the
barricades at night and kept lit throughout from sunset to sunrise. Fluorescent paint
boards or reflective glass boards in red colour shall also be used. Toe-guards shall
be provided.
(2) At the points where traffic is to deviate from its normal path the channel for traffic
shall be clearly marked with the aid of pavement markings, painted drums or a similar
device as per the directions of the Engineer. At night, the passage shall be delineated
with lanterns or other suitable light source.
(3) One-way traffic operation shall be established whenever the traffic is to be passed
over part of the carriageway inadequate for two-lane traffic. This shall be done with
the help of temporary traffic signals or flagmen kept positioned on opposite sides
during all hours. For regulation of traffic, the flagmen shall be equipped with red and
green flags and lanterns/ lights.
(4) On both sides, suitable regulatory/ warning signs with gates (if required) as approved
by the Engineer shall be installed for the guidance of road users. On each approach,
at least two signs shall be put up, one close to the point where transition of
carriageway begins and the other at a suitable distance away. The signs shall be of
approved design and of reflector type, if so directed by the Engineer.
7.3.6 Maintenance of Diversions and traffic control devices

Diversions shall be shaped and graded making full use of all material that can be obtained
from side cut or from the immediate vicinity within the road reserve. If sufficient material
cannot be obtained in this manner, material shall be transported from other sources. Where
necessary, vegetation shall be removed to obtain a satisfactory vertical alignment. All
necessary clearing including the removal of all trees and stumps shall be performed.
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Signs, lights, barriers and other traffic control devices, as well as the riding surface of
diversions shall be maintained in a satisfactory condition till such time they are required as
directed by Engineer.
When traffic is routed permanently into the new road following the completion of construction,
the diversions which are no longer required shall be removed and the ground reinstated to its
original condition.
7.3.7 Access to abutting properties

For the duration of the works the contractor shall at all times provide convenient access to
paths, steps, bridges or drives for all entrances to property abutting the site and maintain
them clear, tidy, and free from mud and objectionable matter.
7.3.8 Road Restoration

The Contractor will be responsible for restoration of roads after laying of pipeline and other
related works either along the road or across the road. Roads shall be restored to the original
conditions as per the specification and material for construction as it stood before excavation
for laying of pipeline and other related works.
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8.0 Supply and Laying Pipeline Works
8.1 General Requirements

The pipe material to be used in the Transmission main system shall be:
(a) DI Pipe (Class K9 pipes) and
(b) Spirally Welded MS pipes for assorted diameters.
The specification and technical requirements are spelt in sub-sequent sections. Unless
specified otherwise, pipes shall be laid at a depth of 1.0m below ground level.
8.1.1 Tools and Equipments

The contractor has to provide all the tools and equipment required for the timely, efficient and
professional implementation of the work as specified in the various sections of the contract
and as specified by the instructions of manufacturers of the pipes and other material to be
handled under this contract. On demand he shall provide to the Engineer a detailed list of
tools and equipment available.
If in the opinion of the Engineer the progress or the quality of the work cannot be guaranteed
by the available quantity and type of tools and equipment the contractor has to provide
additional ones to the satisfaction of the Engineer.
8.1.2 Preparatory Work

The contractor will inspect the route along which the pipe line is proposed to be laid. He
should observe/ find out the existing underground utilities/ construction and propose an
alignment along which the pipeline is to be laid.
Necessary trial trenching and investigation shall be carried out to ascertain and confirm the
existing pipe diameters, pipe material as per field conditions and or as shown in the
drawings.
The cost of this activity is deemed to be included in the relevant activity of pipe laying. He
should make all efforts to keep the pipe as straight as possible with the help of ranging rods.
The alignment as proposed should be marked on ground with a line of white chalk and got
approved from Engineer prior to laying.
The Contractor will prepare Working Drawing showing pipeline alignment plan of proposed
pipeline with all physical features (underground and above ground) in the survey drawings.
The position of valves, flow-meters should be shown on the plan.
8.1.3 Transportation and Handling of Pipes and Specials

All types of pipes and specials shall be received, transported, stored, installed and handled in
accordance with the manufacturer’s recommendations subject to the standard guidelines and
the approval of the Engineer.
Pipe from Store yard shall be stacked in tiers at site. To prevent dirt and debris from entering
the pipe, the bottom tiers shall be kept 150 mm up off of the ground.
Pipes should be handled with care to avoid damage to the surface and the ends, deformation
or bending. Pipes shall not be dragged along the ground or the loading bed of a vehicle.
Pipes shall be transported on flat bed vehicles/trailers. The bed shall be smooth and free
from any sharp objects. The pipes shall rests uniformly on the vehicle bed in their entire
length during transportation. Pipes shall be loaded and un-loaded manually or by suitable
mechanical means without causing any damage to the stacked pipes.
During transport, loading and unloading, pipes and specials shall not be allowed to come in
contact with any sharp projections which may cause damage. During transit pipe and
specials shall be well secured, suitably protected.
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Rolling or dragging pipes along the ground or over other pipes already stacked shall be
avoided too.
Any storage area used by the Contractor to store pipe shall be prepared in the following
manner:
− Establish firm, well-drained and level are as for pipe stacking, with adequate room for
vehicle access and turning
− Posting supervisory staff at the site to resister the arrival of deliveries, supervise off-
loading and guard the inventory of pipe
− Erecting covered storage materials susceptible to damage by the weather.
− Installing approved supports for pipes and specials, which shall keep them at least
150mm clear of the ground and support them securely without damage to their
coatings.
The Engineer shall reserve the right to test the stored pipes and pipe specials, in case he is
dissatisfied with the storage facilities.
8.1.4 Damage to Pipes and Specials

All pipes, specials, valves etc. shall be carefully examined for damage, especially to the joints
(and factory applied coatings, as applicable) prior to laying, joining or backfilling. If any pipe,
specials or accessories is found to be damaged in any way, the Contractor shall notify the
Engineer. The damaged item shall be clearly marked and set aside for repair, cutting to a
shorter length or removal from the site as the Engineer may direct.
All expenses involved in repairing, or replacement of defective or damaged pipe, specials,

etc. shall be borne by the Contractor. The Contractor shall be responsible for any delays
caused thereby. Only pipes which upon inspection are found to be sound in every respect
shall be laid or installed.
8.1.5 Pipe Installation in Trenches

Where pipelines are to be constructed in trench the contractor shall leave open no more than
a 200 meter run of pipe trench ahead of the pipe laying operation, at any time, unless
otherwise approved by the Engineer.
Pipelines shall be constructed in lengths with a separate full-time gang working on each
length. The work on lengths may proceed concurrently. Excavation for the pipeline in any one
length shall not at any time proceed more than 1 km beyond the end of a hydraulically tested,
completed and backfilled length of pipeline, unless otherwise approved by the Engineer. The
exposed joints between tested sections shall be disregarded in the above definition.
Each trench shall be excavated to the minimum width necessary to ensure an adequate
working space.
Pipes shall be laid in a dry trench. If the formation of the trench lies below the water table the
contractor shall install a dewatering system with the approval of the Engineer. Dewatering
shall continue until all work below the water table has been completed or as otherwise
directed by the Engineer.
Before any pipe, special or valve is laid in position , ready for jointing, its internal surface
shall be thoroughly wiped, clean and free of dirt, stones etc. to ensure that no debris, sticks,
stones, rags or other foreign material left in the pipeline. The pipes shall be laid true to
alignment and gradient as indicated by the Engineer. Each pipe shall be aligned between
sight rails so that, except where otherwise specified or ordered by the Engineer, the finished
pipeline shall be in a straight line both in horizontal and vertical planes.
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8.1.6 Trench Excavation to be commensurate with Laying progress

The work of trench excavation should be commensurate with laying and jointing of the pipe
line. It should not be dug in advance for a length greater than the length that can be laid in
one day unless otherwise authorized by the Engineer. The Contractor has to ensure the
following:
− Safety protections as mentioned above have to be incorporated in the work process
− Hindrances to the public have to be minimized
− The trench must not be eroded before the pipes are laid
− The trench must not be filled with water when the pipes are laid
− The trench must not be refilled before laying of the pipes
The Contractor must plug the open pipe ends suitably after the end of days work to prevent
entry of debris and mud.
8.1.7 Dewatering
Underground water table or water from other sources is likely to be encountered during the
laying of pipes. Such water shall be taken into consideration by the Contractor in his
proposed method of working and pumped out suitably. The water shall be removed / pumped
out after excavation and this shall be conveyed to an approved discharge point. No separate
payment shall be made on account of de-watering.
8.1.8 Pipe Bedding

