Specification for Plumbing and Sanitary

Specification for Plumbing and Sanitary
SCOPE OF WORK

1. The general character and the scope of work to be carried out under this contract are illustrated in the drawings and specifications attached herewith.
2. Without restricting to the generality of the foregoing works, the scope of the work shall include the piping works from toilets blocks to pipe shaft and piping shall be done for following services:
   • Internal water supply to all fixtures and fittings
   • External water supply system
   • Internal sewer lines within the building
   • External sewer lines in and around the building and up to existing sewage network.
   • Storm water drainage system with rainwater harvesting system.
   • External storm water collection & disposal.
3. The Contractor shall carryout and completes the said work under this contract in every respect in conformity with the rules and regulations of the local Authority. The Contractor shall furnish labors, supply and install all new materials, appliances, equipment necessary for the complete installation and testing of the entire plumbing services as per the relevant IS codes. This also includes any material, appliance, equipment not specifically mentioned herein or noted in the drawings but which are necessary and customary to make a complete installation as shown on the drawings or described herein, properly connected and in working condition according to the good practice. However, this specification does not relieve the contractor for the correctness of the system.
4. The contractor shall include all implied/allied items in his offer. Nothing extra shall be paid whatsoever for incidental or contingent work.
5. The contractor shall get acquainted with the proposed site for the works and study specifications and conditions carefully before tendering. The work shall be executed as per programmed approved by the Engineer-In-Charge. If some part of site is not available for any reasons or there is some unavoidable delay in supply of materials stipulated by the employer, the Programe of construction shall be modified accordingly and the contractor shall have no claim for any extras or compensation on this account.

SPECIFICATIONS

1. Work under this contract shall be carried out strictly in accordance with specifications attached with this document and all relevant latest Indian Standard Codes and statutory rules.
2. Items not covered under this contact and found necessary during execution, such additional works shall be carried out as per specifications of the latest Central Public Works Department with latest amendments as applicable in the contract.
3. Works not covered under Para 1.2.1 and 1.2.2 shall be carried out as per latest relevant Indian standards specifications or codes of practice. In the event of the works not covered by Indian Standards, British standards specifications or codes of practice shall be used.

EXECUTION OF WORK

1. The work shall be carried out in conformity with the water supply and sanitary drawings and within the requirements of architectural, HVAC, Electrical, and other specialized services drawings.
2. The contractor shall co-operate with all trades and agencies working on the site. He shall make provision for hangers, sleeves, structural openings and other requirements well in advance to prevent hold up or progress of the construction Program. Any work done without regard or in consultation with other trades and found to be incongruent to the specified system; same shall be removed and rectified by the contractor without additional cost to the employer.
3. On award of the work, contractor shall submit a construction Programe in the form of a PERT chart or Bar chart for approval of the Engineer-in-Charge. All dates and time schedule agreed upon shall be strictly adhered to, within the stipulated time of completion/commissioning.
4. The contractor shall install complete working plumbing services as per approved drawings and as per the latest IS codes of practice.
5. Execution of work by the contractor includes complete installation of internal water supply system, sewerage and sewerage appurtenances, controllers, valves and power control wiring for controller etc. inside the toilet blocks, complete installation of all sanitary and plumbing fixtures.
6. It is the responsibility of the contractor to protect all the installed fixtures and fittings until the time of handing over to the employer.

DRAWINGS

1. Water supply and sanitary drawings are indicative but shall be followed as closely as actual site condition permits. Any deviations made shall be in conformity with the Engineer-in-charge without affecting the architectural and other services.
2. Architectural drawings shall take precedence over water supply and sanitary drawings or other services drawings with respect to dimensions.
3. Contractor shall verify all dimensions at site and bring to the notice of the Engineer-in-charge all discrepancies or deviations noticed. Architect's / Engineer-in-charge decision shall be final.
4. Large size details and manufacturer's dimensions for materials to be incorporated shall take precedence over small-scale drawings.
5. The contractor shall submit vendor drawings for approval of the client/consultant and carryout the work as per the final approved drawings only.
6. Any drawings issued by the architects/consultant for the works are the property of the architects/consultant and shall not be lent, reproduced or used on any works other than intended without the written permission of the architects/consultant.

INSPECTION AND TESTING OF MATERIALS

1. Contractor shall produce manufacture's test certificate for the materials supplied by him. The tests carried out shall be as per the relevant Indian standards.
2. For examination and testing of materials and work at the site, contractor shall provide all testing and gauging equipment necessary as listed below but not limited to the following:
   • Theodolite.
   • Dumpy level.
   • Steel tapes.
   • Weighing machine.
   • Plumb bobs, Sprit level, Hammers.
   • Micrometers.
   • Thermometers, stoves.
   • Hydraulic test machine.
   • Smoke test machine.
3. All such equipment's shall be tested for calibration at any approved laboratory, if required by Engineer-In-Charge at the expense of the Contractor
4. All testing equipment shall be preferably located in a special room meant for the purpose.

