00-Division 15-Section 15001 General M&E Requirements-Version 1.0

5/26/2018 00-Division 15-Section 15001 General M&E Requirements-Version 1.0

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ABU DHABI SEWERAGE SERVICES COMPANY(ADSSC)

GENERAL SPECIFICATION FOR M & E WORKS

DIVISION 15 MECHANICAL

SECTION 15001 GENERAL M & EREQUIREMENTS

ADSSC/GSM&EW Division 15 Section 15001General M&ERequirements

Rev: 01 April 2008 Page 1 of 69


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General Specification for M & E WorksAbu Dhabi Sewerage Services Company

(ADSSC)

DOCUMENT CONTROL SHEET

Revision No. Date Revision Description / Purpose of Issue

01 April 2008 First Issue.

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TABLE OF CONTENTS

1. GENERAL ..........................................................................................................6

2. SPECIFICATIONS AND STANDARDS .............................................................6

2.1 GENERAL...............................................................................................6

3. TROPICALISATION...........................................................................................7

3.1 GENERAL...............................................................................................7 3.2 CLIMATIC CONDITIONS .......................................................................8

4. ELECTRICAL EQUIPMENT...............................................................................9

4.1 COMPLIANCE........................................................................................94.2 INSTALLATION ....................................................................................104.3 NOISE...................................................................................................11

5. SUBMITTALS...................................................................................................12

5.1 GENERAL.............................................................................................12 5.2 SUBSTITUTIONS.................................................................................135.3 PROGRAMME OF SUBMITTALS ........................................................135.4 FORMAT AND CONTENT....................................................................145.5 CONTRACTORS STAFF......................................................................155.6 HEALTH AND SAFETY POLICY..........................................................155.7 TECHNICAL DETAILS .........................................................................16

5.8 SPARE PARTS.....................................................................................165.9 TYPICAL PERMIT TO WORK FORMS..............................................16

6. PROJECT MANAGEMENT..............................................................................21

6.1 PROGRESS REPORTS.......................................................................216.2 CONTRACT CORRESPONDENCE .....................................................216.3 PROGRAMS.........................................................................................22 6.4 RECORD DRAWINGS .........................................................................226.5 PHOTOGRAPHS..................................................................................22 6.6 PROVISION OF SAMPLES..................................................................236.7 QUALITY CONTROL PROCEDURES .................................................23

7. PLANT AND EQUIPMENT...............................................................................24

7.1 RESISTANCE TO CORROSION..........................................................247.2 STRUCTURAL STEELWORK..............................................................257.3 ROBUSTNESS.....................................................................................257.4 ROTATING ASSEMBLIES ...................................................................267.4.1 SPEEDS ...............................................................................................267.4.2 COUPLINGS.........................................................................................267.4.3 SHAFTS................................................................................................267.4.4 TRANSMISSIONS................................................................................267.4.5 VIBRATION ..........................................................................................277.4.6 GUARDING OF SHAFTS .....................................................................277.4.7 BEARINGS ...........................................................................................287.4.8 CASTINGS AND FORGINGS...............................................................287.5 STAINLESS STEEL..............................................................................28




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7.6 ALUMINIUM ALLOY .............................................................................28

7.7

CONTACT WITH POTABLE WATER...................................................28

7.8 SPECIAL TOOLS .................................................................................297.9 FIRST FILL OF LUBRICATION............................................................297.10 LIFTING EQUIPMENT..........................................................................307.11 ELECTRICAL CONTROL PANELS......................................................307.12 INTERFACE WITH EXISTING PLANT.................................................317.13 CONCEPT OF PLANT CONTROL.......................................................317.14 MODELLING OF PUMPING STATION PERFORMANCE ...................31

8. DOCUMENTATION REQUIREMENTS............................................................32

8.1 GENERAL.............................................................................................32 8.2 DRAWINGS..........................................................................................32

8.2.1 DRAWING REQUIREMENTS ..............................................................328.3 DOCUMENTATION..............................................................................358.4 RECORD OF TESTS (WORKS AND SITE) .........................................36

9. FACTORY ACCEPTANCE TESTS..................................................................36

9.1 GENERAL.............................................................................................36 9.2 FACTORY BUILT ASSEMBLIES (FBAS).............................................389.3 PUMPSETS..........................................................................................389.4 ELECTRIC MOTORS ...........................................................................399.5 DIESEL GENERATORS.......................................................................39

10. DELIVERY AND STORAGE ............................................................................41

10.1 CLEANING AND PROTECTION AT PLACE OF MANUFACTURE .....4110.2 PROTECTION, PACKING AND TRANSPORTATION .........................4110.3 DEMOLITION AND REMOVAL OF EXISTING PLANT AND

EQUIPMENT ........................................................................................4210.4 TEMPORARY FACILITIES...................................................................43

11. INSTALLATION................................................................................................49

11.1 SITE CO-ORDINATION........................................................................4911.2 PROGRESS MEETINGS......................................................................50

12. COMMISSIONING............................................................................................55

12.1 EQUIPMENT INSTALLATION..............................................................55

12.2 SITE ACCEPTANCE TESTS................................................................5512.3 TRAINING.............................................................................................57 12.3 PUMPSETS AND AIR BLOWERS .......................................................5812.4 ELECTRIC MOTORS ...........................................................................5912.5 PERFORMANCE TESTING OF PROCESSES....................................5912.6 PROVISIONAL ACCEPTANCE............................................................60

13. OPERATIONAL AND MAINTENANCE MANUALS ........................................60

13.1 GENERAL.............................................................................................60

14. IDENTIFICATION .............................................................................................62

14.1 GENERAL.............................................................................................62 14.2 NAMEPLATES......................................................................................63 14.3 TAGS....................................................................................................63




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14.4 STENCILS ............................................................................................64

14.5

PIPE MARKERS...................................................................................64

14.6 INSTRUCTION NOTICES ....................................................................6414.7 SAFETY WARNING SIGNS AND NOTICES........................................6414.8 IDENTIFICATION COLOURS...............................................................6514.9 COLOUR SCHEDULE FOR PLANT AND EQUIPMENT......................6514.10 IDENTIFICATION COLOURS FOR PLANT AND EQUIPMENT ..........6614.11 IDENTIFICATION COLOURS FOR PIPELINES ..................................6714.12 PREPARATION....................................................................................6714.13 INSTALLATION ....................................................................................6814.14 SCHEDULES........................................................................................69

15. WARRANTY.....................................................................................................69

15.1 GENERAL.............................................................................................69




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1. GENERAL

a) This document sets out the general standards and informationrequirements for Mechanical, Electrical, Instrumentation and Control(ICA) Works, and mention of any specific material or plant does notnecessarily imply that such is included in the Works.

b) All component parts of the Works, including procedures, practices andservices, shall unless otherwise stated in the contract, comply with theprovisions of this section or be subject to the written approval of ADSSC.All work undertaken and equipment supplied shall comply with all codes,regulations, and specifications referred to throughout the contract

documents.

c) Only new materials and equipment shall be used, unless otherwisespecified.

d) Neither the contractual relationship, duties and responsibilities of theparties in contract nor those of ADSSC shall be altered by the contractdocuments by mention or inference otherwise in any referencedocument.

e) Provisional positioning of new equipment shall be showndiagrammatically on the tender drawings. Exact positioning of suchequipment shall be agreed during the Drawings for Approval stage ofthe contract. Where equipment is to be installed into existing Works, theContractor shall ensure at the pre-tender visit that the provisionallocation is adequate for the installation of the proposed plant andequipment, or indicate otherwise in their tender return.

f) Unless otherwise stated, all minor civil engineering and building worksassociated with the installation of plant and equipment into existingWorks shall be undertaken by the Contractor.

