ADSSC 15001 General M E Requirements Versio

ABU DHABI SEWERAGE SERVICES COMPANY (ADSSC)

GENERAL SPECIFICATION FOR M & E WORKS

DIVISION 15 MECHANICAL

SECTION 15001 GENERAL M & E REQUIREMENTS

ADSSC/GSM&EW Division 15 Section 15001

General M&E Requirements Rev: 01 April 2008 Page 1 of 69

General Specification for M & E Works Abu 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 ........................................................................................9 4.2 INSTALLATION ....................................................................................10 4.3 NOISE...................................................................................................11

5. SUBMITTALS...................................................................................................12 5.1 GENERAL.............................................................................................12 5.2 SUBSTITUTIONS .................................................................................13 5.3 PROGRAMME OF SUBMITTALS ........................................................13 5.4 FORMAT AND CONTENT....................................................................14 5.5 CONTRACTORS STAFF......................................................................15 5.6 HEALTH AND SAFETY POLICY..........................................................15 5.7 TECHNICAL DETAILS .........................................................................16 5.8 SPARE PARTS.....................................................................................16 5.9 TYPICAL “PERMIT TO WORK” FORMS..............................................16

6. PROJECT MANAGEMENT..............................................................................21 6.1 PROGRESS REPORTS .......................................................................21 6.2 CONTRACT CORRESPONDENCE .....................................................21 6.3 PROGRAMS.........................................................................................22 6.4 RECORD DRAWINGS .........................................................................22 6.5 PHOTOGRAPHS..................................................................................22 6.6 PROVISION OF SAMPLES..................................................................23 6.7 QUALITY CONTROL PROCEDURES .................................................23

7. PLANT AND EQUIPMENT...............................................................................24 7.1 RESISTANCE TO CORROSION..........................................................24 7.2 STRUCTURAL STEELWORK ..............................................................25 7.3 ROBUSTNESS .....................................................................................25 7.4 ROTATING ASSEMBLIES ...................................................................26 7.4.1 SPEEDS ...............................................................................................26 7.4.2 COUPLINGS.........................................................................................26 7.4.3 SHAFTS................................................................................................26 7.4.4 TRANSMISSIONS ................................................................................26 7.4.5 VIBRATION ..........................................................................................27 7.4.6 GUARDING OF SHAFTS .....................................................................27 7.4.7 BEARINGS ...........................................................................................28 7.4.8 CASTINGS AND FORGINGS...............................................................28 7.5 STAINLESS STEEL..............................................................................28




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7.6 ALUMINIUM ALLOY .............................................................................28 7.7 CONTACT WITH POTABLE WATER...................................................28 7.8 SPECIAL TOOLS .................................................................................29 7.9 FIRST FILL OF LUBRICATION ............................................................29 7.10 LIFTING EQUIPMENT..........................................................................30 7.11 ELECTRICAL CONTROL PANELS......................................................30 7.12 INTERFACE WITH EXISTING PLANT.................................................31 7.13 CONCEPT OF PLANT CONTROL .......................................................31 7.14 MODELLING OF PUMPING STATION PERFORMANCE ...................31

8. DOCUMENTATION REQUIREMENTS............................................................32 8.1 GENERAL.............................................................................................32 8.2 DRAWINGS ..........................................................................................32 8.2.1 DRAWING REQUIREMENTS ..............................................................32 8.3 DOCUMENTATION ..............................................................................35 8.4 RECORD OF TESTS (WORKS AND SITE) .........................................36

9. FACTORY ACCEPTANCE TESTS..................................................................36 9.1 GENERAL.............................................................................................36 9.2 FACTORY BUILT ASSEMBLIES (FBAS).............................................38 9.3 PUMPSETS ..........................................................................................38 9.4 ELECTRIC MOTORS ...........................................................................39 9.5 DIESEL GENERATORS.......................................................................39

10. DELIVERY AND STORAGE ............................................................................41 10.1 CLEANING AND PROTECTION AT PLACE OF MANUFACTURE .....41 10.2 PROTECTION, PACKING AND TRANSPORTATION .........................41 10.3 DEMOLITION AND REMOVAL OF EXISTING PLANT AND

EQUIPMENT ........................................................................................42 10.4 TEMPORARY FACILITIES...................................................................43

11. INSTALLATION................................................................................................49 11.1 SITE CO-ORDINATION........................................................................49 11.2 PROGRESS MEETINGS......................................................................50

12. COMMISSIONING............................................................................................55 12.1 EQUIPMENT INSTALLATION..............................................................55 12.2 SITE ACCEPTANCE TESTS................................................................55 12.3 TRAINING.............................................................................................57 12.3 PUMPSETS AND AIR BLOWERS .......................................................58 12.4 ELECTRIC MOTORS ...........................................................................59 12.5 PERFORMANCE TESTING OF PROCESSES....................................59 12.6 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 ....................................................................64 14.7 SAFETY WARNING SIGNS AND NOTICES........................................64 14.8 IDENTIFICATION COLOURS...............................................................65 14.9 COLOUR SCHEDULE FOR PLANT AND EQUIPMENT......................65 14.10 IDENTIFICATION COLOURS FOR PLANT AND EQUIPMENT ..........66 14.11 IDENTIFICATION COLOURS FOR PIPELINES ..................................67 14.12 PREPARATION ....................................................................................67 14.13 INSTALLATION ....................................................................................68 14.14 SCHEDULES........................................................................................69

15. WARRANTY.....................................................................................................69 15.1 GENERAL.............................................................................................69




(ADSSC)

1. GENERAL

a) This document sets out the general standards and information requirements for Mechanical, Electrical, Instrumentation and Control (ICA) Works, and mention of any specific material or plant does not necessarily imply that such is included in the Works.

b) All component parts of the Works, including procedures, practices and

services, shall unless otherwise stated in the contract, comply with the provisions 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 otherwise

specified. d) Neither the contractual relationship, duties and responsibilities of the

parties in contract nor those of ADSSC shall be altered by the contract documents by mention or inference otherwise in any reference document.

e) Provisional positioning of new equipment shall be shown

diagrammatically on the tender drawings. Exact positioning of such equipment shall be agreed during the ‘Drawings for Approval’ stage of the contract. Where equipment is to be installed into existing Works, the Contractor shall ensure at the pre-tender visit that the provisional location is adequate for the installation of the proposed plant and equipment, or indicate otherwise in their tender return.

f) Unless otherwise stated, all minor civil engineering and building works

associated with the installation of plant and equipment into existing Works shall be undertaken by the Contractor.

2. SPECIFICATIONS AND STANDARDS

2.1 GENERAL

a) All plant, equipment, systems, components, workmanship, working practices, procedures and all other items and activities shall comply with the quoted standards and regulations in Section 15002 of this specification and as qualified and amended throughout this specification. Section 15002 covers the main standards and codes of practice that cover most of the contract requirements. Some requirements will not be covered by the above quoted standards, but regardless of whether or not a particular standard is specified, all products and services shall comply with any International ISO, IEC, BS EN, BS and ASME covering such items, as a minimum, unless otherwise specified. Unless otherwise stated, ISO shall take precedent over IEC, which shall take precedence




(ADSSC)

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 to

show that products comply with the specification. Where requested by ADSSC, or specified, the Contractor shall submit supporting test data to substantiate compliance in conformity with specified standards, complete with a statement from the manufacturer that original non-conformities have been observed, and subsequently addressed to meet this specification.

c) All component parts shall be manufactured to a strict system of ‘Limits

and 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 standards

referred to in the contract documents shall, unless otherwise stated, mean the latest edition, amendment or revision of such reference standard in effect as of the date of submission of these bid documents by the bidders.

e) Quoted reference standards referred to herein are deemed mandatory

under this contract unless conflicting with particular specifications contained 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 by applicable codes.

f) Should specified reference standards conflict with contract documents,

then clarification shall be sought from ADSSC before proceeding with the supply or manufacture of plant and equipment.