MATERIAL CONVERSION

1. All dimensions and size of materials and equipment given in this document are in commercial metric units.
2. In the event of any weights or sizes given in this document being changed due to metric conversion, the nearest equivalent size accepted by Indian standards shall be acceptable without any additional cost.

REFERENCE POINTS

1. Contractor shall provide permanent bench marks, flag tops and other reference points for the proper execution of work and these shall be preserved till the end of the work.
2. All such reference points shall be in relation to the levels and locations given in the architectural, water supply and sanitary drawings.

REFERENCE DRAWINGS

1. The contractor shall maintain one set of all drawings issued to him as reference drawings. These shall not be used for site purpose
2. All corrections, deviations and changes made at site shall be shown on these reference drawings for final incorporation in the 'As built' drawings. All changes to be made shall be initiated by the Engineer-In-Charge.

SHOP DRAWINGS

1. The contractor shall submit to the Engineer-In-Charge four copies of the shop drawings
2. Shop drawings shall be submitted under the following conditions:-
   • The contractor shall submit to the Engineer-In-Charge four copies of the shop drawings.
   • Equipment layout and piping, wiring diagrams.
   • Manufacturer's or contractors fabrication drawings for any materials or equipment supplied by him.
3. The contractor shall submit 4 (four) copies of manufacturer's drawings, equipment characteristics or performance charts as required by Engineer-in-charge.

‘AS-BUILT’ DRAWINGS

1. On completion of work, contractor shall submit one complete set of original "As built" drawings to the Engineer-In-Charge. These drawings shall have the following information etc.,
   • Run of all piping & diameter on all floors and vertical stacks.
   • Run of water supply lines with diameters, locations of control valves, access panels.
2. Contractor shall provide four sets of catalogues, performance data and list of spare parts together with the name and address of the manufacturer for all electrical and mechanical equipment provided by him.
3. All warranty cards given by the manufactures shall be handed over to the Engineer-In-Charge.

TESTING

1. Piping and drainage works shall be tested as specified under the relevant clauses of the specifications and Indian Standard Codes.
2. The contractor shall ensure cleaning of all plumbing fixtures and satisfactory performance of all the fixtures at the time of testing and commissioning the plumbing/sanitary systems. Flushing of all pipe work to remove any matter will be carried out in section as work progresses.
3. Tests shall be performed in the presence of the Engineer-In-Charge.
4. All materials and equipment found defective shall be replaced and whole work tested to meet the requirements of the specifications as per Indian Standard Codes.
5. Contractor shall perform all such tests as may be necessary and required by the local authorities to meet various bye-laws in force.
6. Contractor shall provide all labour, equipment and materials for the performance of the tests.
7. Contractor shall be responsible for arranging his own power and water required for installation, testing and commissioning the plumbing/sanitary system.

SITE CLEARANCE AND CLEAN UP

1. The contractor shall, from time to time clear away all debris and excess materials accumulated at the site.
2. After the equipment and appliances have been installed and commissioned, contractor shall clear-up the same and remove all plaster, paint stains, stickers and other foreign matter leaving the construction site in neat and clean condition for ready use.
3. On completion of all works, contractor shall demolish all the temporary structures, remove all surplus materials and leave the site in a neat and clean condition, failing which the same shall be done at contractor's cost.

LICENCE, PERMITS AND APPROVALS

1. Contractor shall hold a valid plumbing license issued by the Municipal authority or other competent authority under whose jurisdiction the work falls.
2. Contractor shall keep constant liaison with the municipal authority and obtain approval of all drawings and works carried out by him.
3. The contractor shall submit his detailed drawings for approval to the client/consultant and carryout the works as per the final approved drawings only.

CUTTING & MAKING GOOD

1. No structural member shall be chased or cut without the written permission of the Engineer-In-Charge.
2. Any tiles or finished surfaces or floors damaged by the contractor while doing his work shall be made good with new tiles or other furnishing material. No payment shall be admissible for such repairs. The Engineer-In-Charge may at his discretion get the damaged work repaired by other agencies and debit the cost of such repairs to the contractor.