2. SPECIFICATIONS AND STANDARDS

2.1 GENERAL

a) All plant, equipment, systems, components, workmanship, workingpractices, procedures and all other items and activities shall comply withthe quoted standards and regulations in Section 15002 of thisspecification and as qualified and amended throughout this specification.Section 15002 covers the main standards and codes of practice thatcover most of the contract requirements. Some requirements will not becovered by the above quoted standards, but regardless of whether ornot a particular standard is specified, all products and services shallcomply with any International ISO, IEC, BS EN, BS and ASME covering

such items, as a minimum, unless otherwise specified. Unless otherwisestated, ISO shall take precedent over IEC, which shall take precedence




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over BS EN, which will take precedence over BS, which will take

precedence over all remaining standards.

b) Supportive technical literature shall be provided from manufacturers toshow that products comply with the specification. Where requested byADSSC, or specified, the Contractor shall submit supporting test data tosubstantiate compliance in conformity with specified standards, completewith a statement from the manufacturer that original non-conformitieshave been observed, and subsequently addressed to meet thisspecification.

c) All component parts shall be manufactured to a strict system of Limitsand Fits and complete interchangeability of similar parts is required,

where international standardisation of such parts is in place.

d) All references to codes, regulations, specifications and standardsreferred to in the contract documents shall, unless otherwise stated,mean the latest edition, amendment or revision of such referencestandard in effect as of the date of submission of these bid documentsby the bidders.

e) Quoted reference standards referred to herein are deemed mandatoryunder this contract unless conflicting with particular specificationscontained herein. Products or workmanship specified by association,trade, or other consensus standards, are also deemed mandatory,

except when more rigid requirements are specified or are required byapplicable codes.

f) Should specified reference standards conflict with contract documents,then clarification shall be sought from ADSSC before proceeding withthe supply or manufacture of plant and equipment.

g) References to published standards shall be construed as reference to arecognised equivalent standard.

3. TROPICALISATION

3.1 GENERAL

a) All plant and equipment shall be designed for the Emirates of Abu Dhabiclimate.

b) Tropical grade materials shall only be used with the exception of theinternals of hermetically sealed equipment.

c) Iron and steel are in general to be painted or galvanised as appropriatein accordance with Section 15004: Corrosion Protection.

d) Small iron and steel parts, other than stainless steel, of all instrumentsand electrical equipment, the cores of electromagnets and the metal




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parts of relays and mechanisms are to be treated in an approved

manner to prevent rusting. Cores etc., which are built up of laminationsor cannot for any other reasons be anti-rust treated, are to have allexposed parts thoroughly cleaned and heavily enamelled, lacquered orcompounded.

e) Unless suitably protected from the elements, the use of iron and steelshall be avoided in instruments and electrical relays. Steel screws shallbe stainless steel, zinc, cadmium or chromium plated.

f) Instrument screws (except those forming part of a magnetic circuit) shallbe of brass or bronze. Springs shall be of stainless steel, brass, bronzeor other non-rusting material. Pivots and other parts for which non-

ferrous material is unsuitable are to be of an approved stainless steel.

g) Fabrics, cork, paper and similar materials that are not subsequently tobe treated by impregnation are to be adequately treated with anapproved fungicide. Sleeving and fabrics treated with linseed oil orlinseed oil varnishes, are not to be used.

h) The use of wood in equipment is to be avoided as far as possible. Whenused, woodwork is to be thoroughly seasoned teak or other approvedwood that is resistant to fungal decay and is to be free from shakes andwarp, sap and wane, knots, faults, and other blemishes. All woodwork isto be suitably treated to protect it against the ingress of moisture and

from the growth of fungus and termite attack. All joints in woodwork areto be dovetailed or tongued and pinned as far as possible. Metal fittings,where used, are to be of a non-ferrous material or stainless steel.

i) Adhesives are to be selected to ensure they are impervious to moisture,resistant to mould growth and not subject to the ravages of insects.Synthetic resin cement only is to be used for jointing wood. Caseincement is not to be used.

j) The use of hygroscopic insulating materials shall not be permitted exceptwhere immersed in oil or suitably sealed to prevent ingress of moisture.

3.2 CLIMATIC CONDITIONS

a) Climatic conditions are harsh. The atmosphere can be very hot, ladenwith salt and humid for long periods. The resulting combination is highlycorrosive. Sand storms and dust storms are frequent.

b) All equipment shall be derated for continuous operation under theambient conditions tabled below, and unless otherwise specified,performance guarantees shall at these conditions.

All materials and equipment subject to certification by testing authorities

etc., shall be certified as being tested at these conditions.




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The following maximum conditions shall be used for all designs:

ELEMENT VALUE

Peak ambient shade temperature 55C

Temperature of metal surfaces indirect sunlight

90C

Relative Humidity 100%

Design Wind Speed 160km/hr

Altitude 1,000m

c) Sun shading shall be supplied where necessary and where specified toensure that plant and equipment operates satisfactorily in the ambient

conditions stated above.

4. ELECTRICAL EQUIPMENT

4.1 COMPLIANCE

a) Electrical equipment shall comply with Abu Dhabi Water and ElectricityAuthority (ADWEA) Regulations. The Contractor shall be responsible forestablishing the exact characteristics of all installed electrical equipment,including fault levels and then ensuring this complies with the specificregulatory requirements. The prevailing supply characteristics are as

follows:

i. High Voltage (HV): 11,000V, 3-phase, 3-wire, 50Hz.ii. Low Voltage (LV): 415V, 3-phase, 4-wire, 50Hz.iii. Voltage: 10% at LV (from ADWEA).iv. Frequency: 3% Transient Disturbed Conditions (from ADWEA).




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b) Typical system characteristics are as follows:

Description 33kV 11kV 415V

Rated Service Voltage 33 11 415/240

Highest System Voltage 36 12.5 1000

Impulse Test Voltage 170 95 ----

Number of Phase 3 3 3

Design Fault level 31.5kA25kA for 3seconds

80kA for 1second

NeutralSolidlyEarthed

SolidlyEarthed

SolidlyEarthed

c) The whole design shall comply with the necessary specifications,statutory requirements and codes of practices listed below:

i. Latest issue of Abu Dhabi Water and Electricity Authority (ADWEA)and their associated group of companies regulations.

ii. Recommendations issued by the International ElectrotechnicalCommission (IEC).

iii. Harmonised European and British Standards or equivalents.

iv. BS 7671 IEE Wiring Regulations and associated Guidance Notes.v. Recommendations issued by the Institute of Electrical and

Electronics Engineers standards (IEEE).vi. Latest issue of the International Organisation for Standardisation

(ISO) especially for Quality, Health and Safety and Environment.vii. The Emirates Telecommunications Corporation Limited

(ETISALAT).viii. General Directorate of Civil Defence.

4.2 INSTALLATION

a) The Contractor shall ensure that the installation is completed to thehighest standard of neatness, particularly with respect to the visiblecable runs and arrangement and alignment of apparatus and fittings, allof which are to be agreed with ADSSC prior to installation.

b) Electrical equipment, components and accessories shall be IEC/BSEN/BS certified for the purpose for which they accessories are used.

c) Power ratings specified in the tender documentation or required for theproposed equipment shall be in accordance with the best informationavailable to ADSSC. Should any item of equipment proposed by theContractor require a larger motor than that indicated within the tender,

the Contractor shall provide all appropriate control equipment,modifications to existing motor control centres, starting equipment,




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feeder and branch circuits and accessories as required to make the new

installation compliant to the specification without any additional cost tothe contract.

d) Where the Contractor is required to interface new electrical equipmentwith existing equipment in existing enclosures or adjacent to existingequipment, the Contractor shall field check the dimensions of existingequipment, ratings, location of conduits, etc., and ascertain all existingconditions and difficulties likely to be encountered in performing suchwork.