g) References to published standards shall be construed as reference to a

recognised equivalent standard. 3. TROPICALISATION

3.1 GENERAL

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

b) Tropical grade materials shall only be used with the exception of the

internals of hermetically sealed equipment. c) Iron and steel are in general to be painted or galvanised as appropriate

in accordance with Section 15004: Corrosion Protection. d) Small iron and steel parts, other than stainless steel, of all instruments

and electrical equipment, the cores of electromagnets and the metal




(ADSSC)

parts of relays and mechanisms are to be treated in an approved manner to prevent rusting. Cores etc., which are built up of laminations or cannot for any other reasons be anti-rust treated, are to have all exposed parts thoroughly cleaned and heavily enamelled, lacquered or compounded.

e) Unless suitably protected from the elements, the use of iron and steel

shall be avoided in instruments and electrical relays. Steel screws shall be stainless steel, zinc, cadmium or chromium plated.

f) Instrument screws (except those forming part of a magnetic circuit) shall

be of brass or bronze. Springs shall be of stainless steel, brass, bronze or 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 to

be treated by impregnation are to be adequately treated with an approved fungicide. Sleeving and fabrics treated with linseed oil or linseed oil varnishes, are not to be used.

h) The use of wood in equipment is to be avoided as far as possible. When

used, woodwork is to be thoroughly seasoned teak or other approved wood that is resistant to fungal decay and is to be free from shakes and warp, sap and wane, knots, faults, and other blemishes. All woodwork is to be suitably treated to protect it against the ingress of moisture and from the growth of fungus and termite attack. All joints in woodwork are to 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. Casein cement is not to be used.

j) The use of hygroscopic insulating materials shall not be permitted except

where 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, laden with salt and humid for long periods. The resulting combination is highly corrosive. Sand storms and dust storms are frequent.

b) All equipment shall be derated for continuous operation under the

ambient 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.




(ADSSC)

The following maximum conditions shall be used for all designs:

ELEMENT VALUE Peak ambient shade temperature 55ºC Temperature of metal surfaces in direct sunlight 90ºC

Relative Humidity 100% Design Wind Speed 160km/hr Altitude ≤1,000m

c) Sun shading shall be supplied where necessary and where specified to

ensure 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 Electricity Authority (ADWEA) Regulations. The Contractor shall be responsible for establishing the exact characteristics of all installed electrical equipment, including fault levels and then ensuring this complies with the specific regulatory 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).




(ADSSC)

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 31.5kA 25kA for 3 seconds

80kA for 1 second

Neutral Solidly Earthed

Solidly Earthed

Solidly Earthed

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 Electrotechnical

Commission (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 the highest standard of neatness, particularly with respect to the visible cable runs and arrangement and alignment of apparatus and fittings, all of which are to be agreed with ADSSC prior to installation.

b) Electrical equipment, components and accessories shall be IEC/BS

EN/BS certified for the purpose for which they accessories are used. c) Power ratings specified in the tender documentation or required for the

proposed equipment shall be in accordance with the best information available to ADSSC. Should any item of equipment proposed by the Contractor 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,




(ADSSC)

feeder and branch circuits and accessories as required to make the new installation compliant to the specification without any additional cost to the contract.

d) Where the Contractor is required to interface new electrical equipment

with existing equipment in existing enclosures or adjacent to existing equipment, the Contractor shall field check the dimensions of existing equipment, ratings, location of conduits, etc., and ascertain all existing conditions and difficulties likely to be encountered in performing such work.

Any interface between old and new equipment requires ADSSC approval at 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 electrical installation.

f) All fixings of electrical components to structures and supports shall be

made by means of stainless steel bolts, brass or stainless steel screws with 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 tools are not acceptable for the making of holes.

h) No structural steel, timberwork or concrete is to be drilled for the support

of cables or fittings, unless indicated on the approved drawings, without the prior approval of ADSSC.

i) Electrical junction boxes in auxiliary control cable circuits for marshalling

a number of cables feeding to a common item of equipment shall be clearly indicated on the drawings for approval or be subject to the approval of ADSSC.

j) Upon request, samples of the following electrical items shall be furnished

to ADSSC prior to installation for approval:

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

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

4.3 NOISE

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




(ADSSC)

radius from any items of plant, and shall not exceed 80 dB(A) at one metre. The Contractor shall include for suitable sound attenuation, if needed, to better this level. This will apply in the audible frequency range 20Hz to 20kHz. Above 20kHz, the Contractor must state whether any fundamental frequencies are generated in the ultrasonic region.

b) Before leaving the manufacturer's works, all major items of rotating

machinery shall be subjected to noise tests and test certificates shall be provided to ADSSC for approval.

5. SUBMITTALS

5.1 GENERAL

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

b) Documentation submittals and requirements, including Operational and

Maintenance (O&M) Manuals, shall follow the requirements of this section of the specification and of Section 16670: Documentation Format.

c) The Contractor shall note that O&M Manuals have to be submitted and

approved by ADSSC before performance tests can commence, and no extension of time will be granted for delays in the approval process unless approved by ADSSC. The number of copies the Contractor shall submit, both paper and software, of complete sets of the O&M manuals shall be as stated in the particular specification of the contract. Four weeks shall be allowed for approval.

d) The requirements for submittals for the Works/Factory and Site testing of

plant and equipment are specified later in this section of the specification.

e) The particular specification may also specify further submittals that are

project specific. f) Unless otherwise stated, the Contractor shall allow two weeks for

approval of a submission, and no extension of time will be granted for delays in the approval process unless approved by ADSSC.




(ADSSC)

5.2 SUBSTITUTIONS

a) The names of manufacturers of materials and equipment proposed for incorporation in the Works shall be as detailed in the completed technical schedules in the tender documents. Substitutions with differing materials, equipment or manufacturer shall not be permitted unless such substitution is forced on the Contractor due to reasons outside of his control, e.g. sub-supplier ceasing to trade. Should the Contractor wish to offer a substitution that is an improvement to the original offer, such as the recent launch of a technically improved new product/component, then this shall be submitted for consideration by ADSSC. Such submittals must be completed on duplicate technical schedules and to the same detail as the original tender submission. No extension of time to the contract period shall be granted for such submittals unless approved by ADSSC.

b) ADSSC shall have the power to reject any items, procedures and

practices that, in their opinion, are unsatisfactory or do not comply with the specification or tendered offer. Such parts shall be replaced by the Contractor at no extra cost to the Contract.

c) A request for substitution constitutes a representation that the Contractor

will:

i) Offer an improvement to the originally specified product originally tendered, or in the case of a Sub-contractor ceasing to trade, at least 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 to ADSSC.

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

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

5.3 PROGRAMME OF SUBMITTALS

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

b) No work represented by required submittals for approval shall be

purchased or commenced until the applicable submittal has been approved by ADSSC.

c) All drawings and data shall be submitted to meet the time schedules

stipulated in these specifications and the approved programme.




(ADSSC)

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 the

Contract, the Contractor shall prepare detailed working drawings and plant and equipment drawings required for the proper execution of the Works and shall submit these with full explanatory notes to ADSSC for approval.

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 Company letterhead. Each submittal shall be accompanied by the relevant proforma as issued by ADSSC showing resubmittal status, if applicable, and fully describing the submittal contents. Such proformas shall be made available at the Contract Mobilisation Meeting.

b) Variations from Contract Documents or system limitations that may be

contrary to the specification or be detrimental to the successful performance of the completed Works shall be clearly identified on the applicable submittal. Should this not be the case, and such discrepancies are subsequently noted by ADSSC then they shall be rectified by the Contractor at no expense to ADSSC. No extension of time shall be allowed for such rectifications.

c) One copy of the submission will be returned by ADSSC to the Contractor

marked 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-related

activities for categories A and B only. e) The Contractor shall make all required corrections and resubmit the

required number of corrected submittals until approved. The Contractor shall not be allowed an extension of time to the original contract period to make such submittals, including the timetable for ADSSC approval, unless otherwise approved by ADSSC. ADSSC shall be given two weeks to review any resubmittal.