MATERIALS

1. All materials used in the works shall conform to the specifications attached herewith and latest relevant I.S. Specifications.
2. As far as possible materials bearing I.S. certification marks or makes approved by Consultant / Architect Engineer-in-charge shall be used unless otherwise specified and expressly approved in writing by the Engineer-In-Charge, materials of makes and specifications mentioned in this document/BOQ shall prevail
3. Samples of all materials including all mechanical items shall be got approved before placing order and the approved samples shall be deposited with Construction Manager.
4. If directed, materials shall be tested in an approved testing laboratory and the contractor shall produce the test certificate in original to the Construction Manager and the entire charges for original as well as repeated tests shall be borne by the Contractor. If required by the Construction Manager, the Contractor shall arrange to test portions of the work at his own cost in order to prove their soundness and efficiency. If after any such test the work or portions of such work is found in the opinion of the Construction Manager to be defective or unsound, the Contractor shall pull down and re-do the same at his own cost. All defective materials shall be removed from site.
5. It shall be obligatory for the Contractor to furnish certificates if demanded by the Construction Manager from manufactures or materials suppliers, that the work has been carried out by using their material and installed/fixed as per their recommendations.
6. Cement required for the plumbing work shall be purchased by the Contractor through the Civil Contractors. However, the contractor shall have to make his own arrangement to lift the cement from the godown to the site. Cost of cement issued shall be recovered from contractor.
7. Cement shall be stored in weather proof shed with raised wooden plank flooring to prevent deterioration by dampness or intrusion by foreign matter. Storing of cement and quality of cement shall be as specified in relevant clauses of I.S.Codes
8. Sand: Sand shall be clean, shells, free from silt, clay, loam, shells, and organic matter and be as approved by the Construction Manager. Sand used shall conform to relevant codes of I.S.
9. Coarse Aggregate: Shall be angular, tough, sharp and well graded stone metal trap obtained from approved source. Coarse aggregate shall conform to relevant codes of I.S.
10. Cement Concrete Block/ Bricks: Bricks shall be local best quality obtainable and shall be as specified in relevant clauses of IS and shall be approved by Engineer-in-charge. Preference shall be given to AA class material.
11. Cement concrete shall be of the proportion specified in the particular item in the schedule of quantities. Sand and Metal shall be measured in suitable measuring boxes and correct quantity of cement shall be added. The materials shall be mixed dry on a clean platform. Clean water is then added, and mixed thoroughly. It shall be prepared in such quantity as can be readily used up. P.C.C., which has partially set, shall under no circumstances be used and shall be removed away from the Site.
12. Reinforced Steel: Reinforced steel shall be ribbed tor-steel. The steel shall be as per relevant IS specifications and as mentioned elsewhere in Civil Detailed specification.
13. M.S. Brackets/Hangers: All M.S. Brackets/Hangers for pipe support shall be fabricated out of Mild Steel sections such as channels, angles, and tees, flats etc. as per drawings or as suitable as per I.S. Code. The welding shall show evenness of ripples or waves and well formed beeds with good fusion along the edges of welds. There should be no unfilled cavities, small pockets of slags or burned metal air or gas pockets.
14. M.S. Brackets/Hangers shall be thoroughly cleaned by wire brush to make the surface clear from any rust before application of paint. The Brackets/Hanger shall be fixed to the ceiling either by hooking or by Anchor dash fasteners as directed by the Construction Manager. In case the Brackets cannot be fixed by above methods, due to site condition, they shall be grouted with the permission and as directed by the Construction Manager.
15. Sturdy hangers, brackets and saddles of approved design shall be installed to support all pipe lengths, which are not embedded, over their entire run. The hangers and brackets shall be of adjustable heights and primer coated with Zinc Chromate primer. Clamps, collars and saddles to hold pipes shall be provided with nuts, bolts and suitable gaskets. The brackets and hangers shall be designed to carry the weight of pipes safely and without excessive deflections.
16. All pipes and fittings shall be supported near every joint change of direction, and to a maximum of 3m run of pipe, unless otherwise specified. Where called for, pipe hangers shall also be supplied with proper sound and vibration dampening devices to minimize noticeable noise and vibration transmission.

GENERAL REQUIREMENTS

1. Pipes and fittings shall be fixed truly vertical, horizontal or in slopes as required in a neat workman like manner.
2. Pipes shall be fixed in a manner as to provide easy accessibility for repair and maintenance and shall not cause any obstruction in shaft, passage etc.
3. Pipes shall be securely fixed to walls/ceilings by suitable clamps at intervals specified / as per standard. Only approved type of anchor fasteners shall be used for RCC ceilings.
4. Valves and other appurtenances shall be so located that they are easily accessible for operation, repairs and maintenance.

SANITARY, PLUMBING & WATER INSTALLATION
WATER SUPPLY:-
Work under this section consists of furnishing all labour, materials and appliances necessary and required to install and commission the water supply systems.
The work shall include but not limited to the following:

• Water distribution system inside toilet blocks including supporting.
• Valves in each riser and other ancillary items.
• Connections to all plumbing fixtures etc.
• Chasing of walls for pipes, making holes in walls/floors, making good the openings.