Any interface between old and new equipment requires ADSSC approvalat the detailed design stage of the contract.

e) The Contractor is responsible for the fixing of all switches, fuseboards,switchgear, unit control panels, motor control centres, cables, fittings,cable trays, accessories and all other items comprising the electricalinstallation.

f) All fixings of electrical components to structures and supports shall bemade by means of stainless steel bolts, brass or stainless steel screwswith plastic rawlplugs or similar approved devices.

g) All holes for fixings into electrical compartments, cubicles, conduits and

supports are to be made neatly with a rotary drill. Percussion type toolsare not acceptable for the making of holes.

h) No structural steel, timberwork or concrete is to be drilled for the supportof cables or fittings, unless indicated on the approved drawings, withoutthe prior approval of ADSSC.

i) Electrical junction boxes in auxiliary control cable circuits for marshallinga number of cables feeding to a common item of equipment shall beclearly indicated on the drawings for approval or be subject to theapproval of ADSSC.

j) Upon request, samples of the following electrical items shall be furnishedto ADSSC prior to installation for approval:

i. A 600mm long section of each cable and/or wire to be used withconnectors, lugs, crimps, terminal blocks etc, as specified.

ii. Electrical back boxes, junction boxes, luminaires, switches,sockets, push button station, telecommunication outlets with backbox, conduit, trunking, cable ducts etc.

4.3 NOISE

a) The sound levels generated from plant, equipment and the whole of theinstallation with the envisaged maximum number of items of plantrunning 'on load', shall be measured outside an envelope of one metre




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radius from any items of plant, and shall not exceed 80 dB(A) at one

metre. The Contractor shall include for suitable sound attenuation, ifneeded, to better this level. This will apply in the audible frequencyrange 20Hz to 20kHz. Above 20kHz, the Contractor must state whetherany fundamental frequencies are generated in the ultrasonic region.

b) Before leaving the manufacturer's works, all major items of rotatingmachinery shall be subjected to noise tests and test certificates shall beprovided to ADSSC for approval.

5. SUBMITTALS

5.1 GENERAL

a) Technical schedules and supportive information, as completed by theContractor at the tender stage, forms the base submittal of theContractors offer. These schedules are sufficient to confirm what theContractor is offering, the manufacturers and suppliers ofplant/equipment/key component parts, and that the technical details areto meet the specification. Further submittals will be required throughoutthe contract period as listed later in this section. Such submittals shallcover such details as, but not limited to, materials for approval, plant andequipment for approval, drawings and designs for final approval, testresults, maintenance procedures, safety tests, certifications etc., and allother contractual requirements.

b) Documentation submittals and requirements, including Operational andMaintenance (O&M) Manuals, shall follow the requirements of thissection of the specification and of Section 16670: DocumentationFormat.

c) The Contractor shall note that O&M Manuals have to be submitted andapproved by ADSSC before performance tests can commence, and noextension of time will be granted for delays in the approval processunless approved by ADSSC. The number of copies the Contractor shallsubmit, both paper and software, of complete sets of the O&M manuals

shall be as stated in the particular specification of the contract. Fourweeks shall be allowed for approval.

d) The requirements for submittals for the Works/Factory and Site testing ofplant and equipment are specified later in this section of thespecification.

e) The particular specification may also specify further submittals that areproject specific.

f) Unless otherwise stated, the Contractor shall allow two weeks forapproval of a submission, and no extension of time will be granted for

delays in the approval process unless approved by ADSSC.




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5.2 SUBSTITUTIONS

a) The names of manufacturers of materials and equipment proposed forincorporation in the Works shall be as detailed in the completedtechnical schedules in the tender documents. Substitutions with differingmaterials, equipment or manufacturer shall not be permitted unless suchsubstitution is forced on the Contractor due to reasons outside of hiscontrol, e.g. sub-supplier ceasing to trade. Should the Contractor wishto offer a substitution that is an improvement to the original offer, such asthe recent launch of a technically improved new product/component,then this shall be submitted for consideration by ADSSC. Suchsubmittals must be completed on duplicate technical schedules and tothe same detail as the original tender submission. No extension of time

to the contract period shall be granted for such submittals unlessapproved by ADSSC.

b) ADSSC shall have the power to reject any items, procedures andpractices that, in their opinion, are unsatisfactory or do not comply withthe specification or tendered offer. Such parts shall be replaced by theContractor at no extra cost to the Contract.

c) A request for substitution constitutes a representation that the Contractorwill:

i) Offer an improvement to the originally specified product originally

tendered, or in the case of a Sub-contractor ceasing to trade, atleast an equal or equivalent one.

ii) Meet the specifications and standards.iii) Provide the same warranty for the substitution.iv) Coordinate installation and make changes to other work that may

be required for the work to be complete with no additional cost toADSSC.

v) Waive any later claim by the Contractor, Sub-contractor andmanufacturer for additional costs or time extension, which maysubsequently become apparent due to the substitution.

vi) Reimburse the ADSSC for any review/redesign services, orchanges to associated civil works, and costs associated with thereapproval by the statutory authorities, etc.

5.3 PROGRAMME OF SUBMITTALS

a) Immediately following contract award, the Contractor shall provide alisting of all the submittals due during the course of the contract showingthe planned forecast date for submission of each item.

b) No work represented by required submittals for approval shall bepurchased or commenced until the applicable submittal has beenapproved by ADSSC.

c) All drawings and data shall be submitted to meet the time schedulesstipulated in these specifications and the approved programme.




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d) Submittals to ADSSC are not acceptable directly from Sub-contractors,suppliers or manufacturers.

e) Prior to the execution of any Works, and in accordance with theContract, the Contractor shall prepare detailed working drawings andplant and equipment drawings required for the proper execution of theWorks and shall submit these with full explanatory notes to ADSSC forapproval.

5.4 FORMAT AND CONTENT

a) Submittal copies shall be neatly bound, have an index listing the

contents and dated, signed and sequence numbered on Companyletterhead. Each submittal shall be accompanied by the relevantproforma as issued by ADSSC showing resubmittal status, if applicable,and fully describing the submittal contents. Such proformas shall bemade available at the Contract Mobilisation Meeting.

b) Variations from Contract Documents or system limitations that may becontrary to the specification or be detrimental to the successfulperformance of the completed Works shall be clearly identified on theapplicable submittal. Should this not be the case, and suchdiscrepancies are subsequently noted by ADSSC then they shall be

rectified by the Contractor at no expense to ADSSC. No extension oftime shall be allowed for such rectifications.

c) One copy of the submission will be returned by ADSSC to the Contractormarked with one of the following categories:

i. A : "Approved" subject to contract requirements.ii. B : "Approved except as noted", resubmission not required.iii. C : "Disapproved" pending corrections, resubmission required.iv. D : Rejected, not to specification.v. E : Incomplete.

d) The Contractor may proceed with manufacture or other contract-relatedactivities for categories A and B only.

e) The Contractor shall make all required corrections and resubmit therequired number of corrected submittals until approved. The Contractorshall not be allowed an extension of time to the original contract periodto make such submittals, including the timetable for ADSSC approval,unless otherwise approved by ADSSC. ADSSC shall be given twoweeks to review any resubmittal.

f) Whenever a variation causes a change to the information contained in

previously approved submittals, the Contractor shall resubmitinformation and data corresponding to the changed requirements forapproval. Each resubmittal shall be accompanied by the relevant




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proformas as listed in a) above issued by ADSSC.