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

previously approved submittals, the Contractor shall resubmit information and data corresponding to the changed requirements for approval. Each resubmittal shall be accompanied by the relevant




(ADSSC)

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 the Contract 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 to

Electrician and Mechanical Fitter level and shall amplify and reflect the details already given by the Contractor in the Bidder's Schedule of Data submitted with the bid and incorporated into the Contract. Such listings shall be supported by authenticated details of the qualifications and experience of such personnel, for review and approval by ADSSC.

c) Before approving personnel, ADSSC has the right to interview any of the

Contractor's proposed staff, and notwithstanding their approval, ADSSC retains the right to instruct the removal of any person employed by the Contractor in or about the Works, who, in their view, misconducts himself, or is incompetent or negligent in the proper performance of his duties, or whose employment is otherwise considered to be undesirable.

d) The Contractor shall demonstrate, to the satisfaction of ADSSC, that

staff 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 Area Applications Guidelines.

5.6 HEALTH AND SAFETY POLICY

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

b) The Contractor shall submit their Health and Safety Policy Document to

ADSSC for approval during the mobilisation period. It shall include:

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

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

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




(ADSSC)

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

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

c) The Safety Officer shall be available at all times for consultation with and

to receive instructions from ADSSC. d) The Safety Officer shall ensure and be responsible for ensuring that

work proceeds in accordance with the ADSSC approved permit systems given overleaf.

5.7 TECHNICAL DETAILS

a) Copies of the completed technical data sheets issued with this specification and catalogue data for every item of Mechanical, Electrical and ICA plant and equipment to be incorporated in the Works shall be submitted for approval. One of the copies must be an original. The number of copies shall be as stated in the particular requirements.

b) Such submittals shall be accompanied by more detailed supportive information, as necessary, to satisfy ADSSC that the plant and equipment 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




(ADSSC)

"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 : ...................................................................................




(ADSSC)

The following is a list of equipment, personworks. This list is not to be considered exhau the complete safety of his personnel and the .... Breathing Apparatus (umbilical Surface Ai.... Rescue Harness and Lifeline (To be worn .... Tripod, block and tackle (Lifeline to be atta.... Minimum of two men in attendance outside

• Breathing apparatus, harness and lmanholes.

• Breathing apparatus shall be worn

assistance required. The attendantat frequent intervals.

• The covers of a sufficient number o

ensure adequate ventilation. All ope

• No naked lights, matches or lighter

• If the flammable gas testing equipmimmediately and not re-entered unt

CONTRACTOR ACCEPTANCE

We fully understand the precautions and prmaintenance of all equipment in good workinall other measures necessary to ensure the c

Signed for and on behalf of the Contractor

Name (print)

Date

AUTHORISATION TO WORK

The Contractor is hereby permitted to woraforementioned.

Signed for and on behalf of Drainage Network

Name (Print)

Date

"PERMIT TO WORK" APPLICATION FORM SAFETY PRECAUTIONS


SAFETY PRECAUTIONS

nel and procedures which MUST BE PROVIDED AND USED throughout the stive and does not relieve the Contractor of his general responsibility to ensure

general public.

r line type only) at all times inside manholes) ched to block and tackle) the manhole

ifelines shall be used at all times by all personnel entering and working in

by one of the attendants outside the manhole in readiness for any emergency s shall keep in touch with the men in the manhole by calling or signalling to them

f manholes upstream and downstream of the working site shall be removed to n manholes shall be properly guarded.

s shall be used in the manhole or in close proximity to an open manhole.

ent detects the presence of flammable gases, the manhole shall be evacuated il the system has been satisfactorily purged.

ocedures outlined above, and shall be fully responsible for the provision and g order, for the implementation of the above precautions and procedures and for omplete safety of our personnel and general public.

: ..........................................................................................................

: ..........................................................................................................

: ..........................................................................................................

k in the locations and during the period prescribed subject to the provisions

Division : ........................................................................................

: ........................................................................................

: ........................................................................................

001 General M&E Requirements Rev: 01 April 2008 Page 18 of 69


(ADSSC)

TYPICAL "PERMIT TO WORK" SYSTEM FOR MECHANICAL & ELECTRICAL WORKS

Control of Working on Electrical Equipment To obviate misunderstanding in the operation of the electrical plant leading to accidents and damage, the following procedure should be followed under the control of the Senior Authorised Person whose authority in this matter must be absolute. Engineer Shall 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 authorised persons to carry out such works to which these regulations apply. Authorised Person: Shall mean a person designated in writing by the Senior Authorised Person as an authorised person employed to carry out the works to which these regulations apply or to instruct 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 person employed to carry out the works to which these regulations apply in accordance with instructions from an Authorised Person. Switching of all power circuits is to be carried out by Authorised Persons only at the permission of the Senior Authorised Person. All movement of switches is to be documented in conjunction with a "Permit to Work" system. No person shall work on electrical apparatus that has previously been in commission until such 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 "Danger Men Working on Line" notice. Open all other points where a return feed may occur and lock these out whilst affixing "Danger" notices.




(ADSSC)

TYPICAL "PERMIT TO WORK" SYSTEM FOR MECHANICAL & ELECTRICAL WORKS

Check by means of approved testing instrument that the required section has been made dead. Earth the apparatus that has been made dead whenever possible, via a switched position at each point of isolation. Lock switches in the “Earthed” position. Where Earth switch positions are 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, the cable 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 signed for 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 work the apparatus is to be considered live and no further work is to be carried out until such time as the "Permit to Work" has been reissued. The Authorised Person and the person carrying out the work are to ensure that the work is complete. The person carrying out the work is to warn all those under his control that the apparatus is live. 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 to ensure that the ring will parallel. During the course of any work on high voltage systems, the electrical phasing of the work is to be checked:- - 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 voltage systems to be made by messenger or a system of signals.




(ADSSC)

6. PROJECT MANAGEMENT

The Contractor shall nominate a Project Manager (PM), to manage the Contractor’s activities from contract award through to the end of the warranty period. 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 the Site Mobilisation Meeting. Work activities, procurement reports, testing procedures etc., shall be referenced where relevant to the approved Contractor's manufacturing and installation schedule. Interfaces with other parties, such as a related Civil/M&E Contract, ADSSC, Supply Authorities and any other stakeholder, shall be clearly identified.

b) A daily report shall be prepared and submitted. It shall describe the

labour force and its allocation, material, and equipment utilised and describe the work progress during the day, site conditions and any other occurrence that may or may not affect the progress of the Works.

c) A plant and equipment status report shall be submitted on a weekly

basis. It shall include a list of plant and equipment that have been manufactured, works tested, ready for delivery/inspection or have been delivered to Site. The report shall also refer to all correspondence and transmittals between the Contractor and ADSSC regarding approval of such plant and equipment.

d) A Monthly Report shall be submitted every 30 days reflecting the

previous 30 days progress and status of work. It shall include a description of problem areas, current or anticipated causes of delay and their estimated impact on progress, together with a description of corrective measures taken or proposed. Installation photographs shall also 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 on Microsoft Access software issued at the Site Mobilisation Meeting, for entry onto the ADSSC asset register by others.

6.2 CONTRACT CORRESPONDENCE

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

i. One original and three photocopies of transmittals and letters

including attachments/enclosures, completed on Company letterhead.