General Requirements:

1. Pipes and fittings shall be fixed truly vertical, horizontal or in slopes as required in a neat workman like manner.
2. Wherever required, bends shall be used on all main pipelines as far as possible and use of elbows shall be restricted for short connections only. As far as possible all bends shall be formed by means of a hydraulic pipe bending machine for pipes up to 65mm dia.
3. Accessibility for repair and maintenance of pipes, valves etc. shall be ensured while executing the work. Pipes shall be securely fixed to wall and ceiling by suitable clamps/hangers brackets at intervals as specified/ directed by the Engineer-in-charge.

Materials:
Pipes:

1. PPR pipes shall conform to the requirement of latest revision of IS:15874. They shall be of the size (nominal bore) specified in the description of the item.
2. Galvanized mild steel welded pipes shall conform to the requirement of latest revision of IS:1239 (Part-1 & 2) for medium/heavy grade. They shall be of the diameter (nominal bore) specified in the description of the item.
3. Copper pipes shall conform to the requirement of latest revision of ASTM B88. They shall be of the size (nominal bore) specified in the description of the item.
4. The pipes shall be clearly finished, and free from cracks, surface flaws, laminations & other defects. All screw threads shall be clean & well cut.

Pipe Fittings:

1. Pipe tube & fittings shall comply with all the appropriate requirements as specified. The fittings shall be designated by the respective nominal bore of the pipes for which they are intended.
2. The PPR pipe fittings shall have spigot – and – faucet (fusion) welding at the ends conforming to the requirements of DIN – 8077/8078.
3. GI tube fittings shall comply with all the appropriate requirements as specified. The fittings shall be designated by the respective nominal bore of the pipes for which they are intended.
4. The Copper pipe fittings shall have seamless brazed- joint at the ends conforming to the requirements of ASTM B-302.

Cutting & Jointing:

1. The pipes & fittings shall be inspected at site before use to ascertain that they confirm to the specification given above. The defective pipes shall be rejected. Where the pipes have to be cut, the ends shall be carefully filed out so that no obstruction to bore is offered. The taps & dies shall be used only for straightening screw threads which have become bend or damaged & shall not be used for turning of the threads so as to make them slack, as the later procedure may not result in water tight joint.
2. The pipes shall be cleaned & cleared of all foreign matter before being laid. Welding parts should be cleaned in the joint area from any kind of dirt and degreased with the help of spirit or specific cleaner.
3. The welding parts should be prepared carefully. It is strongly recommended to cut the both ends of the pipes at angle 30-45 degree, especially when pipes with diameter 40 mm and more than this.
4. Welding dies and welding machine should be kept clean. Remove the left over material with the help of rough napkin; avoid damaging of Teflon surface of welding dies.
5. Thermal insulation for hot water piping should be installed on the heating system.

Internal Work:

1. For internal work, the pipes & fittings shall run on the surface of the walls or on brackets fixed to walls or ceiling or hangers fixed to the ceiling unless otherwise specified. The fixing shall be done by means of standard pattern holder bat clamps or on brackets as mentioned in the drawings, keeping the pipes at least 50mm clear of the wall/slab. When it is found necessary to conceal the pipes, chasing may be adopted or pipes fixed in the ducts or recess etc., provided there is sufficient space to work on the pipes with usual tools. The pipes shall not ordinarily be buried in walls or solid floors; where as unavoidable
2. pipes may be buried for short distance, provided adequate protection is given against damage. Joints shall not be buried. Where directed by the Engineer-in-charge, a MS tube sleeve shall be fixed at the place where the pipe is passing through a wall or floor, for protection of the pipe & allow freedom for expansion & contraction & other movements. In case the pipe is embedded in walls or floors, it shall be painted with two coats of anticorrosive bituminous of approved quality. All pipes & fittings shall be fixed truly vertical & horizontal unless unavoidable. The pipes shall be fixed to walls with standard pattern holder bat clamps / MS brackets of required shapes & size so as to fit tightly on the pipes when tightened with screwed bolts.
3. These clamps / MS brackets shall be embedded in brickwork in cement mortar 1:3 / in CC blocks & shall be spaced at regular intervals in straight lengths as shown in the table given below.

The clamps shall be fixed at shorter lengths near the fittings as directed by the Engineer-in-charge.

All pipes above ground shall be painted with one coat of primer and two coats of synthetic enamel paint of approved shade and quality. Pipes shall be painted to standard colour code/or as specified by the architect/ Engineer-in-charge.