5.5 CONTRACTORS STAFF

a) The Contractor shall, no later than two weeks from the start of theContract award date, and before commencement of design activities,submit a full listing of his proposed design staff for the organisation,management and supervision of the Contract.

b) The lists shall include all personnel from Project Manager through toElectrician and Mechanical Fitter level and shall amplify and reflect thedetails already given by the Contractor in the Bidder's Schedule of Datasubmitted with the bid and incorporated into the Contract. Such listings

shall be supported by authenticated details of the qualifications andexperience of such personnel, for review and approval by ADSSC.

c) Before approving personnel, ADSSC has the right to interview any of theContractor's proposed staff, and notwithstanding their approval, ADSSCretains the right to instruct the removal of any person employed by theContractor in or about the Works, who, in their view, misconductshimself, or is incompetent or negligent in the proper performance of hisduties, or whose employment is otherwise considered to be undesirable.

d) The Contractor shall demonstrate, to the satisfaction of ADSSC, thatstaff who are expected to work in hazardous areas have the required

training. Hazardous areas are deemed to include, but are not limited to,confined spaces, chlorine stores and potentially explosive atmospheres.The Contractor shall refer to Section 16680: Hazardous AreaApplications Guidelines.

5.6 HEALTH AND SAFETY POLICY

a) The Contractor shall comply with the safety standards and guidelines asspecified in the ADSSC Construction Safety Manual. It is included in theContract documentation.

b) The Contractor shall submit their Health and Safety Policy Document toADSSC for approval during the mobilisation period. It shall include:

i. A Company Health and Safety Policy Statement, signed by theauthorised signatory of the Company.

ii. A Curriculum Vitae of the Company Safety Officer assigned to theContract. The Safety Officer shall have sufficient experience tosatisfy the requirements of the Ministry of Labour and Social Affairsand of the Abu Dhabi Municipality Drainage Network Division. TheSafety Officer may be interviewed by ADSSC to determine hissuitability for the post. Works shall not commence until a SafetyOfficer has been approved by ADSSC.

iii. Safety responsibilities of all Company staff.iv. Details of the Company Health and Safety procedures.




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v. Detailed information on how the Company intends to comply with

ADSSC Construction Safety Manual, and eliminate, control orcontain the main hazards/risks applicable to the Contract.

c) The Safety Officer shall be available at all times for consultation with andto receive instructions from ADSSC.

d) The Safety Officer shall ensure and be responsible for ensuring thatwork proceeds in accordance with the ADSSC approved permit systemsgiven overleaf.

5.7 TECHNICAL DETAILS

a) Copies of the completed technical data sheets issued with thisspecification and catalogue data for every item of Mechanical, Electricaland ICA plant and equipment to be incorporated in the Works shall besubmitted for approval. One of the copies must be an original. Thenumber of copies shall be as stated in the particular requirements.

b) Such submittals shall be accompanied by more detailed supportiveinformation, as necessary, to satisfy ADSSC that the plant andequipment meets the specification.

5.8 SPARE PARTS

The Contractor shall supply a complete list of specified spare parts (if any)and consumable items and a complete list of recommended spare parts.

5.9 TYPICAL PERMIT TO WORK FORMS




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"PERMIT TO WORK" APPLICATION FORM

ABU DHABI SEWERAGE SERVICES COMPANY

OPERATION AND MAINTENANCE DIVISION

PERMIT TO WORK IN MANHOLES

Permission to enter manholes is authorised by the completion of this PERMIT. It is for the location,duration and type of work outlined below only.

NAME OF CONTRACTOR OR ORGANISATION

.........................................(Hereinafter called the Contractor)

LOCATION OF WORK

Manhole No............ Sector No............

TYPE OF WORK

Brief description of work to be done.

..................................................................................................................................................................................

..................................................................................................................................................................................

DURATION OF WORK

Date: .................. Start time: ..................... Finish time: ....

SUPERVISOR OF WORK

Name of Supervisor (Print Name) : ...................................................................................

Signature : ...................................................................................

Date : ...................................................................................




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SAFETY PRECAUTIONS

The following is a list of equipment, personnel and procedures which MUST BE PROVIDED AND USED throughout the

works. This list is not to be considered exhaustive and does not relieve the Contractor of his general responsibility to ensure

the complete safety of his personnel and the general public.

.... Breathing Apparatus (umbilical Surface Air line type only)

.... Rescue Harness and Lifeline (To be worn at all times inside manholes)

.... Tripod, block and tackle (Lifeline to be attached to block and tackle)

.... Minimum of two men in attendance outside the manhole

Breathing apparatus, harness and lifelines shall be used at all times by all personnel entering and working inmanholes.

Breathing apparatus shall be worn by one of the attendants outside the manhole in readiness for any emergencyassistance required. The attendants shall keep in touch with the men in the manhole by calling or signalling to themat frequent intervals.

The covers of a sufficient number of manholes upstream and downstream of the working site shall be removed toensure adequate ventilation. All open manholes shall be properly guarded.

No naked lights, matches or lighters shall be used in the manhole or in close proximity to an open manhole.

If the flammable gas testing equipment detects the presence of flammable gases, the manhole shall be evacuatedimmediately and not re-entered until the system has been satisfactorily purged.

CONTRACTOR ACCEPTANCE

We fully understand the precautions and procedures outlined above, and shall be fully responsible for the provision and

maintenance of all equipment in good working order, for the implementation of the above precautions and procedures and for

all other measures necessary to ensure the complete safety of our personnel and general public.

Signed for and on behalf of the Contractor : ..........................................................................................................

Name (print) : ..........................................................................................................

Date : ..........................................................................................................

AUTHORISATION TO WORK

The Contractor is hereby permitted to work in the locations and during the period prescribed subject to the provisions

aforementioned.

Signed for and on behalf of Drainage Network Division : ........................................................................................

Name (Print) :

........................................................................................

Date :

........................................................................................

"PERMIT TO WORK" APPLICATION FORM

SAFETY PRECAUTIONS




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TYPICAL "PERMIT TO WORK" SYSTEMFOR MECHANICAL & ELECTRICAL WORKS

Control of Working on Electrical EquipmentTo obviate misunderstanding in the operation of the electrical plant leading to accidents anddamage, the following procedure should be followed under the control of the SeniorAuthorised Person whose authority in this matter must be absolute.

EngineerShall be as stated in the Contract.

Senior Authorised Person:Shall mean the person designated in writing by the Engineer to be responsible for the

administration of the operation of the "Permit to work" system and shall instruct authorisedpersons to carry out such works to which these regulations apply.

Author ised Person:Shall mean a person designated in writing by the Senior Authorised Person as anauthorised person employed to carry out the works to which these regulations apply or toinstruct a responsible person as defined below to carry out such works.

Responsible Person:Shall mean a person designated in writing by the Authorised Person as a responsible personemployed to carry out the works to which these regulations apply in accordance withinstructions from an Authorised Person.

Switching of all power circuits is to be carried out by Authorised Persons only at thepermission of the Senior Authorised Person. All movement of switches is to bedocumented in conjunction with a "Permit to Work" system.

No person shall work on electrical apparatus that has previously been in commission untilsuch time that a "Permit to Work" has been issued to him by the Authorised Person.

Procedural Requirements:Open feeding isolators and padlock in the "Off" or "Earthed" position and affix "DangerMen Working on Line" notice.

Open all other points where a return feed may occur and lock these out whilst affixing"Danger" notices.




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TYPICAL "PERMIT TO WORK" SYSTEMFOR MECHANICAL & ELECTRICAL WORKS

Check by means of approved testing instrument that the required section has been madedead.

Earth the apparatus that has been made dead whenever possible, via a switched position ateach point of isolation. Lock switches in the Earthed position. Where Earth switch positionsare not available, earthing is to be carried out by approved methods.

Where work is to be carried out on any high voltage cable, which is presumed to be dead, thecable must be proved dead by the use of an approved instrument.