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




(ADSSC)

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 nominated

Consultant as required. c) The Contractor can request that correspondence be submitted

electronically through e-mail utilising the ADSSC Project Management Web 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 work of a complexity comparable to the Project and have use of computer facilities capable of delivering a detailed graphic printout within 24 hours of a request from ADSSC.

b) The format of the program report shall be:

i. Prepared in bar chart form and critical path diagram, covering all

stages of the Contract. ii. Prepared on a programming tool such as Primavera, or other

similar software, approved by ADSSC. iii. Dated and ordered sequence of listings and interdependence of

activities, in chronological order of the start of each item of Work. iv. Include conferences, meetings, key milestones, and submittal dates

in the schedules. v. Include a narrative report that defines problem areas, anticipated

delays, 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 a version of AutoCAD to be approved by ADSSC.

b) Full details of any amendments of previously approved working drawings

because of manufacture and installation shall be presented to ADSSC for 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 of the existing site conditions. The number of photographs shall be as




(ADSSC)

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

For Works interfacing with existing operational plant, the Contractor shall

agree the above series of photographs with ADSSC. b) The Contractor shall supply one print of each photograph and forward

these to ADSSC for approval. After approval, three sets of prints shall be labelled and mounted in separate albums by the Contractor. In addition, one copy of the CD-ROM containing software versions of the photographs shall be provided to ADSSC.

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

c) More photographs shall be taken to include site and installation work

throughout progress of the Contract produced by an experienced photographer and be approved by ADSSC.

d) At the end of the Contract, the Contractor shall provide ten (10) colour

photographs framed 60×30 cm previously selected by ADSSC. e) Photographs taken under the provision of the Contract shall not be used

for commercial advertisement either of the Contractor’s organisation or of any materials or equipment used on the Works without the written approval 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 mechanical component, cables and wiring etc. in order to ascertain compliance with the specification.

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

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

b) Unless otherwise accepted by ADSSC, samples will only be considered

if taken at random. ADSSC shall witness the selection of samples. Inspection or tests of items or materials that fail shall be sufficient cause to terminate further inspections/tests of the same brand, make, or source of 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 to be conducted under the terms of the contract.




(ADSSC)

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

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

c) The Contractor shall develop, implement and maintain a Quality Control

Program (QCP) that assures equipment and material conformance to the applicable requirements of every section of the specification. Documentation shall include an organisation chart, plans, and procedures, detailed work instructions and records.

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

i. To implement the QCP, specify responsibilities assigned, and

clearly delineated individual job authorities. ii. To identify potential quality problems with work or materials, and

appropriate directions for solving and reporting such problems. iii. To establish preventive measures and maintaining effective QC

practices in all areas of the project. iv. To define the methods and responsibilities for the identification,

documentation, control, and processing of non-conforming equipment 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 than

four weeks from the start of the Contract. The number of copies shall be as stated in the particular requirements.

g) No work covered by the QCP shall start until approval has been granted

by ADSSC. 7. PLANT AND EQUIPMENT

7.1 RESISTANCE TO CORROSION

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

b) All materials utilised in the plant shall be the most suitable for the duty

concerned, shall be new and of first class commercial quality and be selected to eradicate or reduce corrosion to a minimum. Steel items requiring corrosion protection to be in accordance with Section 15004: Corrosion Protection.

c) Particular attention shall be paid to material selection to minimise

corrosion 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 but

where 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 be

avoided wherever possible but where this has to be used, all woodwork shall 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 unsuitability for the purpose for which they are installed, they shall be replaced, at no cost to ADSSC, notwithstanding that they may otherwise be working in a satisfactory manner.

7.2 STRUCTURAL STEELWORK

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

b) The design of structural steel work to be in accordance with Section

15003: 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 and guaranteed free from defects in materials, design, and workmanship. It shall be the manufacturers’ responsibility to ascertain the conditions and service under which the equipment will operate and to warrant such operation trouble-free in service and meeting the specification.

b) All equipment shall be designed, fabricated, and assembled in

accordance with the best modern engineering and shop practice. Individual parts shall be manufactured to standard sizes and gauges so that repair parts, furnished at any time, can be installed in the field. Like parts of duplicate units shall be interchangeable.

c) Iron castings shall be tough, close-grained grey iron, free from

blowholes, flaws or excessive shrinkage. d) Except where otherwise specified, all structural and miscellaneous

fabricated steel used in items of equipment shall conform to the appropriate standards specified. All structural members shall be considered as subject to shock or vibratory loads.

e) All parts of the equipment shall be amply proportioned for all stresses

that may occur during fabrication, erection, and stalled, intermittent or




(ADSSC)

continuous operation.

f) Unless otherwise specified, stainless steel that will be submerged all or

in part during normal operation shall have a minimum nominal thickness of 6mm and be of at least Grade 316L.

g) The Contractor shall provide ADSSC two weeks notice of the start of

production of fabricated and cast items and shall provide the shop schedule in order that ADSSC can schedule shop inspections, if required.

h) The use of dissimilar metals in contact is to be avoided, but where

unavoidable they are to be selected such that the natural potential difference between them does not exceed 250mV. Electro-plating or other treatment of contacting surfaces is to be employed as necessary to reduce 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 optimum selection requiring 3,000rpm drives, an alternative selection running at 1,450rpm (if possible) shall also be priced using duplicates of the tender schedules and questionnaires.

7.4.2 COUPLINGS

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

7.4.3 SHAFTS

Shafts shall be of high tensile steel or stainless steel. To reduce stress concentrations, section changes on the shaft shall be properly radiused at the root of any steps and keyways shall be internally radiused or gradually run out. The shaft shall have its first critical speed well above maximum operating speeds.

7.4.4 TRANSMISSIONS

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




(ADSSC)

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 not

employed in the assembly of the plant, locating dowels shall be fitted on completion of erection and alignment. Fitted bolts shall be identified by means of stainless steel tags installed under the bolt head.

d) Gearboxes shall be helical spur or worm and wheel reduction gear

trains. A gear case of robust cast iron construction shall be provided with a large inspection cover, oil breather and oil level indicator for routine maintenance and inspection.

e) Gearboxes shall be oil bath lubricated; the system being designed to

ensure that all the gears receive adequate lubrication, particularly with gearboxes mounted on an inclined plane. All gearboxes shall be capable of being emptied by gravity.

f) All gears shall be amply designed for both surface durability and bending

strength. Gearboxes shall be rated to match the maximum rated output of the motors as specified and shall be capable of transmitting maximum motor torque in the partially-stalled condition.

g) Jacking screws shall be provided, where required, to enable gearboxes

to be accurately positioned in all three principal axes. Suitable support plates shall be welded to the supporting steelwork to carry the gearboxes. The top surface of the plates shall be machined after welding in position to ensure an even bearing for the gearbox base plates. Allowances shall be made for inserting shims (up to 1.5mm in thickness) between the support plates and the gearbox base plates to ensure even support of the gearbox.

7.4.5 VIBRATION

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

7.4.6 GUARDING OF SHAFTS

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

b) Shaft guards shall extend the whole length of shafting and include

hinged 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 pump station structure. The other half is to be fitted with the hinged access. Brackets and securing arrangements for guards shall be of substantial construction. All mild steel used in the production of guards, including bolts, nuts, washers and brackets shall be hot dipped galvanised and finish painted to match the pump and motor.

7.4.7 BEARINGS

Bearings shall be capable of taking all radial and axial loads resulting through the normal and extreme conditions. Class of fit, bearing clearance classification 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 repair of castings shall be submitted to ADSSC for approval.

b) All major stress-bearing forgings shall be made to a standard

specification and be subject to internal examination, non-destructive tests for the detection of flaws and heat treated for the relief of residual stresses. ADSSC may inspect forgings at the place of manufacture with a representative of the Contractor.

c) All castings shall be of standard grey close grained to BS 1452 (or

equivalent) Grade 220 or better and be sound and free from defects, non-metallic inclusions or blowholes. All non-machined surfaces shall be carefully fettled and all foundry irregularities removed.

7.5 STAINLESS STEEL

Stainless steel shall have a resistance to atmospheric corrosion not less than that provided by BS EN 1461 or equivalent Grade 316 S13 or by BS EN 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-EP aluminium alloy, as appropriate, for the sections, plate, sheet and other forms employed.