Bedding for the pipeline shall depend on the soil strata and shall be prepared as per laid
specifications and the direction of the Engineer. The bedding shall be as per technical
requirements for the specific pipe material and shall be constructed as follows:
− The bedding shall be compacted, at optimum moisture content and by mechanical
equipment with suitably shaped tamping feet or plates, to 95% of modified proctor
density.
− The trench bottom or compacted fill shall as far as possible be in a profile to match
the pipe profile to form a “cradle” which will provide a 120 degree uniform support to
the pipe.
− The profile of pipe in compacted fill for uniform support shall not be made more than
2 days prior to actual laying of pipes.
When soil strata in the trench are other than soft or hard rock, the trench shall be properly
compacted and no extra bedding shall be provided. The pipe shall rest on well compacted
trench bottom.
8.1.9 Backfilling
On completion of the pipe laying operations in any section, for a length of about 100 m and
while further work is still in progress, backfilling of trenches shall be started by the Contractor
with a view to restricting the length of open trenches. For the purpose of backfilling the depth
of the trench shall be considered as divided into the following three zones, starting from the
bottom of the trench to its top.
(a) From the bottom of the pipe to the level of the center line of the pipe.
(b) From the level of the center line of the pipeline to a level 300 mm above the top of the
pipe.
(c) From a level 300 mm above the top of the pipe to the top of the trench.
Special care shall be taken during all backfilling operations to avoid damage to the pipe
coating or displacement of the pipe.
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Backfilling in layer (i) shall be done with selected approved material available from
excavation, well graded sand, fine gravel or other approved material placed in layers not
exceeding 150 mm. The backfilling material shall be deposited in the trench for its full width
on each side of the pipe, fittings and appurtenances simultaneously, and shall be compacted
so as to achieve 90 to 95% modified proctor density. Backfill immediately adjacent to the pipe
shall be carefully placed and compacted using suitably shaped hand tampers. Backfill in the
remaining space up to the sides of the trench shall be compacted by mechanical means.
Backfilling in layer (ii) shall be done with selected approved material available from
excavation, well graded sand, fine gravel or other approved material placed in layers of 150
mm. The back filling material shall be deposited in the trench for its full width of each side of
the pipe, fittings and appurtenances simultaneously. The column of backfill along the sides of
the pipe shall be compacted by mechanical means to achieve 90 to 95% modified proctor
density, while the area immediately above the crown of the pipe shall be compacted by hand
to achieve 90% modified proctor density. Care shall be taken to ensure that mechanical
compacting equipment is not used in the zone from the top of the pipe up to 300 mm above
the crown of the pipe.
Backfilling in layer (iii) shall be done with excavated material which is suitable for backfilling
with the prior approval of the Engineer. The trench shall be backfilled with selected
excavated material free from topsoil and vegetation, or boulders, clods of earth or stones
larger than 200 mm in size. Filling shall be done in layers not exceeding 200 mm in thickness
and mechanically compacted so as to achieve 90% modified proctor density. No stones shall
be allowed to touch the pipe directly.
All backfill material shall be free from cinders, ashes, slag, refuse, rubbish, vegetable or
organic materials, lumpy or frozen material, boulders, rocks or stones or other material which
in the opinion of the Engineer is unsuitable or deleterious.
Unless otherwise specified or permitted by the Engineer, all backfill material shall be
compacted by mechanical means using equipment with suitably shaped feet or plates. At the
time of placing the backfill, the Contractor will be responsible to ensure that the optimum
moisture content is achieved so that the required degree of compaction is achieved. If
necessary, the Contractor shall be required to add water to the backfill material in such a
manner so that the moisture content is uniform throughout each layer during compaction.
8.1.10 Backfilling with Sand

Sand wherever used for backfill material shall be natural sand complying with Clause 8.2.1 of
IS 3114, graded from fine to course. The total mass of loam and clay in it shall not exceed 10
percent. All material shall pass through a sieve of an aperture size opening of 20 mm (see IS
2405 Part 2 (1980) and not more than 5 percent shall remain on IS sieve of aperture size
opening of 30 mm.
8.1.11 Backfilling With Excavated material

The excavated material can be used for backfill provided that such material consists of loam,
clay, sand, fine gravel, or other materials which are suitable for backfilling and is approved by
the Engineer. If suitable material for refilling is not available from already excavated material
the Contractor shall import material of approved quality as directed by the Engineer.
Care shall be taken during backfilling not to injure or disturb the pipes, joints or coating.
Filling shall be carried out simultaneously on both sides of the pipes so that unequal pressure
does not occur.
The Contractor shall be responsible to ensure that the water content of the soil shall be kept
as near the optimum moisture content as possible. Regular measurement of the field dry
density shall be taken by the Contractor at various levels in the backfilling as required by
specifications and the Engineer. Any backfill which fails to achieve the required degree of
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compaction shall be re-excavated, replaced and re-compacted to the required density, all at
the Contractor’s cost.
Only mechanical compaction shall be done unless otherwise specified or approved by the
Engineer. No mechanical plant other than approved compacting equipment shall run over or
operate within the trench until backfilling has reached its final level or the approval for the
Engineer has been obtained.
Walking or working on the completed pipeline shall not be permitted unless the trench has
been filled with the specified bedding and backfilling up to height of at least 300 mm over the
top of the pipe except as may be necessary for tamping, etc., during backfilling work.
The trench shall be refilled so as to build up to the original ground level, keeping due
allowance for subsequent settlement likely to take place. The surface of the refilled
excavations shall be left slightly higher than the adjacent ground and shall be maintained by
the Contractor to a smooth even slope. Should any subsidence take place either in the filling
of the trenches or near about it during the works the Contractor shall make good the same at
his own cost. All the surplus excavated stuff (including rock) will be the Contractor’s property
and he will be responsible to make proper arrangement for disposal of the same.
Suitable surplus excavated material shall be used to fill in any low spots above the pipeline
as instructed by the Engineer. Such material shall be evenly placed and compacted in layers
not exceeding 200 mm thick after compaction. The method of compaction employed shall
achieve not less than 90% modified proctor density.
8.1.12 Anti-floatation and anchor blocks

The Contractor shall construct thrust, anti-floatation and anchor blocks, as and where
directed by the Engineer as an acceptable means of pipe restraint. Reinforced / Plain
concrete of Class M 20 shall be used for such blocks and provide them at close interval to
prevent floatation.
8.2 Supplying and Laying of DI pipes

8.2.1 Scope of Work
This scope covers the requirements for manufacturing, stacking, testing, supplying, jointing of
Ductile Iron (DI) pressure pipes (Class K9) confirming to IS:8329 including all pipe-fittings,
specials confirming to IS:9523, excavation, backfilling in all kinds of soil all complete as per
design and drawings prepared by the contractor. The Ductile Iron pipes may be socket-spigot
type or double flanged type or a combination of both.
All DI pipes and fittings conforming to IS: 8329 and IS: 9523 respectively shall be procured
free from flaws, air bubbles, sand holes and other defects and truly cylindrical and of uniform
bore and thickness. The castings shall be such that they could be cut, drilled or machined
and welded.
The DI pipe and pipe fittings manufacturer should have been certified under ISO 9000 and
ISO 14001.
The scope includes necessary excavation, shoring, strutting bedding as maybe required
including backfilling and disposal of excess earth as maybe required for laying, jointing the
pipe as per requirements.
8.2.2 Applicable Codes

The manufacturing, testing, supplying, laying, jointing and testing at work sites shall comply
with all currently applicable statutes, regulation, standards and codes. In particular, the
following standards, unless otherwise specified herein, shall be referred. In all cases the
latest revision of the standards/ codes shall be referred to. If requirements of this
specification are at variance with the requirements of the standards/ codes, this specification
shall govern.
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IS:5382 Specification of rubber sealing rings for gas mains, water mains and sewers
IS:8329 Centrifugally cast (spun) ductile iron pressure pipes for water, gas and sewage –
Specification
IS:9523 Ductile iron fittings for pressure pipes for water, gas and sewage – Specification
IS:12288 Code of practice for use and laying of ductile iron pipes
IS: 638 Sheet Rubber jointing and rubber insertion jointing
Other IS codes not specifically mentioned here but pertaining to the use of DI pipes and
fittings form part of these specifications.
8.2.3 General Requirements for Pipes

The pipes will be centrifugally cast (spun) Ductile Iron pipes for Water Supply confirming to
the IS 8329: 2000.
The pipes used will be either with push on joints or flanged joints. EPDM rings / gaskets shall
confirm to IS: 5382 and shall be supplied by the manufacturer of the pipes.
8.2.4 General Requirements for Pipe Fittings

All DI fittings shall be of class K-12. DI fittings shall be manufactured and tested in
accordance with IS: 9523 and shall include the following types of specials:
− Flanged socket / spigot
− Double socket bends (900, 450, 22½0, 11¼0)
− double socket branch flanged tee
− All socket tee
− Double socket taper
− All Flanged Tee
− Flanged Socket and Spigot
− Mechanical collar joint
− Companion Flanges
All flanges of all Ductile iron pipes shall be of integrally cast type or screwed or factory
welded (flanges are welded at the point of manufacture under factory conditions with
inspection agency certification) complete with all nuts, bolts, gaskets and two washers per
bolt unless otherwise stated.
Nuts, bolts and washers for flanged joints shall be of high tensile steel and shall comply with
BS EN 14399 – Part II – 2005. The bolting shall be comply with ISO 2531(2009) or BS EN
1092-2.
Restrained joints are required to avoid settlement in weak soil area without thrust blocks and
shall comply with ISO 10804-1 or equivalent. Rubber gasket for these joints shall be of
neoprene rubber with ductile iron locking rings, nuts and bolts.
All DI fittings shall be supplied with EPDM rubber rings. Flanged fittings shall be supplied with
EPDM gasket per flange and the required number of nuts and bolts. The EPDM ring /
gaskets shall confirm to IS: 12820 and IS: 5382.
8.2.5 Rubber Gaskets

The gaskets shall be EPDM and should also be supplied by the manufacturer of the pipes.
They should preferably be manufactured by the manufacturer of the pipes. In case they are
not, it will be the responsibility of the contractor to see that the manufacturer of the pipes get
them manufactured from a suitable manufacturer under its own supervision and have it
tested at his/sub contractor’s premises as per the contract. The pipe manufacturer will
however be responsible for the compatibility and quality of the products
Test for Rubber Gasket: The test reports for the rubber gaskets shall be as per acceptance
tests of the IS 5832 and will be in accordance to Clause 3.8 and contractor shall submit the
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test certificate issued by the manufacturer with the pipe supply, without which payment for
pipe supply shall not be released
8.2.6 Laying and Jointing

Pipe laying and jointing shall confirm to the requirements of IS: 12288.
8.2.7 Joints and Lubricants

The lubricants shall assist to easily slide the pipe without any damage to sealing rings and
shall not have any effect known to be harmful to health and shall be resistant to bacterial
growth. The lubricant shall be supplied by the manufacturer of the pipe.
Acceptance tests shall be conducted in line with the provisions of the IS 9523
8.2.8 Marking
Each Pipe shall have as cast or stamped or legibly and indelible painted .The marking shall
show the following:-
1 The Manufacturer’s name or trade mark.
2 The nominal diameter of pipes.
3 Year of Manufacture.
4 Batch Number.
5 Class of Pipes
6 ISI certification mark on each pipe
7 Any important information that the manufacturer deems fit to be inscribed on pipe.
8 Name of the Owner (PHED,WEST BENGAL)
8.2.9 Hydraulic testing and Disinfection