Testing the Joints:

1. After jointing, the pipes & the fittings shall be inspected under working conditions of pressure & flow. Any joint found leaking shall be redone & all leaking pipes removed & replaced without extra cost.
2. The pipe & fittings after they are laid shall be tested to a hydraulic pressure of 1.5 to 2 times working pressure or 10kg/sqcm whichever is higher shall be adopted and maintained for 2 hours. The pipes shall be slowly & carefully charged with water allowing all air to escape & avoiding all shocks or water hammer. The draw off taps & stopcocks shall then be closed & specified hydraulic pressure applied gradually. Pressure gauge must be accurate & should be calibrated before the test. The test pump shall be stopped and the test pressure shall be maintained without loss for at least half an hour. The pipes & fitting shall be tested in sections as the work of laying proceeds, keeping the joints exposed for inspection during the testing.

Fittings:

1. General - Brass or gunmetal fittings shall be heavy quality, of approved manufacturer & pattern with screwed or flanged ends as specified. The fittings shall in all respects comply with the Indian Standard Specifications No: IS:778 & IS:781. The standard size of brass or gunmetal fittings shall be designated by the nominal bore of the pipe outlet to which the fittings are to be attached.
2. All cast fittings shall be round & free from blow holes. Both internal & external surfaces shall be clean, smooth & free from sand etc. Burning, plugging, stopping or patching of the casting shall not be permissible. The bonnet, spindles & other parts shall be truly machined so that when assembled the parts shall be axial, parallel & cylindrical with surface smoothly finished.
3. The fittings shall be thoroughly examined & cleaned of all foreign matter before being fixed. The fittings shall be fixed in the line in a workmanlike manner. The joints between fittings & pipes shall be made leak proof. The joints & fittings shall be leak proof when tested to a pressure of 7 Kg/sqrcm as described under the title ‘testing of joints. & the defective fittings & joints shall be replaced or redone.

Brass Bib Cock & Stop Cock:
a) Bib cocks (bib tap) and stop cocks (stop tap) shall be of specified size & shall be of screw down type. The closing device shall work by means of a disc carrying a renewable non-metallic washer which shuts against water pressure on a seating at right angles to the threaded spindle that operates it. The handle shall be either crutch or butterfly type securely fixed to the spindle.

Valve shall be of the loose leather seated pattern. The cocks (taps) shall open in anti-clockwise directions.

b) The bib cock & stop cock shall be polished bright. The minimum finished weights of the bib tap (cock) & stop tap (cock) given in the IS specifications are reproduced below:

When the bib cocks or stop cocks are required to be chromium plated, the chromium plating shall be conforming to IS:1068. The chromium shall never be deposition brass unless coating of nickel is interposed. In case these are required to be nickel plated, the plating shall be of first quality with a good thick deposit of silvery whiteness capable of taking high polish that will not tarnish for scale., In finish & appearance, the plated articles, when inspected shall be free from plating defects such as blisters, pits, roughness. Unplated areas shall not be either stained or discolored. Before a plate is plated, the washer plate shall be removed from the fittings. The gland packing shall be protected from the plating solution.

Gun Metal Bib Cock & Stop Cock:
These shall be of gunmetal screw down pattern of the size as specified. So far as the general requirements of material are concerned, these shall be similar to those as described above. The weight of these shall be the same as for brass bib cocks.

Brass Full Way Valve (Gate Valve):
Full way valve shall be of brass fitted with a cast iron wheel & shall be of gate type, opening full way of the size as specified.
The valve shall be of best quality as approved by the Engineer-in-charge & shall have the following approximate weight with a tolerance of 5%.


Ball Float Valve:
The ball float valve shall be of high pressure class & shall be of sizes as specified. The nominal size of a ball float valve shall be that corresponding to the size of the pipe to which it is fixed. The valve shall be of brass or gun metal as specified & the float shall be of copper sheet. The minimum gauge of copper sheet used for making the float shall be 0.45mm for float up to 115 mm size & 0.55mm for float exceeding 115mm size and shall be made by efficiently burnished, lapped & soldered seam or by bracing. Plastic float may also be used if specified. The body of ball float valve when assembled in working conditions with the float immersed to not more than half of its volume. It shall remain closed against a test pressure of 10.5Kg/Sq. cm.

The ball float valves shall generally conform to I.S. specifications No. 1703.

Sluice Valve:
Sluice valves shall be of specified size & class & shall be of inside non rising screw type with either double flange or double socket ends & with cap or hand wheel. These shall in all respects comply with the IS 14846 for valves up to & including 300 mm. sizes. Class 1 sluice valve shall be used for maximum working pressure of 10Kg/cm2 (100meter head) & Class 2 sluice valve for 15Kg/cm2 (150 meter head).

The body, domes covers; wedge gate stuffing box shall be of good quality cast iron, the spindle of bronze, and the nut & valve seats of leaded tin bronze. The body, spindle & other parts shall be truly machined with surface smoothly finished. The valve shall be marked with an arrow to show the direction of turn for closing of the valve.