"Permits to Work" on the circuit are to be issued by the Authorised Person and signedfor by the person responsible for carrying out the work.

On any occasion that the "Permit to Work" is surrendered by the person carrying out the workthe apparatus is to be considered live and no further work is to be carried out until such timeas the "Permit to Work" has been reissued.

The Authorised Person and the person carrying out the work are to ensure that the work iscomplete.

The person carrying out the work is to warn all those under his control that the apparatus islive.

The "Permit to Work" and all keys are to be surrendered to the Authorised Person and the"Permit to Work" signed off.The Authorised Person will be responsible for removing all earths on the system.

The circuit will be made live by the Authorised Person.

Where the circuit is to be closed on a "ring", it is the responsibility of the Authorised Person toensure that the ring will parallel.

During the course of any work on high voltage systems, the electrical phasing of the work is tobechecked:-

- On the dead circuit before the work is made good.

- On the dead circuit after the work is made good.

- Wherever possible on or between the live circuits by use of approved instruments.

In no circumstances are communications between persons carrying out work on main voltagesystems to be made by messenger or a system of signals.




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6. PROJECT MANAGEMENT

The Contractor shall nominate a Project Manager (PM), to manage theContractors activities from contract award through to the end of the warrantyperiod. The Project Manager shall be approved by ADSSC.

6.1 PROGRESS REPORTS

a) The PM shall produce progress reports in a form approved by ADSSC,using the standard guidelines and proformas issued by ADSSC at theSite Mobilisation Meeting. Work activities, procurement reports, testingprocedures etc., shall be referenced where relevant to the approvedContractor's manufacturing and installation schedule. Interfaces with

other parties, such as a related Civil/M&E Contract, ADSSC, SupplyAuthorities and any other stakeholder, shall be clearly identified.

b) A daily report shall be prepared and submitted. It shall describe thelabour force and its allocation, material, and equipment utilised anddescribe the work progress during the day, site conditions and any otheroccurrence that may or may not affect the progress of the Works.

c) A plant and equipment status report shall be submitted on a weeklybasis. It shall include a list of plant and equipment that have beenmanufactured, works tested, ready for delivery/inspection or have beendelivered to Site. The report shall also refer to all correspondence and

transmittals between the Contractor and ADSSC regarding approval ofsuch plant and equipment.

d) A Monthly Report shall be submitted every 30 days reflecting theprevious 30 days progress and status of work. It shall include adescription of problem areas, current or anticipated causes of delay andtheir estimated impact on progress, together with a description ofcorrective measures taken or proposed. Installation photographs shallalso be submitted with the Monthly Report.

e) The PM shall prepare and update electronic copies of key asset

attributes (such as asset type, size, kW etc) on proformas based onMicrosoft Access software issued at the Site Mobilisation Meeting, forentry onto the ADSSC asset register by others.

6.2 CONTRACT CORRESPONDENCE

a) Except where otherwise specified in the particular specification, allcorrespondence to ADSSC shall be submitted as follows:

i. One original and three photocopies of transmittals and lettersincluding attachments/enclosures, completed on Companyletterhead.

ii. All correspondence from the Contractor to ADSSC shall besubmitted on A4 size paper whenever possible. All




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correspondence shall clearly indicate:

Contract Number.

Title of the Project.

Contractor's Name.

Date and reference number of the correspondence.

b) The PM shall attend meetings with ADSSC or their nominatedConsultant as required.

c) The Contractor can request that correspondence be submittedelectronically through e-mail utilising the ADSSC Project ManagementWeb Portal. Any associated costs will be deemed to have been included

in the Contractors tender price.

6.3 PROGRAMS

a) The Contractor's PM shall have experience in scheduling contract workof a complexity comparable to the Project and have use of computerfacilities capable of delivering a detailed graphic printout within 24 hoursof a request from ADSSC.

b) The format of the program report shall be:

i. Prepared in bar chart form and critical path diagram, covering allstages of the Contract.

ii. Prepared on a programming tool such as Primavera, or othersimilar software, approved by ADSSC.

iii. Dated and ordered sequence of listings and interdependence ofactivities, in chronological order of the start of each item of Work.

iv. Include conferences, meetings, key milestones, and submittal datesin the schedules.

v. Include a narrative report that defines problem areas, anticipateddelays, and impact on the schedule.

vi. Includes of responsibilities of key activities by specified personnel.

6.4 RECORD DRAWINGS

a) Record drawings shall be produced to scale as DXF files suitable for aversion of AutoCAD to be approved by ADSSC.

b) Full details of any amendments of previously approved working drawingsbecause of manufacture and installation shall be presented to ADSSCfor approval.

6.5 PHOTOGRAPHS

a) The Contractor shall take the first series of photographs prior to

commencement of the work with the objective to fully record details ofthe existing site conditions. The number of photographs shall be as




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required to fully detail such conditions and as approved by ADSSC.

For Works interfacing with existing operational plant, the Contractor shallagree the above series of photographs with ADSSC.

b) The Contractor shall supply one print of each photograph and forwardthese to ADSSC for approval. After approval, three sets of prints shallbe labelled and mounted in separate albums by the Contractor. Inaddition, one copy of the CD-ROM containing software versions of thephotographs shall be provided to ADSSC.

They shall then be signed and dated by the Contractor and ADSSC andone set of photographs returned to the Contractor.

c) More photographs shall be taken to include site and installation workthroughout progress of the Contract produced by an experiencedphotographer and be approved by ADSSC.

d) At the end of the Contract, the Contractor shall provide ten (10) colourphotographs framed 6030 cm previously selected by ADSSC.

e) Photographs taken under the provision of the Contract shall not be usedfor commercial advertisement either of the Contractors organisation orof any materials or equipment used on the Works without the writtenapproval of ADSSC.

6.6 PROVISION OF SAMPLES

a) ADSSC may request that the Contractor submit the following samples:

i. Prior to approval, a sample of material, electrical or mechanicalcomponent, cables and wiring etc. in order to ascertain compliancewith the specification.

ii. Prior to approval, painting samples in order to ascertain compliancewith the corrosion protection specification.

iii. Prior to acceptance of tests before completion, verification ofprocess guarantees through sampling and laboratory analysis ofsuch samples.

b) Unless otherwise accepted by ADSSC, samples will only be consideredif taken at random. ADSSC shall witness the selection of samples.Inspection or tests of items or materials that fail shall be sufficient causeto terminate further inspections/tests of the same brand, make, or sourceof the product.

6.7 QUALITY CONTROL PROCEDURES

a) Quality Control (QC) responsibilities lie with the Contractor, except those

additional inspections, tests, and/or audits that ADSSC may require tobe conducted under the terms of the contract.




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b) The Contractor shall submit in writing, the name, qualifications and

experience of the Manager of Quality Control, who, on the approval ofADSSC, shall have full authority to represent and act for the Contractoron all Quality Control-related matters.

c) The Contractor shall develop, implement and maintain a Quality ControlProgram (QCP) that assures equipment and material conformance to theapplicable requirements of every section of the specification.Documentation shall include an organisation chart, plans, andprocedures, detailed work instructions and records.

d) The Contractor shall develop and submit procedures as follows:

i. To implement the QCP, specify responsibilities assigned, andclearly delineated individual job authorities.

ii. To identify potential quality problems with work or materials, andappropriate directions for solving and reporting such problems.

iii. To establish preventive measures and maintaining effective QCpractices in all areas of the project.

iv. To define the methods and responsibilities for the identification,documentation, control, and processing of non-conformingequipment and material.

e) The QCP shall be subject to evaluation and approval by ADSSC.

f) The Contractor shall submit copies of the QCP to ADSSC no later thanfour weeks from the start of the Contract. The number of copies shall beas stated in the particular requirements.

g) No work covered by the QCP shall start until approval has been grantedby ADSSC.