The testing conditions and disinfection for the pipelines shall be as described in IS: 12288.
All pipelines shall be hydraulically tested in lengths between valve stations or in such shorter
lengths as the Engineer may direct or permit. Fittings required for temporarily closing the
openings in pipelines to be tested shall be properly designed for this purpose and shall be
adequately strutted to withstand the test pressure specified.
Each pipeline shall be tested after completion of installation with the exception of any back
filling in case reinstallation of segments will be required after testing. Permanent valves
shall be tested along with the pipelines.
The protocol for testing a pipeline shall include provision for the purging of air from the
pipeline prior to a water test. Testing shall be with water only and air testing shall not be
allowed.
The Contractor shall keep a record of all tests and their results, which shall be available for
inspection at any time and shall be submitted to the Engineer periodically.
The water required for testing shall be arranged by the contractor himself. The Contractor
shall fill the pipe and compensate the leakage during testing. The Contractor shall provide
and maintain all requisite facilities, instruments, reciprocating pumps, pressure gauges, water
reservoirs etc. for the field testing of the pipelines. The testing of the pipelines generally
consists in three phases: preparation, pre-test/saturation and test, immediately following the
pre-test. Generally, the following steps are required which shall be monitored and recorded in
a test protocol:
− Partial backfilling and compaction to hold the pipes in position while leaving the joints
exposed for leakage control
− Opening of all intermediate valves (if any)
− Fixing the end pieces for tests and after temporarily anchoring them against the soil (not
against the preceding pipe stretch)
− at the lower end with a precision pressure gauge and the connection to the reciprocating
pump for establishing the test pressure
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− at the higher end with a valve for air outlet

− If the pressure gauge cannot be installed at the lowest point of the pipeline, an allowance
in the test pressure to be read at the position of the gauge has to be made accordingly
− Slowly filling the pipe from the lowest point(s).
− The water for this purpose shall be reasonably clear and free of solids and suspended
matter
− Complete removal of air through air valves along the line.
− Closing all air valves and scour valves.
− Slowly raising the pressure to the test pressure while inspecting the thrust blocks and the
temporary anchoring.
− Keeping the pipeline under pressure for the duration of the pre-test by adding make-up
water to maintain the pressure at the desired test level. Make up water to be arranged by
Contractor himself at his own cost.
− Start the test by maintaining the test pressure at the desired level by adding more make-
up water; record the water added carefully and the pressure in intervals of 15 minutes at
the beginning and 30 minutes at the end of the test period.
− Water used for testing shall not be carelessly disposed of on land which would ultimately
find its way to trenches.
The pipeline stretch will pass the test if the water added during the test period is not
exceeding the admissible limits. No section of the pipe work shall be accepted by the
Engineer until all requirements of the test have been obtained.
The pipeline stretches shall be tested to the pressures equal to 1.5 times the maximum
operating pressure in the pipeline stretch under test, subject to a maximum of 150 m of water
head or 15kg/cm2. Operating pressure shall be equal to static pressure on the pipeline invert
level with respect to full reservoir level.
The testing conditions for the DI pipelines are summarized as follows:
Pre-test and Saturation Period with addition of make-up water:
• Test Pressure Duration: 24 hrs for DI pipes with cement mortar lining
Pressure Test with addition of make-up water:
• Test Pressure Duration: 3 hrs
Testing Criteria for DI pipes:
• Q = 1.0 liter per km per 10mm of pipe diameter per each 30 m of test pressure per 24
hrs.
No pipe installation shall be accepted until the leakage is less than the amount ‘Q’, as
determined by the above formula.
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8.3 Installation of pipe by HDD

The scope involves Installation of product pipe by Horizontal Directional Drilling (HDD)
method including preparation and setting up the plant and equipment, preparing new pipe
work material, installing the new pipe work, hydro/ pneumatic testing and commissioning pipe
work or making the system ready for commissioning by HDD operation including, all related
civil and mechanical work like excavation, shoring/ strutting, etc, drilling, stringing, reaming
and pulling back the new pipe work on the designed bore path alignment, proper disposal of
drilling fluid all inclusive as per Indian STT:101-2007 code of Practice for Horizontal
Directional drilling Technique suiting Indian Conditions.
Pipe installed by the HDD method shall be located in plan as shown on the drawings, and
shall be no shallower than shown on the Drawings unless otherwise approved. The
Contractor shall plot the actual horizontal and vertical alignment of the pilot bore at intervals
not exceeding 10 m. This “as built” plan and profile shall be updated as the pilot bore is
advanced. The HDD operator shall at all times provide and maintain instrumentation that
shall accurately locate the pilot hole and measure drilling fluid flow and pressure. The HDD
operator shall grant the Engineer/ Inspector access to all data and readout pertaining to the
position of the bore head, the fluid pressures, and flows.
The Equipment proposed to be used for Horizontal Directional Drilling shall have adequate
pulling force. The allowable pulling force shall be worked out based on the pipe size, wall
thickness, and field conditions, pull distance, bearing capacity of soils, adjacent infrastructure
and as per manufacturer’s recommendation.
The ends of each section of pipe shall be inspected and cleaned as necessary to be free of
debris immediately prior to joining the pipes by means of thermal butt fusion/electro fusion.
The pipe shall be of the same type, grade, and class of the polyethylene compound used in
the process.
The handling of the joined pipeline shall be in such a manner that the pipe is not damaged by
dragging it over sharp or jagged objects. Sections of the pipes with cuts and gouges
exceeding 10 percent of the pipe wall thickness or kinked sections shall be removed and the
ends rejoined.
Sufficient space shall be allocated to fabricate and layout the product pipeline into one
continuous pipe length, thus enabling the pull back to be conducted during a single
operation. The drill path alignment shall be as straight as possible to minimize the frictional
resistance during pullback and maximize the length of the pipe that can be installed during a
single pull.
Pipe ends shall be temporarily sealed with a cap until the connection is made permanent, to
prevent water or earth infiltration.
The overcut diameter shall not exceed the outside diameter (OD) of the pipe by more than
37.5 mm, to ensure excessive voids are not created resulting in post installation settlement.
Drilling fluid shall be used during drilling (and back reaming) operations. Using water
exclusively may cause a collapse of the borehole while in unconsolidated soils, and may
also cause soil swelling while in clay soils. Either case may significantly impede the
installation of the pipe.
Excess drilling fluid shall be contained within a lined pit or containment pond, or trailer-
mounted portable reservoir, until removed from the site. Drilling fluids shall not enter the
streets, manholes, sanitary and storm sewers, and other drainage systems, including
streams and rivers. Any damage to any major road, highway or non- highway facility caused
by escaping drilling fluid, or the directional drilling operation, shall be immediately restored by
the HDD operator.
All access pits and excavations shall be backfilled with suitable material, and in a method
approved by the Engineer. Upon completion of the work, the contractor shall remove and
properly dispose of all excess materials and equipment from the work site. The disturbed
grass-surface area shall be top soiled, seeded,
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8.4 Supplying and Laying of MS Pipes

8.4.1 Scope of Work
The scope of work involves supplying, laying, lowering, jointing spirally welded Mild Steel
pipes confirming to IS: 3589 including fabricating and welding Mild Steel specials for
underground works and or hoisting the same for conveyance of potable water over pipe
trestle / pipe supporting bridges.
The specifications stated herein shall be read in conjunction with the standard specifications.
8.4.2 Applicable Codes

Following standards shall be referred for manufacture of Mild Steel pipes. In all cases, latest
revision of the standards / codes shall be referred to. If requirements of this specifications
conflict with the requirements of the standards / codes, this specification shall govern.
IS: 3589: Seamless / electrically welded steel pipes for water, gas, sewage –
specification.
IS: 4853: Recommended practice for Radiographic inspection of fusion welded butt joints
in steel pipes.
IS: 4260: Recommended practice for ultrasonic butt weld in ferric steel.
IS: 3600: Methods of testing fusion welded joints and weld mains in steel: part 1
(Part-1) cruciform fillet weld tensile test
IS: 4711: Sampling of pipe for various tests and criteria for conformity.
IS: 1894: Methods of tensile testing of steel tubes.
ISO: 18286 Hot-Rolled stainless steel plates – Tolerances on dimensions and shape –
International Organization for Standardization.
The MS pipes shall be procured from reputed approved manufacturer (with ISO: 9000 and
ISO 14000 organization). Generally the pipes shall be spirally welded manufactured to IS
3589. In case of non-availability of spirally welded pipes for lower diameter (below 400 NB),
prior approval from the Engineer/Employer shall be obtained.
8.4.3 Grade of Steel

The steel used for manufacture of the pipes (HR coils) shall confirm to IS: 2062, grade-B or
IS: 10748 grade – 3 or equivalent ISO. The dimensions of HR coils shall confirm to IS: 2062.
The quality of steel, chemical composition and tensile strength of the steel plates shall be as
specified in IS: 3589 for steel of grade Fe-410.
8.4.4 Ultrasonic Testing and Chemical Composition of Steel Plates

All plates shall be tested by ultrasonic equipment to check for manufacturing defects such as
voids layers etc. The contractor shall supply test certificate to this effect from the
manufacturer.
The contractor shall also supply certificate for chemical composition of the plates used, from
the manufacturer.
8.4.5 Standard Length of Pipes and Tolerance

The pipes shall be manufactured in lengths of 9 to 12m with beveled ends. Length of each
pipe shall be measured at diametrically opposite four places and average of the four
measured lengths shall be considered for measurements of pipe length.
Finished pipe length shall not deviate from straightness by more than 0.2 percent of the total
length. The allowable tolerance for outside diameter shall be ± 0.75% of the specified
diameter and for Ovality shall not be more than 1% of the specified diameter.
8.4.6 Sampling and Testing

Sampling and conformity criteria for various tests shall be as given in IS: 4711. The test
samples shall be cut from pipes in the final condition of supply. Tests for tensile strength,
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percentage elongation, guided bend test, shall be carried out and the test values shall be in
conformity with those specified in IS: 4711.
8.4.7 Hydraulic Testing at Works

Each pipe shall be hydraulically tested at manufacturer’s works before applying any coating /
lining. The hydraulic test pressure shall be minimum 1.5 times the working pressure.
8.4.8 Surface preparation