Sluice valve shall be fully examined & cleared of all foreign matter before fixing. The fixing of the valve shall be done by means of bolts, nuts & 3mm, 3 ply rubber insertion or 1.5mm minimum thickness chemically treated compressed fiber boards & of weight less than 0.183 km/ Sq. cm with flanges or spigot or socket tail pieces drilled to the same specification in case of S & S pipes & with flanges in case of flanged pipes. The tail pieces shall conform to IS:1938. These shall be jointed to the pipeline by means of lead caulked joints.

Butterfly Valve:
All the isolation valves 65 mm and above on the equipment and water lines, except where specified or shown on drawings shall be wafer type butterfly valves. They shall be designed to fit without gaskets, the watertight seal being obtained by rubber seat projection at the faces compressed between the flanges. The valves shall be supplied inclusive of M.S. pipe flanges and high tensile steel bolts of dimensions recommended by suppliers of valves.

Ball Valves:
These shall be of brass fitted with handle up to 50 mm size. These shall generally conform to latest revision of ASTM A105 & their approximate weights shall be as specified in the code.

Check Valves (Non return valves):
Check valves of 40mm and smaller size shall be gunmetal conventional swing/lift check valve type used in all water services. Check valves larger than 40 mm shall be Bronze wafer/Dual plate check valve type used in all water services. The valves shall be supplied inclusive of M.S. Pipe flanges and high tensile steel bolts of dimension recommended by suppliers of valves

PPR PIPES:
PPR pipes and fittings for SDR 11 shall meet the requirements of ASTM D 2846 and pipes and fittings for SDR 13.5 shall meet the requirements of ASTM F 442. The make of pipe to be adopted shall be approved by the Engineer-in-charge. The pressure rating at different temperatures shall be as follows



Jointing
All PPR pipes shall be laid and jointed as per manufacturer’s specifications and relevant I.S codes. Fusion welding method shall be used for jointing of PPR pipes conform to relevant I.S Codes & manufacturer’s specifications. Recommended time for fusion welding is mentioned in table below:

Horizontal and vertical run of pipes shall be properly supported by pipe clamps or MS brackets as specified by manufacturer or as mentioned in the drawings. All pipes shall be tested after installation for a pressure equal to twice the maximum working pressure or 10 kg/ sq cm whichever is higher in the line as per manufacturer specifications.

GI PIPES:
The pipes shall be galvanized mild steel welded (ERW) or (HFW) screwed and socketed conforming to the requirements of IS:1239-2004 (Part-1) and 1992 (part-2) and IS:3589-1984.Pipe sizes of 65 mm NB and above shall have “V groove butt welded with an electrical resistance welding machine and approved filter electrodes shall be used. For root welding by E-6013 welding electrodes, while fill up and final run shall also be welded by E-6013 electrodes upto the Galvanising shall conform to IS: 4736, the zinc coating shall be uniform, adherent reasonably smooth and free from such imperfections as flux, ash and drop inclusions, bare patches, black spots, rust strains, bulky white deposits and blisters. The pipes and sockets shall be cleanly finished, well galvanized in and out and free from cracks, surface flaws laminations and other defects. All screw threads shall be clean and well cut. The ends shall be cut cleanly and square with the axis of the pipe. The fittings shall be malleable iron and comply with all the requirements of the pipes. The sizes of pipes and fitting to be as per system design.

Laying and Jointing of GI Pipes:

1. The galvanized pipes and fittings shall run in wall chase or ceiling or as specified. The fixing shall be done by means of standard pattern holder bat clamps keeping the pipes about 15mm clears of the wall where to be laid on surface. Where it is specified to conceal the pipes, chasing may be adopted for pipes fixed in the shafts, ducts etc. there should be sufficient space to work on the pipes with the usual tools. As far as possible, pipes may be buried for short distances provided adequate protection is given against damage and where so required special care to be taken at joints. Where directed by the Contractor, pipe sleeves shall be fixed at a place the pipe is crossing through a wall or floor for reception of the pipe and allow freedom for expansion and contraction and other movements. In case of pipe is embedded in walls or floors it shall be painted with anticorrosive bitumastic paints of approved quality. Under the floors the pipes shall be laid in layer of sand filling.
2. Galvanized iron pipes shall be jointed with threaded and socket joints, using threaded fittings. Care shall be taken to remove any burr from the end of the pipes after threading. Teflon tape, White lead or an equivalent jointing compound of proprietary make shall be used, according to the manufacturer’s recommendation.

COPPER PIPES:
Copper pipes shall be conform to the requirement of latest revision of ASTM B88 & fittings shall have seamless brazed- joint at the ends conforming to the requirements of ASTM B-302. The pipes and fittings shall be cleanly finished, well in cut and free from cracks, surface flaws laminations and other defects. All screw threads shall be clean and well cut. The ends shall be cut cleanly and square with the axis of the pipe. The jointing of copper pipes shall be as per suppliers/manufactures installation instructions.