7. PLANT AND EQUIPMENT

7.1 RESISTANCE TO CORROSION

a) All submerged moving parts of the plant, pins and spindles shall be ofnon-corrodible metals. All parts in direct contact with chemicals shall becompletely resistant to corrosion or abrasion by those chemicals, andshall maintain their properties without ageing, exposure to light or anyother cause.

b) All materials utilised in the plant shall be the most suitable for the dutyconcerned, shall be new and of first class commercial quality and beselected to eradicate or reduce corrosion to a minimum. Steel itemsrequiring corrosion protection to be in accordance with Section 15004:Corrosion Protection.

c) Particular attention shall be paid to material selection to minimisecorrosion due to atmospheric conditions, electrolytic action of dissimilar




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metals or any other causes that may reasonably be associated with the

overall performance of the Works.

d) The use of organic materials shall be avoided whenever possible butwhere they have to be used; they shall be treated to make them fire-resistant and non-flame propagating.

e) As defined in Chapter 4 of this document, the use of wood is to beavoided wherever possible but where this has to be used, all woodworkshall be treated to protect it against damage by fire, moisture, fungus,bacteria or chemical effect.

f) Where, in the opinion of ADSSC, during the maintenance period any

moving parts show signs of undue wear, chemical attack or unsuitabilityfor the purpose for which they are installed, they shall be replaced, at nocost to ADSSC, notwithstanding that they may otherwise be working in asatisfactory manner.

7.2 STRUCTURAL STEELWORK

a) No structural steelwork, whether new or existing, shall be drilled for anypurpose without the written approval of ADSSC.

b) The design of structural steel work to be in accordance with Section15003: Plant Manufacturing and shall be protected from corrosion as

detailed in the Section 15004: Corrosion Protection.

7.3 ROBUSTNESS

a) All equipment furnished shall be new, of best commercial quality andguaranteed free from defects in materials, design, and workmanship. Itshall be the manufacturers responsibility to ascertain the conditions andservice under which the equipment will operate and to warrant suchoperation trouble-free in service and meeting the specification.

b) All equipment shall be designed, fabricated, and assembled inaccordance with the best modern engineering and shop practice.Individual parts shall be manufactured to standard sizes and gauges sothat repair parts, furnished at any time, can be installed in the field. Likeparts of duplicate units shall be interchangeable.

c) Iron castings shall be tough, close-grained grey iron, free fromblowholes, flaws or excessive shrinkage.

d) Except where otherwise specified, all structural and miscellaneousfabricated steel used in items of equipment shall conform to theappropriate standards specified. All structural members shall beconsidered as subject to shock or vibratory loads.

e) All parts of the equipment shall be amply proportioned for all stressesthat may occur during fabrication, erection, and stalled, intermittent or




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continuous operation.

f) Unless otherwise specified, stainless steel that will be submerged all orin part during normal operation shall have a minimum nominal thicknessof 6mm and be of at least Grade 316L.

g) The Contractor shall provide ADSSC two weeks notice of the start ofproduction of fabricated and cast items and shall provide the shopschedule in order that ADSSC can schedule shop inspections, ifrequired.

h) The use of dissimilar metals in contact is to be avoided, but whereunavoidable they are to be selected such that the natural potential

difference between them does not exceed 250mV. Electro-plating orother treatment of contacting surfaces is to be employed as necessary toreduce the potential difference to the desired limit.

7.4 ROTATING ASSEMBLIES

7.4.1 SPEEDS

The preferred maximum rotation speed is 1,450rpm. In the case of optimumselection requiring 3,000rpm drives, an alternative selection running at1,450rpm (if possible) shall also be priced using duplicates of the tenderschedules and questionnaires.

7.4.2 COUPLINGS

Drive couplings shall be of the flexible type and be rated to transmit themaximum motor power output. Couplings shall correct minor angular andpositional misalignment without allowing resultant "strain energy" stressingof either driver or driven shaft. They shall be key located on each shaft andeasily removable.

7.4.3 SHAFTS

Shafts shall be of high tensile steel or stainless steel. To reduce stressconcentrations, section changes on the shaft shall be properly radiused atthe root of any steps and keyways shall be internally radiused or graduallyrun out. The shaft shall have its first critical speed well above maximumoperating speeds.

7.4.4 TRANSMISSIONS

a) All transmissions and couplings shall be erected true to line. They shallbe proportioned to transmit the required powers and to resist all forces,including those caused by shock load and repetition or reversal of loadthat may be imposed upon them in use.




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b) Belt and chain drives shall be provided with separate independent

means for adjustment of tension and alignment.

c) Where fitted bolts, spigots or other means for precise location are notemployed in the assembly of the plant, locating dowels shall be fitted oncompletion of erection and alignment. Fitted bolts shall be identified bymeans of stainless steel tags installed under the bolt head.

d) Gearboxes shall be helical spur or worm and wheel reduction geartrains. A gear case of robust cast iron construction shall be providedwith a large inspection cover, oil breather and oil level indicator forroutine maintenance and inspection.

e) Gearboxes shall be oil bath lubricated; the system being designed toensure that all the gears receive adequate lubrication, particularly withgearboxes mounted on an inclined plane. All gearboxes shall becapable of being emptied by gravity.

f) All gears shall be amply designed for both surface durability and bendingstrength. Gearboxes shall be rated to match the maximum rated outputof the motors as specified and shall be capable of transmitting maximummotor torque in the partially-stalled condition.

g) Jacking screws shall be provided, where required, to enable gearboxesto be accurately positioned in all three principal axes. Suitable support

plates shall be welded to the supporting steelwork to carry thegearboxes. The top surface of the plates shall be machined afterwelding in position to ensure an even bearing for the gearbox baseplates. Allowances shall be made for inserting shims (up to 1.5mm inthickness) between the support plates and the gearbox base plates toensure even support of the gearbox.

7.4.5 VIBRATION

Mechanical vibration levels at all duty point conditions shall be stated in theequipment technical datasheets. All equipment shall be statically anddynamically balanced to avoid vibration.

7.4.6 GUARDING OF SHAFTS

a) All rotating shafts, couplings, gears, flywheels, bolts, drives, etc., shall befully guarded with guards fixed to either the plant bedplate or motorstool, whichever is appropriate. Couplings shall be totally enclosed byguards.

b) Shaft guards shall extend the whole length of shafting and includehinged access doors at lubrication/inspection points for couplings,bearings, sliding joints, chain drives, etc.

c) Apertures in guards shall not exceed 12mm diameter or 12mm square.




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d) For pump shafts, guards shall be made of perforated sheet steel, formed

into two semicircular halves. One half is to be rigidly bolted to the pumpstation structure. The other half is to be fitted with the hinged access.Brackets and securing arrangements for guards shall be of substantialconstruction. All mild steel used in the production of guards, includingbolts, nuts, washers and brackets shall be hot dipped galvanised andfinish painted to match the pump and motor.

7.4.7 BEARINGS

Bearings shall be capable of taking all radial and axial loads resultingthrough the normal and extreme conditions. Class of fit, bearing clearanceclassification and L10 life shall be stated in the equipment technical

schedules.

7.4.8 CASTINGS AND FORGINGS

a) Any remedial action that the Contractor proposes to utilise for the repairof castings shall be submitted to ADSSC for approval.

b) All major stress-bearing forgings shall be made to a standardspecification and be subject to internal examination, non-destructivetests for the detection of flaws and heat treated for the relief of residualstresses. ADSSC may inspect forgings at the place of manufacture witha representative of the Contractor.

c) All castings shall be of standard grey close grained to BS 1452 (orequivalent) Grade 220 or better and be sound and free from defects,non-metallic inclusions or blowholes. All non-machined surfaces shallbe carefully fettled and all foundry irregularities removed.