Cleaning
Prior to abrasive blast cleaning, the external surface shall be cleaned to remove oil, grease
or other foreign matter. Only approved solvents that do not leave a residue shall be used for
cleaning.
Abrasive blast cleaning
The surface shall be abrasive blast cleaned to achieve a white metal surface. Prior to blast
cleaning, any sharp protuberances, surface laminations, weld spatter, etc. shall be removed
by thorough cleaning and grinding. The abrasive used should be capable of producing a
minimum profile of 50-75 microns corresponding to “medium” in accordance with BS: 7079
part C4.
8.4.9 Internal and External Epoxy Coating and Lining

Epoxy lining and coating is proposed for internal and external surfaces of the MS pipes, both
Factory applied. Thickness of internal lining shall be 430 micron and external coating 600
micron. First coat shall be a primer coat followed by two or more coats of epoxy to achieve
the required thickness.
The lining and coating shall have one coat of two-part, chemically cured inhibitive Epoxy
primer and two coats of a different two-part, chemically cured, solvent free, and spray applied
epoxy paint. The lining and coating system shall meet the performance requirements of
AWWA C-210 standard.
Final thickness of the internal lining shall not be less than 430 micron DFT and that of
external coating 600 micron DFT. The lining and coating shall be applied leaving 15 cm at
the edge of pipes / specials for welding of the joint. Coating on this portion shall be applied
after welding the joint.
The temperature of mixed lining and coating and that of the pipe at the time of application
shall not be lower than 10oC. Preheating of the coating material, the use of inline heaters to
heat the coating material; or heating of the pipe, fittings or specials may be used to facilitate
the application. Heating shall confirm to the recommendations of the coating material
manufacturer.
The finished lining and coating shall be inspected for damage or reduced thickness. Any
such areas shall be repaired by thoroughly degreasing the surface and abrading using 180
grade abrasive papers, the abraded areas shall extend from the edge of the damage for 50–
75 mm on to surrounding sound coating. The prepared surface can then be re-coated.
Sufficient curing period shall be allowed after application of the lining and coating as per
AWWA C-203 standards to gain required strength. The epoxy applied pipes; specials shall
be stored for curing in accordance with the durations given in the following table.
Ambient Temperature, (deg C) 45 40 35 30 25 20 15 10 7*
Minimum number of days storage 1 1 2 4 5 7 11 17 22
*Minimum possible cure temperature
8.4.10 MS Specials
MS specials as required shall be fabricated on site by cutting the pipes as required. Flanged
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specials shall be with standard flange dimensions and thickness as specified under relevant
IS Standard.
8.4.11 Radiographic / Ultrasonic test

Three percent of all seams of pipes, welded in the fabrication shop, shall be radio graphed
(as per IS: 4853) to render visible inspection of any internal defects such as blow holes, slag,
inclusion of cracks. If any defects are detected, the metal at the location shall be chipped out
and re-welded. In addition to the radiography of the joints, 100 percent testing by ultrasonic
equipment (as per IS: 4260) shall also be done for welding tests. Any defects found out shall
be rectified free of cost. Welds found deficient in quality shall be removed by chipping or
melting and remade as per specifications. Chipping or cutting the weld shall not extend to the
base metal.
8.4.12 Transportation of Pipes

Procurement of pipes shall be done only from reputed manufacturers with consent from the
Engineer.
The Contractor shall transport the internally lined and externally coated pipes with epoxy to
his depot/ workshop to carry out operation of cutting into smaller segment lengths, if required,
edge preparation by providing reverse bevel for butt welding from inside the pip. The
Contractor shall be responsible for any damage to the steel pipes or lining and coating during
loading, unloading and handling the same at own depot/ workshop and at site.
The Contractor shall arrange to transport all pipes/ pipe segments from his depot to work site
in the alignment where they are to be laid. The Contractor should take proper care to ensure
that there is no damage to the pipes/ pipe segments including the protective coating inside
and outside, during loading at his depot, transit and unloading and stacking at site. Damage,
if any, shall be required to be rectified by the Contractor at his cost.
Rectification of the damage, if any, shall be done by the Contractor at his own depot/
workshop and at site. The pipes should be stacked as per standard practice over proper
supports in the Contractor’s depot. The inside of pipes should be kept free of dirt and debris.
The Contractor’s financial offer shall include the full cost of transport of the pipes and pipe
segments with all the elements of loading, transport, unloading and stacking at site of work.
8.4.13 Cutting of Steel Pipes

If required, the MS pipe that is to be procured from approved manufacturer shall have to be
cut into smaller lengths to facilitate butt welding of joints from inside or outside. The pipes
shall be laid in lengths of 9m to 12m as received from supplier as far as possible. They will
require cutting in only special circumstances as listed below:
If the length of a section is such that it cannot be covered only by full length pipes then only
will cutting of pipes is to be done with prior consent from the Engineer.
The methodology to be adopted for cutting should ensure that the cuts are clear. The ends of
such pipe segments shall be required to be bevel edged outside to facilitate butt welding of
joints circumferentially outside after laying. The Contractor’s financial offer should include the
cost of cutting full length pipes into smaller lengths along with bevel edging to suit butt
welding of joints with all elements of cost of materials, labour and equipment. No additional
payment will be made on this account.
8.4.14 Welding of Pipes

The pipes shall be manufactured from steel plates, butt welded spirally by automatic
submerged arc welding process using at least two runs, one of which shall be on the inner
side of the pipes. Welding shall be so done that there will be through fusion and complete
penetration and shall be free from cracks, oxides, and slag inclusion and gas pockets.
The quality of welding should be of radiographic standard. After completion of welding the
welding zone is to be cleaned free from dirt, dust oil etc. and protective coating applied as
per recommended scheme, both inside and outside.
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It is essential to check the capability of the welders who will carry out the job. The welders
engaged in the execution of the pipe work shall be qualified and tested welder in line with
ASME Norms and IS:2825.
The electrodes used for welding shall confirm to IS: 814.
8.4.15 Applicable Standards for Welding of Steel Pipes

The following Indian Standards (Latest edition) would be referred while taking up the welding
joints of the pipes.
IS:228 Methods of chemical analysis of steel
IS:813 Scheme of symbols for welding
IS:814 Covered electrodes for manual metal arc welding of carbon and carbon
manganese steel – Specification
IS:1082 Specification for equipment for eye and face protection during welding
IS:1599 Method for bend test
IS:1608 Mechanical testing of metals – Tensile testing
IS:1757 Method of charpy impact test (V notch) for metallic material
IS:2328 Method of flattening test on metallic tubes
IS:2825 Code for unfired pressure vessels
IS:3589 Steel pipes for water and sewage (168.3 to 2540 mm outside diameter) –
Specification
IS:3600 Method of testing fusion welded joints and weld metal in steel
IS:3803 Steel – Conversion of elongation values
IS:4711 Methods of sampling of steel pipes, tubes and fittings
Indian Boiler Regulations
The following American Standards (Latest edition) would be referred while taking up the
welding joints of the pipes, in case Indian Standards are not exhaustive.
ASME – Section II, A, B & C Ferrous, non-ferrous & welding materials
ASME – Section V Non-destructive examination
ASME – Section VII : Div. 1 & 2 Recommended guide for the care of pressure
vessels
ASME – Section IX Welding & brazing qualifications
8.4.16 Destructive andNon-destructive Tests on Weld Tests

Testing would be done by any laboratory with valid accreditation of NABL. All costs of testing
would be on account of the Contractor.
a) Destructive Test
Destructive examination is normally carried out on test pieces, which are cut and machined
to prepare the required test specimens. The routine quality control tests most frequency
carried out on butt welds are tensile, bend, impact, nick-break and hardness tests and on
spot and seam welds, put-out and shear tests.
Tensile Test
Properties recorded are ultimate tensile stress, yield or proof and elongation. Failure takes
place in the weakest part of the gauge length, which in the case of low alloy steel is likely to
be the parent metal outside the heat affected zone. Whereas with precipitation hardened
material it is in the heat-affected zone itself.
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Bend Test
Bend testing is effective in disclosing brittleness, cracking, or gross defects such as lack of
root fusion, or large slag inclusions in the weld, or cracking. In the heat-affected zone it will
not normally show micro cracking.
Bend tests are usually made in pairs, one with the outside face of the weld in tension and the
other with the root in tension. To be acceptable, a test-piece must be capable of bending
through 1800 over a former of given radius (e.g. 1½ times plate thickness for carbon steel),
with no more than minor surface fissures.
Due to homogeneity of the joint, there is a tendency for free bend test specimens to take up
an irregular shape. This defect is overcome to some extent in the guided bend test, but can
be avoided most effectively by the use of the controlled bend test.
Impact Testing
The notch may be placed with its root in the weld, the weld boundary, or the heat-affected
zone, but most frequently it is placed in the weld metal itself. Impact test results from welds
show even greater scatter than with wrought material due to the in homogeneity of the weld
structure. The grain size of the weld deposit, for example, may vary from run to run, or
according to position relative to the weld exist.
Nick-break Test
One of the oldest methods of testing fusion weld is to cut a strip about 19mm wide at right
angle to the weld axis and make a saw-cut down the centerline of the weld 3mm to 6mm
deep. By holding one half of the specimen in a vice and giving the other half a blow with a
hammer, or by bending in a machine, the weld is broken. This test, which is required by
various boiler and pressure vessel codes, shows up any centerline defects such as lack of
fusion, which may be present in the sample.
b) Non-destructive Test (NDT)
In general, NDT methods are based upon the application of tests involving the use of some
physical property of the material under inspection, whereby the behavior of the material or
component is compared with that of similar material, or part known to be sound and therefore
used as a standard of comparison. The NDT methods applied to welds are the following:
• Visual observations
• Dye penetrant test
• Ultrasonic test
Visual observations
This comprises of cleaning the welds and checking the weld bead profile, presence of cracks,
blowholes, undercut and overlap and spacing of weld bead ripples, etc. for fillet joints,
templates can be used for checking the bead profile.
Dry Pentrant Test
This test is widely used for the detection of surface cracks. This method consists in spraying
the liquid penetrant (paraffin) on to the clean weld surface. After some time all the visible die
is washed out by a suitable remover which washes out the visible dye. A coating of
emulsified white powder (called developer) is applied by spraying. Dye, which is trapped in
discontinuities due to capillary action, is drawn out into the powder coating (like a blotting
paper). The cracks in particular are clearly defined against a white background.
Ultrasonic Test
This procedure establishes requirements for ultrasonic testing (UT) of tubular materials
(pipes and tubes) by manual, contract pulse echo method. This is applicable for ferritic and
austentitic steel tubular products of 12 mm OD and larger size.
• Reference
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This procedure is based on the following:

a) ASME, Section V, Article 5 (2001 Edition)
b) SE 213, Standard practice for ultrasonic examination of metal pipe and tubing
c) PP-P-1981 Rev 1, Requirements for ultrasonic examination procedures
d) ASME, Sec-III-NB, NC, 2001, Rules for construction of nuclear reactor
components
• Equipment & Accessories
UT Equipment
A pulse-echo UT instrument capable of generating frequencies from 2 MHz to 5 MHzshall be
used. Screen height linearity and amplitude control linearity shall be checked before starting
any job.
Probe
Depending on the application following transducers shall be used :
a) Dual crystal (TR) probe for thickness check
b) Angle beam probes : 450
c) Probe frequency : 2 to 5 MHz
Reference and Calibration Blocks
a) IIW VI, V2 blocks shall be used for screen distance range
calibration, beam exit point and measurement of actual angle of
probe
b) Step wedge block shall be used for calibration of TR probe used
for thickness measurement
c) Ref. calibration notches shall be used to establish primary
reference level/ distance amplitude correction curve for
examination & evaluation
Couplant
Oil, grease, glycerin, water or cellulose paste shall be used as couplant. Select a suitable
couplant based on the surface conditions and orientation; roughness and non-horizontal
conditions require a more viscous couplant. Any requirements for protection of the material
under test, such as for sulphur and halogen content, shall be met by the couplant.
• Surface Condition
The scanning surface shall be neat & clean, free of dirt, scale, grease, paint and other foreign
materials. The surface finish shall be better than 3 µm. Excessive surface roughness and
scratches which interferes with free movement of search unit shall be removed.
• Personnel Qualification
Scanning shall be carried out by personnel qualified by the ISNT or the ASNT to UT Level 1
or higher. Verification of calibration, scanning, analysis of indications and reporting shall be
by personnel qualified by the ISNT or the ASNT to UT Level II or higher. The head of the QA
unit may conduct evaluation tests to check the theoretical and practical capability of the
personnel performing UT.
• Scan Directions
Circumferential scanning in both directions is mandatory. As a supplementary requirement
longitudinal scanning also may be required by referencing document, such as NB-2550.
Scanning speed shall be less than 150 mm/sec. Minimum overlap shall be 10% of probe
size. Signal to noise ratio shall be at least 31.
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• Calibration
Reference standard shall be of the same nominal diameter and thickness and the same
nominal composition and heat treatment as the material being examined and should be of
sufficient length to establish efficient calibration facility. The search unit shall be 450 (in steel)
angle probe of size 10 mm or smaller as specified in referencing document.
For circumferential scanning, the reference standard shall have axial rectangular notches on
the inside and outside surfaces. Their length shall be 25 mm or less, width not to exceed 1.6
mm, and a depth not greater than the larger of 0.1 mm or 5% of the nominal wall thickness.
For axial scanning the reference standard shall have a transverse (circumferential) notch on
the inner and outer surfaces. Dimensions of the transverse notches shall be same as that of
longitudinal notches.
Using the calibration standard, adjust the equipment to produce clearly identifiable
indications from both the inner and outer surface notches. The relative response from the
inner and outer surface notches shall be as nearly equal as possible by probe selection. Use
the lesser of the two responses to establish the rejection level.
On large diameter or heavy wall pipe and tubing, if the inner and outer surface notch
amplitude cannot be made equal because of test metal distance and inside diameter
curvature, make DAC curve using inner and outer surface notches to establish separate
rejection levels for flaws clearly identifiable as located at the inner and outer surfaces.
• Examination
Examination shall be conducted on the finished product, unless otherwise the referencing
code calls for an intermediate scanning. Scanning shall be done at +6 dB above calibration
dB, and recording/evaluation shall be carried out at calibration/reference dB.
• Acceptance Criteria
All indications that are equal to or greater than the rejection level established during
calibration shall be considered unacceptable.
• Re-calibration
Calibrations, DAC shall be verified:
a) At the start of examination
b) At least every 4 hrs during examination
c) At the finish of the examination
d) When there is a doubt on the validity of the calibration
e) Substitution of any of the following :
Search unit, cable, power source, couplant, UT instrument, operator.
• Reporting
The report shall include at least the following information :
a) Identification of the material, type, size, lot, heat
b) Identification of the examination equipment and accessories
c) Name &qualifications of UT operator and reviewing Engineer
d) Details of examination technique, including examination speed and
testing frequency
e) Description of the calibration standard with sketches, including the
actual (measured) dimensions of the artificial discontinuities
f) Description of the distance – amplitude correction procedure, if used
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g) Examination results and method of eliminating defects

h) Calibration data and examination results shall be entered in the
proforma as given below.
• Ultrasonic Examination Report

Report no. Date of testing
Reference procedure no. Work order no.
Material description
Material Dimensions
Identification Surface machined/ rolled/
welded condition
Instrument description
Instrument used machine no. & make
Search unit Couplant oil/ water
Calibration
Range calibration
Calibration standard Sensitivity
Method & technique
Examination
Scanning
Examination started at hrs Closed at hrs
Calibration re-checked at 1 hrs 2 hrs 3 hrs
Observation of re-calibration check 1 2 3
Observation
Evaluation
• Post Examination Cleaning

After the examination the test surface shall be thoroughly cleaned free
from grease, oil etc. using dry cloth, acetone etc
• Documentation
The complete record of the UT examination shall be submitted to the
Engineer in two sets.
Interpretation of Test Results, Recording & Reporting
After conducting the tests the weldments as per specification, the testing inspector must
compile the test results and evaluate them. Proper documentation is to be made along with
RG film for submission to the Engineer for his acceptance or otherwise. Some of the welding
defects are mentioned here for general guidance.
• Welding Defects
There may be two classes of welding defects:
i) External
ii) Internal
External defects include:
i) Surface non-uniformity
ii) Deviation from the prescribed dimension
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iii) Unfilled craters

iv) Undercuts
v) Over concavity or over convexity
vi) Overlaps
vii) Surface cracks
viii) Surface holes
Internal defects include:
i) Porosity or worn whole
ii) Lack of fusion
iii) Slag inclusion
iv) HAZ cracking
v) Lamellar tearing
vi) Excess of brittle or crystalline phase
vii) Incomplete penetration
viii) Bead aspect ratio
• External Defects
Some of the major external defects have been described below.
Surface Non-uniformity
Weld surface should have a smooth finish where ripples are regularly spaced and where the
surface plane is free from undulations. Irregularity of the bead surface indicates that during
welding arc had either broken may times or variation in arc length had occurred frequently.
These appearances in most cases show some internal defects like improper fusion or gas
holes.
Deviation from Prescribed Dimension
Shape and size of the weld dimension determine the strength of the joint. Any deviation from
the specified one is a major defect. This indicates the lack of skill in craftsmanship. It is
measured usually by measuring gauges. The gauges are metal plates with cuts
corresponding to the cross-section of a given size and type of weld. The weld size for butt
weld is the thickness of the work with some plus tolerance and that for fillet weld is the leg
length.
Unfilled Crates
Craters on the weld surface should be thoroughly melted and filled. One can have some idea
about the welding parameters used by the operator from the very look of the crater. A very
deep spongy crater will invariably result from the use of high current and overheating
whereas a low current will produce a shallow crater, enhancing the chance of improper
fusion. These craters if left unfilled may, on some occasion, initiate longitudinal crack, which
is likely to propagate along the weld axis when the metal is re-heated by subsequent passes.
The crater left unfilled causes sharp change in section at the spot inviting stress to
concentrate. This may cause slag inclusion.
Undercuts
Undercut shows itself at the toe of the weld. It is caused due to melting away of the base
metal. Undercutting is a serious defect attributable either to the faulty technique of the
operator or to the burning characteristics of a non-quality electrode. Excessive heat input in
most cases of undercutting is the cause as far as arc welding is concerned. Undercutting
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occurring at the junction of a weld layer and the base metal in groove weld has to be carefully
tackled otherwise it can lead to slag inclusions. It reduces the joint strength because it
reduces the cross section of the metal.
Over-concavity and Over-convexity

These defects may occur because of faulty technique of the operator in both butt and fillet
weld. Over-concavity in fillet weld means the sharp reduction in weld size and hence
shortening of the throat length with consequent weakening of joint strength. In butt weld also
it means the reduction in weld-metal thickness and subsequent weakening of the joint.
Over-convexity, in butt weld also reduces the effective cross-section of the weld seam.
Plastic models in tension examined under polarized light clearly show that the stress lines get
deflected at the reinforced zone.
Overlaps
It is a defect generally connected with fillet welds. It is due to improper welding technique or
improper welding heat. This overlapping means only wastage of metal and on some
occasions may give rise to serious notch effect especially on the H Plate.
Surface Holes & Surface Cracks