HYDROPNUEMATIC SYSTEM:
The Hydro-pneumatic pumping system shall be complete with control panels and associated electrical works for domestic and flushing (grey) water supply. All submersible, drainage sump pumps are also included in this document. The domestic and flushing water supply shall have different hydro pneumatic pumping system. All installation work shall comply with the latest rules and regulations.

Equipment offered shall include all minor items and incidental work, equipment accessories and materials may not be specifically mentioned but are required for the proper completion of the installations in accordance with the true intent and meaning of this Specification. Clearly visible and robust manufacturer's name-plates shall be permanently fitted in each and every item of equipment showing the manufacturer's name, type and/or model number, serial number, and all essential operating data such as speed, capacity, voltage etc. The Subcontractor shall allow provision for the inspection of all equipments by the manufacturer during the course of installation. Layout of pipes in pump room shall be suitably supported by necessary MS structural supports.

The Scope of work shall include the following:

1. Hydro-pneumatic pumping system
2. Variable speed pumping units for domestic water supply and flushing (grey) water distribution.
3. Suitably sized pressure vessels complete with necessary interconnections and controls.
4. Control panel for pump control complete with variable speed drives, circuit breakers, fuses, pressure transmitters etc. complete with all interconnections to pumps.
5. Pump control units complete with pre-programmed micro-processor chip.
6. Pump monitoring units to monitor operation of pumps.
7. Each hydro pneumatic pumping unit shall be supplied as a complete set including variable speed pumps, pressure vessels, suction and discharge common manifolds, non-return valves, isolating valves, pressure transmitters on the discharge side and level electrode at the suction tank. Each unit shall be provided with PLC for unit control and all necessary electrical work for the unit.
8. The Hydro-pneumatic system supplier shall provide the pumping units in the designated pump rooms as complete units including all necessary piping within equipment such that only discharge connections are required to be connected into the units discharge manifolds by the Subcontractor. The Subcontractor shall guarantee specified pump performance at various pump speeds and Hydro-pneumatic pumps must be able to supply at least 1.5 Kg/Sq cm at the highest/farthest fitting
9. Electrical equipment and installation work including the PLC in control panel
10. Painting and labeling of pipe work and equipment
11. Provision of all hold down bolts, spigots struts and the like required to be built in during construction.
12. Provision of necessary interface circuits to BMS , to each Pump controller indicating the status of the pumps and pressure vessel in form of Ethernet/IP interfacing panels inside each pump room and control panels of all pumps to achieve an integrated ‘view’ of the pumps being monitored.
13. The contractor shall connect to Ethernet/IP Interfaces for any BMS signal inputs. These signals shall be collectively referred to as the interfacing I/O points.
14. Provision of all level switches, flow switches and other sensing devices for status indication.
15. Provision of SS Anti Vortex Plate on the Pump Suction line inside the Tank.
16. All interfacing work with other trades.
17. Balancing, testing and commissioning of the Hydro-pneumatic pumping system.
18. Provision of twenty four (24) months operational maintenance and breakdown services.
19. Provision of operating instructions and maintenance manuals.
20. Training of the Contractor's staff for proper operation of the entire systems.

HYDROPNEUMATIC PUMPS
Pumps shall be vertical, centrifugal, multistage directly coupled to motor. Provision of pump with pump head and base of cast iron and other parts in SS 304 shall be made for pumps required in Hydro-pneumatic System. Pump shall be mounted on a concrete foundation and the pumps base shall be set on a vibration elimination pad. The pump shall be lubricated in strict accordance with the manufacturer’s instructions and shall be factory aligned prior to shipment. All motors and bases shall be painted with approved finish shop coat of paint. The pump shall be selected for the lowest operating noise level and shall be complete with flexible connections, valves, and pressure gauges.

Pumps shall be so selected that the design duty point is within 5% of the maximum efficiency point. The selected pump casing shall have ample space to take an impeller one size larger than that capable of performing the design duty. The pump shall have a speed of not more than 2800 rpm. All pumps and motors shall be of minimum vibration and noise level during operation. Vibration isolators shall be provided for all pump sets and pumps shall have dry run protection. Facilities shall be provided to prevent starting of pumps when the water tank is at low water level. An indicator for this low water level alarm shall be provided. Facilities to select, which pump to be duty pump and standby pump shall be provided and be interchangeable. Pump curves for all pumps offered shall be submitted. All curve indicating excessive shut-off head shall not be considered. Each pump shall be provided with a gate valve at suction and discharge, check valve at discharge, approved strainer at suction, flexible connections at pump suction and discharge, eccentric reducer at suction, concentric reducer at discharge, pressure gauges at suction and discharge, circulation relief valve and automatic air relief valve. Appropriate neoprene vibration isolation mountings shall be provided for each pump sets.