7.5 STAINLESS STEEL

Stainless steel shall have a resistance to atmospheric corrosion not lessthan that provided by BS EN 1461 or equivalent Grade 316 S13 or by BSEN 100095 or equivalent Grade 316 S12, unless otherwise stated in this

specification.

7.6 ALUMINIUM ALLOY

Aluminium structural supporting members shall be fabricated from HE-30-EPaluminium alloy, as appropriate, for the sections, plate, sheet and otherforms employed.

7.7 CONTACT WITH POTABLE WATER

All materials used in contact with potable water shall be approved by ADDCunder Statutory Water Regulations for use in connection with the Supply of

Water for Drinking, Washing, Cooking and Food Purposes.




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7.8 SPECIAL TOOLS

a) The Contractor shall provide one set of new and unused special tools(i.e. those not obtainable from retail outlets) as part of the plant andequipment for the maintenance of all plant included in the Contract.They shall be contained in a clearly labelled hardwood box with haspand staple suitable for padlocking.

b) Any special tool provided for the operation and maintenance of theWorks shall be supplied and handed over to ADSSC. Prior to handover,ADSSC and Contractor shall examine the tools that have been usedduring plant erection to ensure that they are not damaged and are ingood condition.

c) Recommended tools, including any special tools, gauges, jigs orextractors that may be required for maintenance of the Works shall beset out in the appropriate technical schedule and be clearly referenced inthe O&M Manual.

7.9 FIRST FILL OF LUBRICATION

a) An initial first fill of lubricant for cleaning purposes, and a second fill foroils, greases, electrolyte and similar materials necessary for the correctsetting to work and operation of the plant shall be included in theContractor's price.

b) The Contractor shall supply flushing oil for each lubrication system whenan item of plant is ready for preliminary running and a sufficient quantityof the approved lubricants for setting to work for the commercialoperation of the plant for one year after the Takeover Certificate hasbeen issued.

c) A complete schedule of recommended oils and other lubricants shall beprovided by the Contractor; the number of different types of lubricantsbeing kept to a minimum. Where possible, lubricants shall be chosenfrom those manufactured and available in UAE and deviation from thisbeing approved by ADSSC. In the case of grease-lubricated rollerbearings for electric motors, lithium-based greases are preferred.

d) Where lubrication is effected by means of grease, a pressure systemshall be provided which does not require adjustment or recharging morethan once monthly. A grease system having a shorter period thanmonthly between greasing is not acceptable. Lubrication must beprovided to cope with the 30 days between replenishment. Wherenecessary for accessibility, grease nipples shall be placed at the end ofextension pipes and when a number of such points can be groupedconveniently, the nipples shall be brought to a battery plate mounted in aconvenient position. "Hydraulic" button head nipples, in accordance with

BS 1486 or equivalent, shall be used for normal grease.

e) Nipples shall be unpainted and be an alloy or brass or similar non-




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corrosive material. Arrangements shall be provided to prevent bearings

being overfilled with either grease or oil. A grease gun shall be providedchanged with the first fill of grease.

f) When more than one special grease is required a grease gun for eachspecial type shall be supplied and permanently labelled.

g) Oil sumps shall be fitted with oil level indicators of the sight glass type or,where this is not practicable, with dipsticks. The indicators shall showthe level at all temperatures likely to be experienced in service. Thenormal maximum and minimum levels at 20C shall be clearly visible inthe sight glass from the normal access floor to the particular item ofplant.

h) All lubrication systems shall be designed so as not to present a firehazard and particular care shall be taken to prevent leakage of lubricant.

i) All spare parts supplied shall be treated and packed for long storage in astores exposed to the local ambient conditions specified earlier inChapter 3. Each spare part shall be clearly marked or labelled on theoutside of its packing with its description and purpose and when morethan one spare is packed in a single case a general description of itscontents shall be shown on the outside and a detailed list enclosed.

7.10 LIFTING EQUIPMENT

To be in accordance with Standard Specification Section 15230: LiftingEquipment.

7.11 ELECTRICAL CONTROL PANELS

a) All electrical control panels shall be designed for standalone operationconforming to the requirements described in Division 16 of theSpecification.

b) MCCs shall be fully factory equipped, tested and tagged ready tointerface with communication devices such as telemetry, remote terminalunits, instrumentation and other microprocessor-based controllers asspecified in the extent of Works and other specification sections.

c) A complete system of interlocks and safety devices shall be provided, asnecessary, for the safe and continuous operation of all installed plantand equipment in order to provide for the following:

i. Safety of personnel engaged in operation and maintenance of theplant. These interlocks shall be mechanical.

ii. Correct sequence of operation of the plant during start up and shutdown.

iii. Safety of the plant when operating under normal or emergencyconditions.iv. Interlocks and interlocking schemes that are preventative and not




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corrective in operation. The design of the interlocks is subject to

ADSSC approval.v. Locks for interlocking purposes that are of the figure lock type(Castell or equivalent approved). No spare or master key shall beprovided.

vi. Change numbers that are to be arranged to ensure that there is nodanger of interchange with existing locks on other units.

7.12 INTERFACE WITH EXISTING PLANT

a) The Contractor shall ensure his equipment interfaces with any existingequipment correctly, and that such interfaces do not affect the integrity ofthat equipment, or invalidate any existing warranties or guarantees.

b) The Contractor shall ensure that when interfacing with existingoperational plant and equipment the method of work employed and thetiming of such work will not disrupt the operation of the Works, unlessotherwise agreed with ADSSC.

c) Each item of equipment, component or assembly shall have beenproven in service in a similar application and under conditions no lessthan those specified therein. References may be requested by ADSSCto prove this at the drawings for approval stage.

d) The equipment shall be compatible with the civil structure and with

sufficient space for safe and adequate operator access for O&Mprocedures.

7.13 CONCEPT OF PLANT CONTROL

a) The general concept of the plant control system shall be that of a fullyautomatic works that will be manned only by exception. The plant shall becapable of being operated across its range according to local or remotelyentered control set points or schedules on the HMIs and/or SCADA asappropriate.

b) On mains power failure, the plant shall revert to a safe condition and apower fail alarm shall be reported to the RTS outstation. This fail-safeprocedure must also operate on failure of the standby generator (ifinstalled).

c) On mains power recovery, after a pre-defined delay to allow stabilisation ofthe supply, the plant shall automatically restart.

d) When PLC failure occurs (e.g. as detected by the Watchdog) the plantshall revert to a safe condition.

7.14 MODELLING OF PUMPING STATION PERFORMANCE

For pumping stations delivering flows in excess of 10m3s-1, the Pump




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Supplier shall cooperate with the Contractor to construct a fully operational

1/10

th

scale model of the installation to determine the pumping stationperformance at a range of flows. The model shall be utilised to specificallydetermine the following:-

a) Grit deposition.b) Screenings settlement.

c) Initiation of eddy currents in the pumping station under all combinationsof pump operations.

8. DOCUMENTATION REQUIREMENTS

8.1 GENERAL

a) The Contractor shall provide fully detailed drawings, documentation andOperating and Maintenance (O&M) manuals for the Works, for everyitem of plant or system supplied under the Contract, to the extent as toallow ADSSC to fully understand the Works, its theory of operation, itsapplication, performance and maintenance.

b) All drawings and documentation produced by the Contractor's Sub-Contractor shall be checked, signed and given a contractreference/document number/drawing number (as appropriate) by theContractor before submitting to ADSSC.

c) All drawings and documentation shall be checked by the designateddesigner and approved by the Contractors Representative on complyingwith the ADSSC requirements prior to submission to ADSSC forapproval.

d) All drawings, documents, schedules and datasheets and othermiscellaneous information collectively described as documentation shall conform to the requirements of Section 16670: DocumentationFormat.