Surface holes are generally due to incorrect application of electrode or wrong manipulation of
filler wire or inadequate amount to flux used during gas welding. Sometimes, though less
frequently, they may be caused due to defective electrodes. The obvious cure is to apply the
electrodes correctly or to use the good quality electrodes free from any surface blemishes
and having the required degree of re-drying before use.
Surface cracks may be transverse, longitudinal and crater crack. The origin of all cracks is
due to one or combined effect of the following reasons:
i) Localized stress, which at times exceeds the yield stress of the

material
ii) Un-fused area at the root of the weld
iii) Cross-sectional thinness of the first layer
iv) Crater unfilled
v) Composition of weld – metal specially its ‘S’ & ‘P’ content
• Internal defects
Some of the major internal defects have been described below.
Porosity
By porosity is meant a type of minute voids inside the weld metal occurring during
solidification of weld metal. This results for the Chemical reaction, which evolves gases. As
the weld metal starts falling in temperature. Its capacity to keep gas in solution decreases. As
a result, the gas is released forming voids. The causes may be as follows:
i) Insufficient pudding as this does not give time for the trapped gas to
escape the molten metal before it solidifies
ii) Excessive welding heat
iii) Inadequate protection against atmosphere contamination
iv) Moist electrodes &fluxes and shielding gases
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The porosities may be of the following nature :

i) Uniformly scattered throughout the weld
ii) Isolated in small groups
iii) Distributed linearly at the root
Lack of Fusion
Complete and thorough union of two metals in molten state is known as fusion. When applied
to weld joint, it means complete coalescence between the base and the deposited metals or
that between the individual layers of the deposited metals. In absence of this phenomenon,
weld joint is sure to give away. Even if it does not fail during welding due to thermal stress or
solidification stress, a little loading will invariably make that fail. The poor fusion may result
from any one of the following causes:
i) Low welding current for a given size of electrode

ii) Improper weaving procedure or two rapid arc travel so that the base
metals are not melted thoroughly
iii) Inadequate beveling and narrow spacing
iv) Improper edge (not freed from dirt, rust, scaly etc.) cleaning
Slag Inclusion
In welding by metal arc welding, the principle is such that sound and clean weld metal will be
obtained as a result of desired chemical reaction amongst the molten base metal, molten
filler metal and molten coating ingredients or flux. The design is such that the resultant slag
being of lower specific gravity than that of weld metal will flow up to the surface. If for any
reason it cannot do so, it will remain entrapped in the weld metal. This causes inclusion in the
weld metal making it a mechanically weak metal. The following are generally the causes:
i) Defective aspect ratio

ii) Wrong manipulation of electrodes during welding
iii) Frequent breaking of arcs causing uneven or peaky weld surface
iv) Injudicious layer runs of bead during welding in groove
v) Careless cleaning of undercuts occurring at the junction of base metal
and a layer of welds in groove welding
vi) Use of too large a size of electrode during root-run using low current
vii) Excess convexity in multi-layer welds
HAZ Cracking
Hydrogen induced Cracking : These are not actually weld metal cracks and are usually
associated with base metals. But yet these cracks are frequently caused during welding.
Lameller Tearing
Sometimes base metals, because of manufacturing faults, contain some non-metallic
constituents embedded in it in a flattened, fine leafy form in the rolling direction. When
subjected to thermo stress by welding, base metal gives way in the form of crack along the
line of inclusion. It is most often seen approximately parallel to the surface of the metal under
the weld metal in the heat affected zone. It can under certain conditions extend in the weld
metal also. Because of the stepped appearance of this sub-surface crack, it is popularly
known as Lameller tearing. Fracture when observed under microscope has a characteristic
terraced surface.
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• Bead Aspect Ratio

Width and depth ratio of the weld bead is known as its bead aspect ratio. Normally it should
be greater than unity. Anything less than unity is not desirable, because it upsets the steady
solidification of the metal pool-giving rise to unsatisfactory metal structure and transverse
void for slag accumulation.
8.4.17 Storage of Wires

Although welding wires and rods do not have a flux coating, poor storage condition can be
detrimental to the performance and shelf life of the product. Inadequate storage condition can
lead to surface rusting or contamination of the wire, such that feedability and diffusible
hydrogen levels are adversely affected. Wires should not be left on the machines or out of
the stores for prolonged periods especially overnight, as condensation of moisture from the
atmosphere may lead to rapid surface deterioration. The wire should always be replaced in
original packaging and returned to the controlled storage.
8.4.18 Coating of Joints after Welding

The joint portion shall be cleaned thoroughly as stated above from inside and outside and
lining and coating shall be applied in required coats for same thickness.
8.4.19 Touch up and repair procedure

The finished lining and coating shall be inspected for damage or reduced thickness. Any
such areas shall be repaired by thoroughly degreasing the surface and abrading using 180
grade abrasive papers, the abraded areas shall extend from the edge of the damage for 50–
75 mm on to surrounding sound coating. The prepared surface can then be re-coated.
8.4.20 Safety in Welding

The welding arc is a source of intense energy. It emits harmful rays like ultraviolet rays and
infrared rays and fumes, which may cause unpleasantness. Hot metal, stag and spatter often
can be hazardous to the welder and to the surroundings. In the following paragraphs a few of
these hazards and general precautions to be taken to overcome them are discussed.
Eye Protection
In welding and cutting operations by arc process intense radiations are emitted by electric
arc. These radiations may be classified as follows:
i) Invisible ultraviolet rays
ii) Invisible infrared rays
iii) Visible rays
• Ultraviolet Rays/ Infrared Rays

Strong ultraviolet rays cause severe inflammation similar to sun burn in the eyes and on the
exposed skin. Extremely intense visible rays may cause eyestrain or even temporary
blindness. Infrared rays are not absorbed but will penetrate the eye. They are suspected to
be the cause of cataracts, retina-injuries as well as opacity of the cornea. As the intensity of
these radiations depends upon the temperature of the welding arc, the danger from arc
welding is most likely.
An experienced welder seldom exposes himself to the welding arc. Even with safety glasses
he may get exposed to flashes from welding arcs from nearby co-welders. An exposure of a
few seconds may produce, four to eight hours later, a feeling of sand in the eyes with pain,
watering of the eyes, and possibly headache. This is known as “Arc-Eye”. Recovery is
complete in 24 to 48 hours and no permanent effects need be feared.
It is easy to guard against ultraviolet rays. There are very few materials which are transparent
to both ultraviolet and common light. Even moderately thick ordinary clear glass, amber mica
or coloured celluloid, gelatin or plastic materials are opaque to ultraviolet rays. All welders
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and helpers should be protected from the rays produced by the welding arc by the use of
proper handshields or goggles fitted with proper coloured fitter glasses.
The problem with radiation emitted by arc welding does not confine itself to shutting out
ultraviolet rays alone. Provision must be made to protect the eyes of the welder from infrared
rays and intense light as well. Infrared rays have a wavelength ranging from 750 to 2000
millimicrons. These rays are commonly called heat rays, because when they encounter any
material, which they cannot penetrate, they are absorbed and changed into heat waves.
These are the rays which produce the sensation of heat when they fall upon the skin.
Prolonged exposure of the skin will result in a sunburn condition.
Since coloured glasses have to be used for protection against ultraviolet rays and infrared
rays, the intensity of visible light also is reduced. However, not any type of coloured lens will
do. The lens used should meet definite specified standards. In this connection, reference
may be made to IS:1082 entitled “Specification for equipment for eye and face protection
during welding”.
When welding in the open or large ventilated shops, fumes are scarcely noticeable. Only
when the ventilation is very poor and the fumes of the arc are abnormally heavy and cut
down the amount of fresh air taken in by the welder, some uneasy symptoms, such as
stuffiness, are felt by the welder. The remedy is simply a matter of adequate ventilation.
There are, of course, a few exceptions to the general statement that welding fumes are
normally harmless. Lead and cadmium fumes are certainly dangerous. Zinc fumes (produced
from welding galvanized iron), though not as dangerous as lead and cadmium, are also
harmful.
General Ventilation
In case welding operation has to be carried out inside a confined space viz. steel pipe line
etc., suitable method of ventilation should be provided. The only way to protect the welders is
by supplying uncontaminated air by means of an airline respirator. The specification on “fume
extraction, air supply system” as given below may also be referred to in this connection.
General Safety Precautions
There are minor hazards such as burns that may occur from flying hot metal, slag, spatter,
etc. In order to protect the welder from possible effects of all these hazards, the following
general safety precautions are recommended. It should be borne in mind that the welder is
ultimately responsible for using in a proper manner the safeguards suggested by the
Employer.
Precautions are required in respect of danger from :
• Electric shock
• Radiations from the arc
• Scattering of hot particles & globules of metal
• Flying pieces of sharp slag being chipped
• Heat and fumes

The welder should, therefore, follow the instructions given below:
o Welder/ helper should wear clothing of a kind that is closely woven to protect all parts of
his body from the rays of the arc.
o Welder/ helper should wear additionally leather or asbestos apron, gloves and leather
armlets to protect him from scattered hot metal, slag etc.
o Welder/ helper should protect his eyes and face using helmets, shields or goggles fitted
with the right type of filter glasses.
o Welder/ helper should use dry leather gloves to act as good insulator. It is preferable to
use shoes with rubber soles.
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o The electrode holder should be sufficiently insulated and should have an insulating flange
between the handle and the bare part that grips the electrode. The welding cable should
be examined periodically, particularly where it enters the holder as the insulation is liable
to become ineffective through heat and constant flexing.
o The welding equipment must be safely earthed. There should be two distinct and
different earthing circuits, so that in case one of them fails, the other will afford protection.
o An insulated board should be used for hanging up the electrode holder when not in use.
o The welder/ helper should be protected from flying pieces of slag while chipping by
wearing chipping goggles fitted with clear glasses. When welding is done in confined
spaces, forced ventilation must be provided.
o Combustible materials should never be stored near the welding booth, nor should they be
used to support the work.
o The welding and earthing cables should be laid such that they never get trampled over by
any moving vehicle.
o Pipeline, tank, or portable containers should be welded first making sure that they are
free from an explosive mixture of vapours.
o If others are working near the site of welding, they should be protected from the rays of
the arc by means of movable screens, if this is not possible, they should be made to wear
protective goggles.
o The power lines connected to the welding power source should be out of reach of any
one standing on the ground.
o Even if there is the least chance of causing a fire, a fire extinguisher should be kept
within reach.
o It is recommended that welders and helpers should equip themselves with “auto
darkening safety helmet,gloves, boiler suit type apron and industrial type safety boots”.
8.4.21 Lighting
Sufficient lighting arrangement (sodium vapour type explosion proof) and hand lamps are to
be provided inside pipe for the purpose of welding. Power should be supplied from captive
source at site.
8.4.22 Air Supply System

It is necessary to employ forced ventilation system through pipe lines, which will ensure
extraction of fumes from welding place inside the pipe as well as supply of fresh air for ease
of breathing. Necessary ducting etc. may be required to be employed to ensure fresh air
supply and extraction of fumes. The oxygen content in fresh air at the mid-span of pipe, say
200m from open end is to be maintained as 21% minimum. Blowers of adequate capacity are
to be used to supply air from one end. A portable oxygen and explosive gas meter should be
made available at the mid-length (say 200m from end) of the pipe to monitor oxygen content
in the air constantly.
8.4.23 Laying of Pipe in Trenches