7.7 CONTACT WITH POTABLE WATER

All materials used in contact with potable water shall be approved by ADDC under Statutory Water Regulations for use in connection with the Supply of Water for Drinking, Washing, Cooking and Food Purposes.




(ADSSC)

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 and equipment for the maintenance of all plant included in the Contract. They shall be contained in a clearly labelled hardwood box with hasp and staple suitable for padlocking.

b) Any special tool provided for the operation and maintenance of the

Works shall be supplied and handed over to ADSSC. Prior to handover, ADSSC and Contractor shall examine the tools that have been used during plant erection to ensure that they are not damaged and are in good condition.

c) Recommended tools, including any special tools, gauges, jigs or

extractors that may be required for maintenance of the Works shall be set out in the appropriate technical schedule and be clearly referenced in the O&M Manual.

7.9 FIRST FILL OF LUBRICATION

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

b) The Contractor shall supply flushing oil for each lubrication system when

an item of plant is ready for preliminary running and a sufficient quantity of the approved lubricants for setting to work for the commercial operation of the plant for one year after the Takeover Certificate has been issued.

c) A complete schedule of recommended oils and other lubricants shall be

provided by the Contractor; the number of different types of lubricants being kept to a minimum. Where possible, lubricants shall be chosen from those manufactured and available in UAE and deviation from this being approved by ADSSC. In the case of grease-lubricated roller bearings for electric motors, lithium-based greases are preferred.

d) Where lubrication is effected by means of grease, a pressure system

shall be provided which does not require adjustment or recharging more than once monthly. A grease system having a shorter period than monthly between greasing is not acceptable. Lubrication must be provided to cope with the 30 days between replenishment. Where necessary for accessibility, grease nipples shall be placed at the end of extension pipes and when a number of such points can be grouped conveniently, the nipples shall be brought to a battery plate mounted in a convenient 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 provided changed with the first fill of grease.

f) When more than one special grease is required a grease gun for each

special 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 show the level at all temperatures likely to be experienced in service. The normal maximum and minimum levels at 20ºC shall be clearly visible in the sight glass from the normal access floor to the particular item of plant.

h) All lubrication systems shall be designed so as not to present a fire

hazard 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 a

stores exposed to the local ambient conditions specified earlier in Chapter 3. Each spare part shall be clearly marked or labelled on the outside of its packing with its description and purpose and when more than one spare is packed in a single case a general description of its contents shall be shown on the outside and a detailed list enclosed.

7.10 LIFTING EQUIPMENT

To be in accordance with Standard Specification Section 15230: Lifting Equipment.

7.11 ELECTRICAL CONTROL PANELS

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

b) MCCs shall be fully factory equipped, tested and tagged ready to

interface with communication devices such as telemetry, remote terminal units, instrumentation and other microprocessor-based controllers as specified in the extent of Works and other specification sections.

c) A complete system of interlocks and safety devices shall be provided, as

necessary, for the safe and continuous operation of all installed plant and equipment in order to provide for the following:

i. Safety of personnel engaged in operation and maintenance of the

plant. These interlocks shall be mechanical. ii. Correct sequence of operation of the plant during start up and shut

down. iii. Safety of the plant when operating under normal or emergency

conditions. 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 be provided.

vi. Change numbers that are to be arranged to ensure that there is no danger of interchange with existing locks on other units.

7.12 INTERFACE WITH EXISTING PLANT

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

b) The Contractor shall ensure that when interfacing with existing

operational plant and equipment the method of work employed and the timing of such work will not disrupt the operation of the Works, unless otherwise agreed with ADSSC.

c) Each item of equipment, component or assembly shall have been

proven in service in a similar application and under conditions no less than those specified therein. References may be requested by ADSSC to 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&M procedures.

7.13 CONCEPT OF PLANT CONTROL

a) The general concept of the plant control system shall be that of a fully automatic works that will be manned only by exception. The plant shall be capable of being operated across it’s range according to local or remotely entered control set points or schedules on the HMIs and/or SCADA as appropriate.

b) On mains power failure, the plant shall revert to a safe condition and a

power fail alarm shall be reported to the RTS outstation. This “fail-safe” procedure must also operate on failure of the standby generator (if installed).

c) On mains power recovery, after a pre-defined delay to allow stabilisation of

the supply, the plant shall automatically restart.

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

7.14 MODELLING OF PUMPING STATION PERFORMANCE

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




(ADSSC)

Supplier shall cooperate with the Contractor to construct a fully operational 1/10th scale model of the installation to determine the pumping station performance at a range of flows. The model shall be utilised to specifically determine the following:-

a) Grit deposition. b) Screenings settlement. c) Initiation of eddy currents in the pumping station under all combinations of pump operations.

8. DOCUMENTATION REQUIREMENTS

8.1 GENERAL

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

b) All drawings and documentation produced by the Contractor's Sub-

Contractor shall be checked, signed and given a contract reference/document number/drawing number (as appropriate) by the Contractor before submitting to ADSSC.

c) All drawings and documentation shall be checked by the designated

designer and approved by the Contractor’s Representative on complying with the ADSSC requirements prior to submission to ADSSC for approval.

d) All drawings, documents, schedules and datasheets and other

miscellaneous information – collectively described as documentation – shall conform to the requirements of Section 16670: Documentation Format.

8.2 DRAWINGS

8.2.1 DRAWING REQUIREMENTS

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

i) The civil, structural, hydraulic and geotechnical engineering and

services, building, landscaping and any other services illustrating the full extent and detail of the Works to be undertaken including modifications to any existing installation(s).

ii) Plant and general arrangement drawings and area layout drawings showing locations of equipment, structures, enclosures, routing of pipework, cabling and transmission, tubing, tapping points, etc.

iii) Detailed plant and equipment drawings. Such drawings shall




(ADSSC)

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 and efficiency curves. Pump characteristic curves shall be superimposed on hydraulic profiles of system curves.

v) Detailed interface drawings with any existing equipment, if applicable.

vi) Process/engineering flow diagrams, which are schematic diagrams of the equipment, pipework and control systems making up the Plant 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, Instrumentation

and 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. One schematic diagram covering a number of similar circuits is not acceptable. The diagrams shall include the following:

i) A schedule of apparatus, including an explanation of any symbols

or 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 associated

equipment 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 and for 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 be

drawn as viewed from the normal working position with the door opened. Separate wiring diagrams (diagram of connections) shall be provided for each control cubicle. One wiring diagram covering a number of similar control cubicles is not permitted.

f) Diagrams of the earthing arrangements in accordance with Section

16340: Earthing and Bonding. g) Multicore cable/tubing routing. Overall plot plans show the locations of

the main junction boxes and the routing of the multicores. Where applicable, cable trench/duct cross section and cable tray layouts shall also be shown.

h) Junction box layout drawings showing details of individual junction boxes

location, 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 mounting

arrangements for the various instruments, with an itemised material list for each arrangement.

l) Potentially Explosive Atmosphere drawings to IEC 60079-10 or

equivalent. Sufficient information shall be provided by the use of plan, side elevations and sections to indicate the zone boundaries for each individual installed process or item.

m) General arrangement of the site, structures, buildings, roads, access

provision, pipelines and services. n) Sections through the Works, hydraulic and geotechnical sections and

excavation ‘cut’ and ‘fill’ sections. o) Piping diagrams including the enclosure pipe runs, the routing of air

headers and transmission tubing. p) North point, level datum setting out details as may be applicable for the

full referencing of the Works. q) For structural steelwork, the Contractor shall prepare shop drawings

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




(ADSSC)

between shop and site connections.

r) Drawing Register

i. Each drawing submission shall be accompanied by a drawing register to identify each design drawing submitted and their respective amendment state. The register shall be in tabular form indicating: drawing reference; title; amendment state and approval dates, including a record of previous issues together with the respective dates of approval.