8.2 DRAWINGS

8.2.1 DRAWING REQUIREMENTS

a) Drawings fully detailing the Works shall include the following as aminimum:-

i) The civil, structural, hydraulic and geotechnical engineering andservices, building, landscaping and any other services illustratingthe full extent and detail of the Works to be undertaken includingmodifications to any existing installation(s).

ii) Plant and general arrangement drawings and area layout drawingsshowing locations of equipment, structures, enclosures, routing of

pipework, cabling and transmission, tubing, tapping points, etc.iii) Detailed plant and equipment drawings. Such drawings shall




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include dimensional and sectional drawings showing all details of

the plants and equipment, component parts, tolerances etc.iv) Hydraulic profile drawings, system curves, pump curves, power andefficiency curves. Pump characteristic curves shall besuperimposed on hydraulic profiles of system curves.

v) Detailed interface drawings with any existing equipment, ifapplicable.

vi) Process/engineering flow diagrams, which are schematic diagramsof the equipment, pipework and control systems making up thePlant or process.

vii) Process and Instrumentation Drawings (P&I Drawings).viii) Power and control schematics plus logic diagrams showing the

schematic logic of interlocks, and shutdown/special control circuits.

ix) Control schematics wiring diagrams of Electrical, Instrumentationand Telemetry Remote Terminal Unit (RTU).

x) Single Line Diagrams.xi) Cause and Effect Diagrams.xii) Loop Diagrams.xiii) Cable Termination Drawings.xiv) Overview Topology Drawing showing plant operation,

communication links and protocols.

b) A schematic diagram shall be provided for each control cubicle. Oneschematic diagram covering a number of similar circuits is notacceptable. The diagrams shall include the following:

i) A schedule of apparatus, including an explanation of any symbolsor abbreviations.

ii) All ferrule numbers.iii) Wire colours.iv) Terminal colours.v) Details of the Electrical and ICA equipment as follows:

Equipment nomenclature.

Type of instrument, manufacturer and duty.

Calibrated range.

Input and output signal levels.

c) Connections between all equipment included in the Contract to associatedequipment supplied under a separate contract.

d) Equipment enclosure drawings shall include the following:

i. Overall enclosure dimensions.ii. Position of all equipment mounted on or in the enclosure, the

position and connections for incoming power/multicore cabling andfor instrumentation tubing.

iii. Individual compartment dimensions within a multi-compartment

enclosure.iv. Shipping lengths and approximate weights of multi-compartment




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enclosures.

v. Foundation and fixing details.vi. Lifting details with eyebolt or lug positions.

e) Wiring diagrams (diagrams of connections 3.3kV and above) shall bedrawn as viewed from the normal working position with the door opened.Separate wiring diagrams (diagram of connections) shall be provided foreach control cubicle. One wiring diagram covering a number of similarcontrol cubicles is not permitted.

f) Diagrams of the earthing arrangements in accordance with Section16340: Earthing and Bonding.

g) Multicore cable/tubing routing. Overall plot plans show the locations ofthe main junction boxes and the routing of the multicores. Whereapplicable, cable trench/duct cross section and cable tray layouts shallalso be shown.

h) Junction box layout drawings showing details of individual junction boxeslocation, cabling connections, terminal details and box identification.

i) Basic symbolic instrument loop schematics (BS 1646: Part 1).

j) Detailed symbolic instrumentation interconnection schematics (BS 1646:Parts 1 to 4 inclusive).

k) Instrument installation drawings showing cabling, piping and mountingarrangements for the various instruments, with an itemised material listfor each arrangement.

l) Potentially Explosive Atmosphere drawings to IEC 60079-10 orequivalent. Sufficient information shall be provided by the use of plan,side elevations and sections to indicate the zone boundaries for eachindividual installed process or item.

m) General arrangement of the site, structures, buildings, roads, accessprovision, pipelines and services.

n) Sections through the Works, hydraulic and geotechnical sections andexcavation cut and fill sections.

o) Piping diagrams including the enclosure pipe runs, the routing of airheaders and transmission tubing.

p) North point, level datum setting out details as may be applicable for thefull referencing of the Works.

q) For structural steelwork, the Contractor shall prepare shop drawings

giving complete information necessary for the fabrication of structuralsteelwork. The shop drawings shall show clearly the location, type andsize of all bolts and welds. They shall also clearly indicate the difference




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between shop and site connections.

r) Drawing Register

i. Each drawing submission shall be accompanied by a drawingregister to identify each design drawing submitted and theirrespective amendment state. The register shall be in tabular formindicating: drawing reference; title; amendment state and approvaldates, including a record of previous issues together with therespective dates of approval.

8.3 DOCUMENTATION

a) In addition to Drawings, the following documentation shall be providedby the Contractor as a minimum:

i. Contract Overview.ii. CVs of personnel for approval.iii. Project Plan - Activities and Timescale.iv. Resources Plan Manpower.v. Method statements.vi. Terminal Points plus Interface Information.vii. Process Control Philosophy.viii. Functional Description.ix. User Requirement Specification

x. Process calculations.xi. Product data sheets.xii. Electrical calculations.xiii. Type test certificates.xiv. Factory test certificates.xv. Software Specification.xvi. Pressure vessel manual in accordance with BS 5500 or

equivalent.xvii. Proof load certificates.xviii. Pump characteristic curves.xix. Pump test data sheet.xx. Fabrication details.xxi. Welding details.xxii. Structural calculations.xxiii. Hydraulic calculation.xxiv. Pressure test reports.xxv. Contract program of Works.xxvi. Schedule of tests.xxvii. Inspection reports.xxviii. Staff organisation chart.xxix. Health and safety policy document.xxx. Quality control program.xxxi. Project As Built record drawings.

xxxii. Operation and Maintenance manual.xxxiii. Spare parts inventory.xxxiv. Asset Register completed to the ADSSC guidelines.




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xxxv. Safety instructions.

xxxvi. Photographic Records.

b) Further information, as required by ADSSC, to show that the proposeddesign, plant and equipment meets the specification, shall be provided.

c) All documents shall be typed on A4 format.

8.4 RECORD OF TESTS (WORKS AND SITE)

a) A test report shall be submitted by the Contractor for each testundertaken, and shall be as detailed on the relevant test proforma asissued at the Site Mobilisation Meeting, and include as a minimum:

i. ADSSC name.ii. Contractors name.iii. Specification section number, Product, and name of Sub-contractor/

Supplier.iv. Name of testing agency and name of inspector.v. Name of manufacturer's representative present.vi. Date, time, and duration of tests.vii. Type of test, and results.viii. Recommendation of acceptance/rejectionix. Retesting required (if applicable).

9. FACTORY ACCEPTANCE TESTS

9.1 GENERAL

a) All products shall be works tested as required by the Specification andby the manufacturers quality control procedures.

b) All products shall be subjected to inspection, examination and witnesstesting by the ADSSC or its representative unless waived by ADSSC.The Contractor shall inform ADSSC of the date when the product(s) willbe ready for works inspection and witness testing.

c) Unless otherwise stated, ADSSC shall witness the inspection and testingof fabricated equipment and/or Factory Built Assemblies at the factory.The Contractors and Manufacturers costs of such inspections and testsshall be borne by the Contractor, unless otherwise stated.

d) The Contractor shall notify ADSSC 4 weeks prior to such tests, so thatpreparation for travelling to the factory inspection and testing can bearranged.

e) Where specified, the Contractor shall provide prepaid air travel, hotelaccommodation, surface travel and other advanced arrangements for

designated personnel from ADSSC to witness the manufacture or testingof plant and associated systems. Airline transportation shall be, as a


Rev: 01 April 2008 Page 36

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