This will include but not be restricted to the following operations. Any other items required for
the work shall have to be carried out by the Contractor.
Preparation of Surface for Cutting the Trench

The surface of the alignment should be surveyed in detail and got ready for taking up the
trenching work. This may require dismantling of structures, relocation of fencing, boundary
markers, drains etc. opening out of the road surface, diversion of underground and overhead
utilities such as electrical lines, telephone lines, etc. temporarily or permanently. For any
work on temporary relocation or permanent diversion, the Contractor should intimate the
requirements to the Project Authority through the Engineer. Temporary relocation of fencing,
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boundary markers, drains, opening out of road surface etc. and their permanent restoration
shall be done by the Contractor following the direction/advice of the Project Authority through
the Engineer. In case of underground/ overhead utilities such as electric lines/ telephone
lines etc. temporary relocation/ diversion/ supporting shall be done by the Contractor under
the guidance of the owner of the utilities. Permanent relocation of the utilities, if required, to
be done as decided by the owner of the utility will be got done through the owner of the utility
at the cost of the Employer and the Contractor need not include it in his cost.
Earthwork in Digging the Trench

The pipes shall generally be laid at a depth to maintain an earth cushion of about 1.0m from
the pipe crown or as directed by the Engineer. Wherever it is not possible to maintain the
minimum earth cushion as above, suitable protection measures shall have to be taken
subject to prior approval of the Engineer. The width of excavation should be kept to the
minimum so that the existing surface as well as below ground infrastructure facilities are
affected to the minimum extent thus causing least disturbance to the general public. In case
the Contractor decides to do butt welding of joints from inside, inside bevel edging of pipe
ends shall have to be done. In case the Contractor decides to do butt welding of joints from
outside, while there may be no difficulty in welding of top and sides of the pipe surfaces for
welding of the bottom portion, extra depth of excavation of trench may be required to
facilitate overhead welding. The Contractor may also adopt, if he finds it convenient, butt
welding of joints outside of the contact surface accessible from top and sides of trench and
butt welding of joints inside of the pipe ends resting on trench bed and in this case bevel
edging of ends of pipes shall have to be done partly from outside and partly from inside. The
method to be adopted for the excavation in trenches shall depend on the characteristics of
the soil, width of trench, depth of trench, ground water level and the system of lowering of the
pipe from the ground surface to the bottom of the trench. It is up to the Contractor to decide
on the method of digging the trench. It is for the Contractor to decide on the most economical
method of cutting the trench, causing least disturbance and at the same time facilitating
completion of the work within the stipulated time.
Laying of pipe in the Trench

The bed should be dressed to a uniform level with medium coarse sand bed of minimum 150
mm thickness. The pipes stacked on the top at ground level along the trenches, should be
lowered down into the trench gently with the help of chain pulley block or by a crane. The
pipes should be laid true to the alignment and grade. The alignment of the pipe should be
with a maximum tolerance of 50 mm in the horizontal plane and 25 mm in the vertical plane
with reference to the design alignment. The ends of the bevel edged pipes should be butt
welded against each other. It should be ensured by the Contractor that tolerance allowed in
manufacturing of pipes does not affect jointing of pipes in any way. Force jointing using
hammering of the pipes is not permitted. Since the ground water level is fairly high special
arrangements will be required to be made for dewatering the trench so that the trench is in a
dry condition while sand bedding is being done and facilitating laying of pipes in proper
alignment and grade as well as welding of joints. For anchoring of the pipes in the alignment,
properly designed thrust blocks shall be provided at locations considered necessary. Smooth
negotiation of bends has to be made as per direction of Engineer by cutting of MS pipes in
match strips with necessary edge preparation to facilitate butt welding.
8.4.24 Laying of Pipe in Elevated Alignment

Preparation of Surface
The pipes will have to be laid on RCC pedestals. The pedestal locations shall have to be
decided by the Contractor based on site conditions. The pedestals and its spacing should be
designed to take the load of pipes full with water and the length of pipes involved. The
pedestals will be required to be provided with RCC or other suitable foundation taking into
consideration the bearing capacity of the soil. Thus the survey of the alignment area should
pay special attention to the locations where the pedestals will be sited. Specifications listed in
above regarding preparation of the surface should be followed as far as they are applicable.
Page 99
Construction of Pedestals
Suitable foundation with RCC or otherwise will have to be designed and provided. It has to
be kept in mind that the pipes after laying in alignment will have the ends butt welded and the
design and location of pedestals should be decided keeping this in mind. RCC pedestals and
foundation may need to be provided with nominal temperature and shrinkage reinforcement.
Synthetic rubber pads or equivalent will be required to be provided at pipe seating on the
pedestal.
Laying of Pipes on the Pedestals

The pipes shall be lowered on to the pedestals by use of a crane. The pipes shall be laid true
to the alignment and grade. The ends of the bevel edged pipe should be butt welded against
each other. Appropriate strapping arrangement shall be done with due approval of the
Engineer.
Provision of air release valve

The Contractor shall provide, air release valve with sluice valve for isolation of air release
valve during maintenance. Air release valve shall conform to IS:14845 and sluice valve shall
conform to IS:14846. The extension tap-off pipe for installation of air release valve shall
comply to IS:3589.
8.4.25 Miscellanous Provisions

Re-welding
Incase, any of the joint does not pass through the test procedures described above, it is to be
got re-welded by the Contractor at this own cost that will include gauging, cleaning, edge
preparation, re-welding and testing etc.
Marking
Each joint shall have a distinct marking at a prominent place indicating year & month,
agency, welder’s number and joint number. This should be done by punching on an
aluminum strip of 3mm thickness x 100mm long x 30mm wide. The aluminum strip should be
fixed at a prominent place by any possible means.
Butt welding of joints shall be done from inside or outside. The detailed specifications for
welding of the joints including the qualifications/experience stipulated for the welding
personnel, specifications on welding rods etc. to be used, the welding procedure and the
procedure for examination of welds including ultrasonic examination are given above. On
completion of the jointing, the Contractor shall have to finish the external coating and internal
epoxy lining on the joint strip. The Contractor’s financial offer should include the cost of all
materials and labour for the welding operation including 100% ultrasonic testing (UT) of
welds.
8.4.26 Non-Destructive Testing (NDT)

Pipe string after welding should be tested with NDT and hydraulically. The lengths of sections
to be tested shall be decided by the Engineer. Arrangements for isolating such section for
carrying out the tests and for removal of the end plates once the testing is over form an
important part in the scope of work of the Contractor.
8.4.27 Hydro-testing of Pipes

For hydraulic testing of pipe system the standard procedure as indicated in CPHEEO Manual
on Water supply and Treatment issued by the Ministry of Urban Development, Government
of India is to be followed.
The field test pressure to be imposed should be not less than the maximum of the following:
a) 1½ times the maximum sustained operating pressure
Page 100
b) 1½ times the maximum pipeline static pressure

c) Sum of the maximum sustained operating pressure and the maximum surge
pressure
d) Sum of the maximum pipeline static pressure and the maximum surge
pressure, subject to a maximum equal to the works test pressure for any
pipe fittings incorporated
The field test pressure should wherever possible be not less than 2/3rd of works test
pressure appropriate to the class of pipe and should be applied and maintained for at least
four hours. If the visual inspection satisfies that there is no leakage, the test can be passed.
The maximum sustained test pressure is 5 kg/cm2, the maximum pipe line static pressure
(sum of pressure of pumps) is 7.5 kg/cm2 and surge pressure due to water hammer is 23
kg/cm2.
Where the field test pressure is less than 2/3rd of the work test pressure, the period of test
should be increased to at least 24 hours. The test pressure shall be gradually raised at the
rate of 1 kg/cm2/min. If the pressure measurements are not made at the lowest point of the
section, an allowance should be made for the difference in static head between the lowest
point and the point of measurement to ensure that the maximum pressure is not exceeded at
the lowest point. If a drop in pressure occurs, the quantity of water added in order to re-
establish the test pressure. The quantity of water added should be carefully measured. This
should not exceed 0.1 litre/mm of pipe diameter/km of pipeline/day for each 30 metre head of
pressure applied.
The hydrostatic test pressure at works and at field after installation and the working pressure
for different pipes materials should be as given in Appendix 6.4 of the CPHEEO Manual on
Water Supply and Treatment.
The allowable leakage during the maintenance stage of pipes carefully laid and well tested
during construction, however, should not exceed:
qL = (ND √P)/115
Where,
qL = Allowable leakage in cm3/hour
N = No. of joints in the length of pipe line
D = Diameter in mm
P = Average test pressure during the leakage test in kg/cm2
Where any test of pipe laid indicates leakage greater than that specified as per the above
formula, the defective pipe(s) or joint(s) shall be repaired/ replaced until the leakage is within
the specified allowance.
The above is applicable to spigot - socket cast iron pipes and AC pressure pipes, whereas,
twice this figure may be taken for steel and pre-stressed concrete pipes.
Detailed instructions to be issued by the Engineer will be required to be followed during the
hydraulic testing.
8.5 Laying of pipes across River / Canal Crossing

The transmission main across river / canal is proposed to be supported over steel trusses /
steel girders, resting on RCC pedestals suitably supported on foundation as per drawings,
designs and direction of the Engineer.
It is the responsibility of the Contractor to assess the suitable location of the foundation and
carryout necessary geotechnical investigation required for the design of the foundation. The
site of the proposed pipe supported structures shall be surveyed and layout and alignment of
the transmission main finalised.
The design of steel trusses / steel girders shall have provision of access to carryout repair
works if required.
Page 101
The pipe supports of the pipe bridge shall be designed and constructed in accordance with
approved standards. The final detailed arrangements shall be designed by the Contractor
and approved by the Engineer prior to the commencement of work.
For canal and river crossing, suitable span are to be designed to minimize the number of
pier. All Pier and abutment shall be on suitably designed (Raft) foundation and or foundation
suitably anchored to rock, based on the soil investigation report.
For the purpose of data on flow, High Flood level etc, are to be collected from the concerned
authority. The Engineer will assist in collection of those data.
For crossings of the road side drains, wherever required, the pipeline shall be laid below the
bottom of the side drain with adequate cover. The transmission pipeline at such crossings
shall be laid by carrying out only required excavation below drains by caving from both sides
and simultaneously inserting the pipes.
8.6 Pipe laying below major Roads