8.3 DOCUMENTATION

a) In addition to Drawings, the following documentation shall be provided by 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 proposed

design, 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 test undertaken, and shall be as detailed on the relevant test proforma as issued 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/rejection ix. Retesting required (if applicable).

9. FACTORY ACCEPTANCE TESTS

9.1 GENERAL

a) All products shall be works tested as required by the Specification and by the manufacturer’s quality control procedures.

b) All products shall be subjected to inspection, examination and witness

testing by the ADSSC or its representative unless waived by ADSSC. The Contractor shall inform ADSSC of the date when the product(s) will be ready for works inspection and witness testing.

c) Unless otherwise stated, ADSSC shall witness the inspection and testing

of fabricated equipment and/or Factory Built Assemblies at the factory. The Contractors and Manufacturers costs of such inspections and tests shall be borne by the Contractor, unless otherwise stated.

d) The Contractor shall notify ADSSC 4 weeks prior to such tests, so that

preparation for travelling to the factory inspection and testing can be arranged.

e) Where specified, the Contractor shall provide prepaid air travel, hotel

accommodation, surface travel and other advanced arrangements for designated personnel from ADSSC to witness the manufacture or testing of plant and associated systems. Airline transportation shall be, as a




(ADSSC)

minimum, full fare economy class. Hotels shall be single rooms, minimum of 4 stars following a recognised grading criteria. Surface transportation shall be by rental car or similar private means. The Contractor shall also provide a per diem amount for subsistence equal to 1,000Dhs per person per day. The full cost of the programme shall be borne by the Contractor and shall be included in the unit price of the equipment, or system indicated in the Contract schedule of prices.

f) Prior to the witness test, the Contractor shall assure ADSSC that the

equipment requested for inspection and testing has already been thoroughly tested by the manufacturer. Provisional Test Reports of such tests, showing that the plant has past such tests shall be submitted to ADSSC prior to the works witness test.

g) Where tests and inspections have been completed to the satisfaction of

ADSSC and when test certificates, tabulated and graphical results, etc. have been checked, ADSSC shall confirm acceptance. The plant shall not be incorporated in the Works and made ready for delivery until this acceptance has been received.

h) Successful works witness testing shall allow the manufacturer to deliver

the equipment to the site, but it does not constitute final acceptance or approval of the equipment. Such approval will only be granted on successful completion of final testing during commissioning tests of the installed equipment.

i) If works tests are beyond the resources of the manufacturer, the

Contractor shall state another location for these tests to be conducted in the appropriate tender technical schedules.

j) During the course of the contract, additional testing, or retesting may be

requested by ADSSC to prove that the plant, equipment, product, material or workmanship meets the specification. Such tests will be at no extra cost to ADSSC.

k) When required by the Specification or ADSSC, testing of products shall

be undertaken by an independent organisation or national organisation. l) Test results shall be submitted to ADSSC for approval in accordance

with the Submittals section of this specification. m) The Contractor shall carry out tests as stated in the current appropriate

British Standard and/or Harmonised European standards or other approved equivalent standard.

n) All test certificates, curves, supporting engineering calculations,

drawings and documentation, etc. shall be submitted to ADSSC within two working weeks from the date of completion of any witnessed tests.

o) Equipment that fails witness testing shall be subjected to retest. All

costs involve rearranging the test, including the ADSSC costs, shall be




(ADSSC)

borne by the Contractor. An extension of time for the preparation and retesting will not be allowed unless approved by ADSSC.

p) Testing equipment and instruments used during witness testing shall

have been recently calibrated and comply with the appropriate testing standard and safety regulations and/or requirements for the safety of the Plant and the men working thereon. The test equipment furnished by each Contractor shall have a calibration tag of an acceptable calibration service.

9.2 FACTORY BUILT ASSEMBLIES (FBAS)

Testing of FBAs shall be in accordance with Section 16020: Factory Built Assembly (FBA).

9.3 PUMPSETS

a) Pumpsets shall be subjected to a works test to ensure that they function correctly, perform to the guaranteed duty, and are manufactured and supplied to the specification.

b) For all pumpsets regardless of size, type test certificates shall be

submitted as indicative of the pumpset performance. Where such certified evidence is not available, a letter of intent from the testing authority shall be submitted.

c) Each pump shall be statically and hydraulically tested at the works to a

pressure at least 50% greater than the maximum working pressure it will incur on site. During the test, the pump shall show no signs of leakage or failure of any components.

d) Each pump shall be tested with its own motor supplied from its soft

starter or variable speed controller at the manufacturer's premises to show the plant is capable of achieving the guaranteed duty point values as detailed in the Contract. Site conditions shall be simulated as near as possible, particularly the suction conditions.

e) Pump characteristic curves shall be produced for the following:

i. Head/Quantity. ii. Power Absorbed/Quantity. iii. Overall Efficiency/Quantity. iv. NPSH Required/Quantity.

f) Contrary to ISO 9906: 2000, the overall efficiency of each combined

motor-pump derived in accordance with the tests shall not be less than that guaranteed.

g) Cavitation tests, as detailed in ISO 9906: 2000, shall form part of the

tests.




(ADSSC)

9.4 ELECTRIC MOTORS

9.4.1 GENERAL

a) General requirements for design, construction and installation of motors are detailed in Section 16000: Electric Motors.

b) Where required by the Contract, each motor shall be tested in

accordance with BS 4999 Part 143 or equivalent to ensure that it functions correctly and is supplied to according to the specification.

c) When required by the Contract, basic tests shall be carried out and

duplicate tests carried out on all motors rated at 55kW and above. Routine check tests shall be carried out on all other motors.

d) Motors for use in potentially explosive atmospheres shall be tested in

accordance with ATEX or other similar Testing Organisation procedures. e) Test certificates shall be provided to show details of the insulation

resistances, temperatures, load readings, power factors, efficiencies, slip values, starting performance and any other measurements taken during tests.

f) Calibration certificates for instruments and testing equipment used for all

tests shall be provided. 9.4.2 VARIABLE FREQUENCY DRIVES (VFDS)

a) Testing of VFDs shall also be in accordance with Section 16130: Variable Frequency Drive (VFD).

b) Where required by the Contract, motor driven plant, when supplied from

a variable speed controller or electronic soft starter, shall be tested with its motor and variable speed controller or electronic soft starter. For pump applications, the procedures described in ISO9906: 2000, BS 599 and BS 4999 or equivalent shall apply. The combined tests shall include:

i. A temperature rise test at rated output. In addition, where motors

are supplied from variable speed controllers at the outputs that relate to the maximum loss of cooling under harmonic generation.

ii. A measurement of starting current. When this test is carried out at a reduced voltage due to limitation of test plant, due allowance shall be made for the effects of saturation when deducing the value at nominal voltage.

iii. A high voltage and insulation resistance tests and where required by the Contract polarisation index.

9.5 DIESEL GENERATORS

a) Generator sets shall be in accordance with Section 15060: Diesel




(ADSSC)

Engine Generator System and be subject to inspection and testing at works before despatch, with the Contractor giving a minimum of two working weeks notice to ADSSC.

b) Alternators and diesel engines shall first be tested by the alternator

manufacturer and engine manufacturer respectively for each set supplied. Such tests shall not be witnessed.

c) The complete diesel alternator set shall be tested with its own exhaust

system and alternator using a load bank resistor, with site conditions simulated as near as possible. This test may be witnessed, and the Contractor shall give a minimum of 4 weeks notice of this to ADSSC.

d) The local control panel shall be visually inspected with routine and

functional tests carried out on control systems to ensure full compliance with the specification.

e) Preliminary running checks and adjustments shall include the following:

i. Engine Start/Stop Controls. ii. Engine Oil Pressure. iii. Nominal Frequency and Voltage. iv. Oil and Water Leaks. v. Undue Vibration. vi. Performance checks with the rated load applied to the alternator.