Vertical Multi-Stage Pumps shall be of centrifugal type and arranged with shafts vertically installed. The impellers shall be of stainless steel mechanically balanced and keyed to shaft. Pumps shall be driven by elevated in-line TEFC squirrel cage motors via extended vertical shaft complete with universal couplings. The shafts shall be stainless steel. Stainless steel sleeves shall be provided to protect the shaft in the water space and through the sealing glands. The sleeves shall be keyed to prevent rotation and secured against axial movement. The bearings shall be of ball or roller type protected against ingress of water, dirt and other matter. The shaft seal shall be easily serviceable and shall allow for correct adjustment and loading of the seal. Pump motors above 7.5 kW shall be equipped with a spacer coupling which allows changing of shaft seals without removing the motor. The pump motors shall be of Class “F” insulation and IP55 rating and shall be provided with built in thermostats for protection against overheating.

VARIABLE SPEED HYDRO-PNEUMATIC PUMPING SYSTEM
Variable speed Hydro-pneumatic pumping units shall be provided for supply of domestic water, flushing (grey) water to all the points of use throughout the terminal. The units shall be selected so as to provide at minimum of1.5 Kg per Sq.cm at the highest/farthest fitting. The hydro-pneumatic pumping units shall have the following features:

System Description
The pumping system shall have positive suction and variable speed drive. The system shall be supplied as complete sets including suction and discharge common manifolds, non-return valves, isolating valves, pressure transmitter on the discharge side and electrode at the suction tank.

The system operation will be such that the initial small water demand shall be met by the charged diaphragm pressure vessel. Should the water demand continue the system pressure will dip to a preset pump cut-in point when the lead pump starts to operate at reduced speed through the variable speed drive. However, should the system pressure be still below the preset value, the controller continuously increases pump speed to meet the system demand. When the lead pump is not able to meet the system pressure at full speed, the second pump also starts to operate. At peak demand all the pumps operate, similarly, if there is a drop in water demand the duty pump speed starts to reduce, then standby pumps cuts-off, followed by stopping of the duty pump.

The closed diaphragm pressure vessel shall be of fibre reinforced plastic (FRP) material with a pressure gauge and isolating valve. The interior shall be of non-toxic lining suitable for use with domestic water. The vessel shall be manufactured to conform to ASME pressure vessel code/standards. A pressure transmitter shall detect the pressure at the delivery manifold and feedback to the PLC control panel via control circuit. The system shall incorporate a frequency converter or frequency converter motors on the pumps and the pressure transmitter shall register the actual pressure on the discharge side.

The variable speed drive pumping system shall maintain a constant pressure regardless of the system demand. If there is a drop in pressure outside the preset point, the Variable Speed Drive (VSD) pump shall start to run until the pressure increases to the preset limit, or it will continue to increase the pump speed to the upper limit of the frequency. If the water system demand still cannot be met, the second pump shall be called in to run, the VSD will then alter the pump speed to meet the preset pressure point. If the set point is still unable to be met, the third pump is then activated to run (in case of 3 pumps units).This shall be achieved by continuously varying the motor speed of the duty pump according to the demand up to a maximum designed capacity.VSD shall be provided for each pump. Under decreasing hydraulic demand the reverse sequence to the above description shall apply. The frequency converter shall be linked to the motor of the duty pump for continuous speed adjustment and ultimately the water delivery shall be maintained at constant pressure at the preset value.

Local Motor Control Panel
The motor control panel shall be equipped with all the necessary electrical components including a PLC and a frequency drive. The control panel shall cover the followings functions:

Flexibility and simplicity in allowing the necessary re-adjustment of the pumping system pre-set delivery pressure to operate the pumps within the specified maximum and minimum delivery ranges.
Built-in frictional loss compensation factor which will automatically increase the delivery pressure setting, in collaboration with the increase in flow demand. This shall be able to minimize the system pressure differences and provide a more constant pressure along the supply line and also to save the energy consumption of the motor when running at low speed.

Pump Pressure Vessel
Diaphragm type pressure vessels shall be provided as shown on the drawings. They shall be incorporated into the system so that during normal operation the pump shall not need to be start within 30 seconds of it switching off in order to prevent the pump hunting. The pressure vessel shall be of adequate capacity to accommodate a considerable fluctuation in water demand by the system with minimum start/ stop cycles of the pumps. The vessel shall be constructed of steel plate built to ASME Standards for Unfired Pressure Vessel. A rubber diaphragm shall be provided in the vessel for separating the water and pre-charge nitrogen. The pre-charge pressure shall be adjustable and charging port with non-return device shall be provided. The adjustable cut-in and cut-off pressure unit for the pumps shall be built-in at the vessel to suit the system.

For Detailed Technical Specification, Download Below Attachment