8.6.1 General
Laying of the transmission main across major roads (National Highways and State Highways)
shall be carried out by suitable trenchless methods, unless stated otherwise. In select
stretches, which are densely congested, the transmission main may also be laid by
trenchless methods based on proposal of the Contractor and approval of the Engineer.
The Contractor shall supply and lay the pipe and carryout all other associated works for the
pipe crossings as required based on site condition. The Contractor shall follow the
procedures laid down in the permissions and comply with instructions given by these
authorities provided they do not constitute a risk to health and safety. The Contractor shall
immediately inform the Engineer in any such event.
The Contractor shall be deemed to be familiar with the normal requirements for such works
and have included for all such items in the contract price.
The Contractor shall submit the method statement for the laying / installation of the pipe by
trenchless methods for approval of the Engineer. The approval of the methodology shall be a
pre-requisite condition prior to the Contractor to carry out any such work.
8.6.2 Topographic Survey

The Contractor shall carryout detailed Topographic survey and soil investigation prior to the
commencement of the works. The Contractor shall mention the following before
commencement of work.
(a) The stretch / stretches of the pipe main to be laid by trenchless methods
(b) The effective length of pipes to be laid by trenchless method
(c) The number and size of the jacking and reception shafts
(d) The area of the end thrusting surfaces
(e) The thrust loads for which the pipe is designed
(f) Number of pipes required
8.6.3 Excavation
Excavation shall be undertaken within a shield which must be kept close to the working face
at all times. The shield shall be equipped with steering jacks to adjust the alignment. In loose
materials, face boards shall be available for closing the exposed excavation at the end of
each shift, or when jacking ceases.
8.6.4 Pipe Jacking Crew

Pipe jacking crew must be experienced and well versed in pipe jacking work. An Engineer or
Ganger experienced in the pipe jacking technique, representing the Pipe Jacking Contractor,
Page 102
shall be present at all times during the progress of work and shall be responsible for
maintaining correct line and level.
8.6.5 Pit Details

The size of thrust pit shall be adequate for handling/ lowering/ lifting of equipment, men,
materials, shield, joists etc. The pit shall be suitably supported with sheeting/ walling & strut
for safe working. A detailed drawing shall be submitted by the Contractor for information and
understanding of the Engineer.
The thrust wall shall be adequate to withstand the loads for installation of the pipeline. It shall
be constructed normal to the proposed line of thrust. Intermediate pits / stations may be
used, only after approval of the Engineer. All such information shall be furnished by
Contractor prior to commencement of work.
8.6.6 Jacking Equipment

The Contractor shall use suitable equipment which is designed to provide the forces
necessary for installation of the pipes. The thrust load shall be imparted through the pipe to a
suitable thrust ring which shall be rigid to ensure even distribution of the load without creating
point loading.
8.6.7 Safety Measures

The Contractor shall take all requisite safety measures during the operations.
8.7 Valve Chamber and Flow-meter Chamber

8.7.1 Type of Chambers
The valve / flow meter chambers shall be provided in accordance with the specifications,
drawings and approval by the Engineer. The chambers shall normally be of RCC / Brick-
work. The decision of construction of RCC / Brick Chambers shall be based on site
Conditions, and shall be as approved by the Engineer.
8.7.2 Size of Chamber

The chambers shall be of adequate size to allow ease of operation and maintenance
including replacement of the valves. The location of each valve / flow-meter chamber shall be
shown on the drawings and agreed upon before the commencement of the construction. The
clearance from the Outer diameter of the valve / flow-meter flange and dismantling joint
flange shall be atleast 300mm on either sides, along the length of the pipe main.
The clearance from the valve / flowmeter across the pipe main shall be atleast 400mm from
the maximum projected portion / end.
8.7.3 Requirements
The top of the chambers shall be raised (atleast 25mm) above the (existing) ground level to
avoid ingress of storm water. In case, the chambers are constructed on road edges, the
same should be made flush with the carriage way top / shoulder.
The height of valve / flow meter top from the top slab shall be minimum 30 cms.
After the completion of the chambers the space between the structure and the excavation
shall be backfilled with compacted material. Such backfill shall be placed in layers of 15 cm.
The chambers shall have suitable arrangement for drainage of storm water. Where washouts
have their outfalls to ditches/ water-bodies, it will be necessary to install an outfall structure to
prevent any possibility of soil erosion. The Contractor shall identify all the washout locations
Page 103
during the initial route survey and shall agree with the Engineer including the type of outfall to
be used at each location.
The valves / flow-meters shall be seated on a concrete block, of atleast 300mm height.
8.7.4 Brick Masonry Chamber

The brickworks shall be with 1st class slightly over burnt brick in cement mortar 1:4 as shown
in drawing or as instructed by the Engineer. Brickwork in arches shall be with 1st class brick
in cement mortar 1:3. Brick masonry round the pipes shall also be with 1st class brick in
cement mortar 1:4. The joints shall be made thoroughly leak proof.
All edges / angles shall be rounded to 7.5 cm radius and all rendered internal surfaces shall
have hard impervious finish obtained by using a steel trowel. The external trowel joints of the
masonry shall be finished smooth.
Brick masonry Chambers shall be plastered internally and externally with cement mortar of
required thickness with water proof compound. This plaster shall be water proofed with
addition of water proofing compound of approved brand in proportion specified by the
manufacturer. Water proofing compound proposed to be used shall be approved by the
Engineer before use.
Cement plaster shall be provided with a floating coat of neat cement on the internal surface
and base slab. Pointing shall be provided on the external surface.
8.7.5 RCC Chamber

RCC works for walls/slabs for chambers shall be in cement concrete of grade M20 with steel
reinforcement as per detail drawings. Unless otherwise mentioned in drawings and directed
by the Engineer all RCC will be with 20 mm and downgraded stone chips.
The design of the RCC walls and slabs of the chambers shall be done by the Contractor,
when specifically asked for. No extra shall be paid for carrying out the design and detailing
work.
8.7.6 Top Slab

All chambers shall be provided with pre-cast concrete slab, suitably reinforced of adequate
thickness and dimensions with MS angles frame to take the overburden traffic load. The pre-
cast slabs shall be of such size (and weight), which could be lifted and removed, manually.
Provision for lifting hooks / lugs shall be provided, if specifically ordered by the Engineer. No
separate payment will be made for such arrangements.
8.7.7 Footrests
Access steps shall be of specially designed rungs (PVC encapsulated) in accordance with
the drawings and specification. No improvised units shall be installed unless otherwise
directed/ approved by the Engineer.
Footrests shall be of polypropylene coated, conforming to ASTMD 4101 specification,
injection moulded around a 12 mm steel reinforcing bar of grade Fe 415 conforming to
IS:1786 (approx. wt. of 0.9 kg) as shown in drawing. These shall be embedded in cement
concrete (1:2:4) at least 100 mm, while the brickwork is in progress. These shall be fixed 30
cm apart vertically and staggered laterally and shall not project more than 11 cm from the
wall.
Page 104

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Bid Document Section-6: Employers Requirement

Contract Package No.: WBDWSIP/DWW/NCB/BK/03/2018-19 Particular Requirements for Civil Works

Section-6: Employer’s Requirements

1.0 Project Background ....................................................................... 7

2.0 General Information .................................................................... 10

2.12.5 Temporary diversion of Utilities and drains................................................................... 21

3.0 Survey and Investigation ............................................................. 25

4.0 Design Norms and Criteria .......................................................... 33

4.2.8 Seismic Load .................................................................................................................. 35

5.0 Raw water Intake well and allied works ..................................... 47

6.0 Design and Construction: Water Treatment Plant .................... 52

6.1 Scope of Works ................................................................................................. 52

7.0 Design and Laying of Transmission main system ...................... 65

7.1.10 Thrust block and Anchor block ...................................................................................... 68

8.0 Supply and Laying Pipeline Works............................................. 76

8.4.3 Grade of Steel ................................................................................................................. 85

1.0 Project Background

1.1 Background to the Project

1.2 Project Output

1.3 Salient features of the Project

1.3.1 Intake, WTP and Primary Transmission Main

1.3.2 Overhead reservoirs and Water Supply Distribution Network

1.4 Supplementary information

1.4.1 Communication and Accessibility

1.4.2 Climatic Condition and Annual Rainfall

2.0 General Information

2.1 Scope of Work and Services

2.2 Brief Description of Specification

The Standard Specification provides minimum standards of materials and workmanship to be

2.3 Details of Activities

2.3.2 Activities related to Project implementation

2.3.3 Project Sign Board

2.3.4 Project Photographs

2.4 Contractors Submittals

(r) Detailed spare-part-list

2.5 Rates of Work Items

updating the water supply network drawings, including finalisation of as-built

2.6 CPM / PERT Schedule (Work Programme)

2.6.2 Schedule of Submittal of Work Programme

2.6.3 Contractors Monthly Progess Report

2.7 Operation and Maintenance of the “As Built” Components

2.8 Battery Limits of the Work

2.9 Interfacing of works

2.10 Safety Measures

2.10.2 Project Sign Board

2.11 Applicable Standards and Codes

2.12 Protection and Maintaining Utility services during Construction

2.12.2 Safeguarding Public Utility

2.12.3 Temporary protection of Utility Services

2.12.4 Removal / Shifting of Utilities

2.12.5 Temporary diversion of Utilities and drains

2.13 Work Program and Methodology

2.13.2 Contractor’s Monthly Progress Report

2.13.3 Submission of Project Progress Photographs

2.13.4 Obtaining Permission and approvals

2.14 Establishment of Site Office, Laboratory, Testing facilities

2.14.2 Facilities to be provided at Site

2.14.3 Establishment of Testing facilities and Laboratory

2.15 Contractors Project Facilities

2.15.2 Electricity Provisions in the Camps

2.15.3 Water Supply and Sanitary Provisions

2.15.4 Maintenance of Camps and Offices

2.15.5 Removal of Camps