Engine speed and output voltage shall be adjusted to their rated values and recorded, including overload capability checks and off load checks.

vii. Load Acceptance Tests carried out by applying a single step load of 60% of the rated load.

viii. Speed Governing and Voltage Regulation tests from no load to 110% load.

ix. Load Duration tests, with the rated load applied for one hour. During the load duration tests, checks shall be undertaken for fuel, oil and water leaks, and all parts of the plant investigated for excessive temperatures.

x. Checks and tests, figures for voltage, frequency (or speed) load current, oil pressure/temperature and coolant temperature shall be recorded. In the case of the load duration tests, records shall be kept at 15-minute intervals for the duration of the test. Insulation resistance values at the end of the tests shall be recorded and compared with the values recorded by the alternator manufacturer.

xi. When detailed in the particular specification, load testing shall be undertaken utilising the connected load available at the site.

f) Once commissioning and setting to work procedures are complete and

the electricity supply is available, the manufacturer (or qualified representative in UAE) shall attend site to perform tests before completion. Such tests shall last one day and shall consist of simulating supply failure and the transfer of load to the diesel alternator plant. Four simulations shall take place, with the diesel alternator plant allowed to




(ADSSC)

sustain the load for a minimum of four hours total throughout the day.

10. DELIVERY AND STORAGE

10.1 CLEANING AND PROTECTION AT PLACE OF MANUFACTURE

a) Parts shall be cleaned prior to testing at the manufacturer's works. Parts subject to hydraulic test shall be tested before any surface treatment. After testing, all surfaces shall be thoroughly cleaned and dried out prior to surface treatment.

b) Materials and components shall be stored, handled and installed in such

a manner as to preserve their quality and condition to the standards required by the Contract and in accordance with the manufacturers’ recommendations.

c) Bright parts and bearing surfaces shall be thoroughly polished and

protected from corrosion by the application of rust preventative lacquer or high melting point grease before the parts are packed. A sufficient quantity of the correct solvent for removal of the protective compounds shall be supplied and packed with each particular part.

10.2 PROTECTION, PACKING AND TRANSPORTATION

a) Before any plant is despatched from a manufacturer's works it shall be properly prepared and packed, and the Contractor shall give ADSSC at least two weeks notice that these preparations are to commence.

b) Prior to despatch, all plant shall be adequately protected by painting or

by other approved means, for the whole period of transit, storage and erection, against corrosion and incidental damage.

c) The flanges of the pipes, valves and fittings shall be protected by

wooden discs attached by means of service bolts (which shall not be used at Site) or by other approved means.

d) The sleeves and flanges of flexible couplings shall be securely tied.

Cases containing rubber rings, bolts and other small items shall not normally weigh more than 50kg gross.

e) All items of plant shall be clearly marked for identification against the

packing list. f) Every crate or package shall contain a packing list in a waterproof

envelope. A duplicate copy of the packing lists shall be sent by post to ADSSC at site.

g) All crates, packages, etc, shall be clearly marked with a waterproof

material to show the weight, where the slings should be attached and shall have an indelible identification mark relating them to the packing lists.




(ADSSC)

h) The Contractor shall be responsible for making all the arrangements

necessary for the transportation of equipment and plant to site including investigation of the route for bridge clearances, loading etc and for the provision of a police escort, if required. All transportation details shall be submitted to ADSSC for approval.

i) Unless otherwise specified, temperatures up to 75ºC and RH up to

100% shall apply during transport, storage and installation. Equipment subjected to these extreme service conditions without being operated shall not suffer irreversible damage when operated under normal specified conditions.

10.3 DEMOLITION AND REMOVAL OF EXISTING PLANT AND EQUIPMENT

a) The Contractor shall produce a method statement, for approval by ADSSC, indicating the plant removal and/or demolition of structures/supports procedure, and any proposed measures to protect any existing plant and equipment that is to remain, from such removal activities.

b) The Contractor shall conform to any applicable regulatory procedures

when discovering hazardous or contaminated materials. c) Before dismantling plant in sewage channels, tanks at Sewage

Treatment Works, or pumping wet wells and valve chambers at pumping stations, the Contractor shall thoroughly flush out the pumps, wet wells, pumping mains and incoming sewers, and then desludge, clean and appropriately dispose of all surplus water and residuals.

d) All salvageable plant and equipment that is removed shall be cleaned,

disinfected, and made available to ADSSC (such as, but not limited to, the sewage pump guide rails, delivery pipework, valves, fittings, float switches, cables, control equipment, kiosk, basket stone traps, access covers, frames and ladders). Salvaged items, as then agreed with ADSSC, shall be delivered to the Drainage Network Division's warehouse in Abu Dhabi.

e) On Operational sites, the Contractor shall conduct activities with the

minimum risk to or interference with the operation of the Works, and shall maintain safe egress and access at all times.

f) Redundant designated utilities within demolition areas shall be

disconnected and properly capped off. g) Materials that are to be reinstalled shall be retained in a manner to

prevent damage, and stored and protected in accordance with storage requirements specified in this specification.

h) Any remaining debris resulting from demolition work shall become the

property of the Contractor who shall be responsible for its appropriate




(ADSSC)

disposal off-site to an approved tip or otherwise.

i) Relics, antiques, and similar objects shall remain the property of

ADSSC. The Contractor shall obtain direction from ADSSC regarding the method of removal.

10.4 TEMPORARY FACILITIES

10.4.1 ELECTRICITY SUPPLY

a) For the construction of new Works that have no existing electricity supply, a Civil Contractor shall make provision for, and pay all fees and expenses for a temporary power supply from ADDC under a separate Civil Contract. The M&E Contractor shall be responsible for providing a new permanent power supply and shall make all arrangements with ADDC, provide all necessary associated equipment, and pay all fees and expenses for the supply under this Contract.

b) The electrical services of ADDC, provided by the Civil Contractor, shall

be of adequate capacity for all construction tools and equipment generally used by the M&E Contractor without overloading the temporary facilities. The electrical services shall be made available to the M&E Contractor, free of charge, for power, lighting and construction operations of all trades throughout the installation period. The temporary power supply is for installation activities only, and shall not be available for running the permanent plant and equipment (such as pumpsets) during performance tests.

c) For M&E refurbishment of existing works where there is no Civil

Contractor and there is a requirement to uprate or replace the existing electricity supply, the provision of both the permanent and temporary power supply from ADDC shall be the responsibility of the M&E Contractor under this contract.

d) Termination shall be provided complete with circuit breakers, disconnect

switches and other electrical devices as required to protect the power supply system in accordance with ADDC regulations. Adequate distribution equipment and wiring shall also be provided for lighting and power socket outlets.

e) Temporary equipment and wiring for power and lighting shall be in

accordance with the applicable provisions of ADDC and governing codes. Temporary wiring shall be maintained in a safe manner and utilised so as not to constitute a hazard to persons or property.

f) At the completion of the Works, or at such times as ADSSC may direct,

the Contractor shall remove all temporary electrical installations and equipment and replace all worn or damaged parts of the permanent systems, leaving such systems in first-class condition equal to new.

10.4.2 STORAGE AND ACCOMMODATION




(ADSSC)

a) The Contractor shall include for temporary on-site stores, used for the

storage and protecting from the elements, of all materials and equipment prior to their installation. Existing facilities for storage, if available, shall be permitted for use subject to the approval of ADSSC.

b) Plant and equipment shall be stored in accordance with manufacturers'

instructions and seals and labels kept intact and legible. c) Sensitive plant and equipment shall be stored in weather-tight, climate-

controlled enclosures in an environment favourable to the item. Plant stored externally shall be supported off the ground.

d) Petroleum products, paints and other combustible, dangerous or

hazardous goods shall be safely stored to the approval of ADSSC, and shall comply with all rules regulations and orders made by any authorities having jurisdiction. Gasoline and other flammable liquids shall be stored in and dispensed from 'UL' listed safety containers and in conformance with requirements of the Fire Service.

e) The Contractor shall provide, maintain and keep clean, temporary

portable or mobile office accommodation for his staff, constructed with floors raised above ground, securely fixed to foundations, with steps and landings at entrance doors. Permanent facilities shall not be used for field offices unless agreed with ADSSC, or stated in the particular specifications. The building shall remain on site until the issue of the final acceptance certificate.

f) In addition to the above office accommodation for his staff, the

Contractor shall provide, maintain and keep clean one number temporary static prefabricated office partitioned to the approval of ADSSC and having a floor area of not less than 50 square metres for the exclusive use of the ADSSC and their Engineer’s staff.

g) Unless otherwise stated, ADSSC/Engineer's accommodation shall

include for the following, inclusive of furniture fittings equipment and conveniences in the ADSSC/Engineer's office, as listed below:

i. 6No. Double Pedestal Desks. ii. 6No. Side Tables. iii. 1No. Large Plain Table. iv. 6No. High Back, Swivel Arm Chair. v. 12No. Plain Chairs. vi. 2No. Hanging Drawing Cabinet, A0 size. vii. 20 metres of Shelving, 300mm in depth. viii. 5No. Lockable 4-Drawer filing Cabinets. ix. 1No. 6-Drawer plan chest and 1No. free standing drawing

hanging file (both to suit AO drawing size). x. 1No. A3 copier. xi. 1No. Colour computer printer (print up to A3 size). xii. 2No. Fire Extinguishers - 1kg capacity, powder type. xiii. 1No. Wall-mounted First Aid Kit.




(ADSSC)

xiv. 6No. Waste baskets. xv. A telephone connection, switching system type, with an intercom

facility, comprising one main telephone and six extensions. xvi. A separate facsimile connection and facsimile machine. xvii. A private toilet/washbasin room. xviii. A kitchen facilities comprising, 2 metres of free worktop space, 2No.

floor-mounted kitchen cabinets, and 1No. wall cabinet, sink, hot water boiler/kettle, and microwave oven.

xix. Cutlery plates, dishes and mugs for ten people.

h) The Contractor shall also provide the following equipment within the ADSSC/Offices accommodation:

i. 6No. adjustable band protective helmets for visitors. ii. One 250mm outdoor weather thermometer and all levelling and

measuring instruments. iii. Adequate supply of special tools, as required.

i) All site office accommodation shall be installed and ready for occupancy

during the site mobilisation period. j) Both the storage facility and the office accommodation shall be

insulated, and protected from excess temperature transmission, by providing adequate insulating materials to floors, walls, and ceilings.

k) Exterior materials shall be weather resistant, and finished in a colour that

is acceptable to the ADSSC. Interior materials in office accommodation shall be sheet type materials for walls and ceilings, and prefinished or painted resilient material for floors and bases.

l) Lighting for offices shall be adequate at desk top height. Exterior lighting

shall be provided at all entrance doors. m) Fire Extinguishers shall be provided at each end of the offices

accommodation and in the storage area and shall be of an approved type.

n) Offices and storage rooms shall have adequate heating, cooling, and

ventilating for automatic regulation of the working environment conditions.

o) Unless otherwise stated, a site will be allocated to the Contractor to erect

the above temporary site offices and store rooms. The site will be located adjacent to the Works and be shown on the Contract drawings.

p) Unless otherwise specified, temperatures up to 75ºC and RH up to

100% shall apply during transport, storage and installation. Equipment subjected to these extreme service conditions without being operated shall not suffer irreversible damage when operated under normal specified conditions. The Contractor shall ensure that any equipment stored on site prior to installation is appropriately protected from




(ADSSC)

damage.

10.4.3 WORKING CONDITIONS

a) The Contractor shall provide and maintain a temporary lighting system as required throughout the Works that will satisfy the minimum requirements of visibility, safety and security, and shall provide branch wiring from power source to distribution boxes with lighting conductors, pigtails, and lamps as required. The Contractor shall maintain the system in good and safe repair.

b) Permanent building lighting and air conditioning, forming part of the

completed Works may be utilised during installation with the prior approval of ADSSC.

c) The Contractor shall provide and pay for ventilation, cooling and heating

devices and heat, as required, to maintain the specified conditions for installation procedures.

d) The Contractor shall maintain a minimum ambient temperature of 10ºC

and a maximum of 26ºC in areas where installation is in progress, unless stated otherwise.

e) Temporary cooling devices shall be provided as required to maintain

specified conditions for installation operations. Permanent equipment may be used for temporary cooling purposes if approved by ADSSC. Should such equipment be used, the Contractor shall provide and pay for operation, maintenance, and regular replacement of filters and worn or consumed parts.

f) Enclosed plant areas shall be ventilated to provide comfortable working

conditions, dissipate humidity, and to prevent accumulation of dust, fumes, vapours, or gases. Temporary filters shall be utilised to remove dust generated from installation processes to the satisfaction of ADSSC.

g) After fixing of plant and equipment and before testing is undertaken, the

Contractor shall totally cover such equipment with polythene to the satisfaction of ADSSC.

h) At completion of Work, the Contractor shall remove,

redundant/temporary utility services and debris and restore areas to a condition at least equal to that in which it was handed over.

10.4.4 POTABLE WATER AND SANITATION

a) Unless otherwise stated, the Contractor shall provide an adequate temporary supply of potable water at the kitchen sink in both the Contractors and ADSSC’s accommodation, and externally on the site at a convenient point adjacent to the Works, and as agreed with ADSSC.

b) Potable water outlets shall be conveniently located about the Site at




(ADSSC)

ground level for the use of all trades, including Sub-contractors, and drinking water dispensers shall be conveniently located where work is in progress.

c) The Contractor shall provide temporary sanitation facilities for the site

accommodation to the approval of ADSSC. Such facilities shall be either a septic tank and percolating pit or a temporary connection to an existing foul sewer. Such facilities shall comply with all statutory regulations.

d) All provisions for water and sanitation shall meet the requirements of the

Municipal and Health Department of Abu Dhabi. Labour, workers or staff found to be using areas other than these accommodations shall be removed from site immediately.

e) The sanitary accommodation shall comprise a temporary toilet

containing one water closet cubicle for the use of employees, including those of Sub-contractors, each size 1.00x1.50m on plan, with an Asiatic or European WC complete with high-level cistern and a tap for washing purposes.

f) The Contractor shall provide and maintain, up to Final Acceptance

Certificate, adequate daily janitorial services for offices, and stores inclusive of periodic cleaning and maintenance for toilet facilities, washrooms and kitchen facilities, including appliances.

g) Unless otherwise specified in the particular specification, The Contractor

shall pay all fees and expenses for temporary water, electricity, sanitation and communication links in respect thereof.

h) Temporary fire fighting equipment shall be provided and maintained in

good order at all times. All Contractors personnel shall be trained in its use. The type, location and sufficiency of the fire fighting facilities and equipment shall be to the approval of ADSSC and in accordance with the ADSSC Health and Safety manuals.

10.4.5 SITE ACCESS, PARKING, OUTSIDE STORAGE AND WORKING

CONDITIONS

a) The Contractor shall have access to the site for the duration of the Contract and the Maintenance Period and shall take all necessary steps to ensure the safety of persons on the site. Use of the site shall be restricted to the purposes of this Contract only and the Contractor must not rent the site, or any portion of it, to others. The site is provided on a temporary basis only and the ADSSC has the right to cancel and/or reclaim the site at any time without reimbursement of any costs incurred by the Contractor.

b) Before commencement of work, the Contractor shall meet with ADSSC

to present and discuss arrangements for the establishment of such measures as may be necessary to provide security and protect the Works from theft, vandalism, and unauthorised entry.




(ADSSC)

c) The Contractor shall maintain site entry control and restrict entrance of

persons and vehicles into the Project site and existing facilities, allowing entrance only to authorised persons with proper identification, and shall maintain a log of workers and visitors, which shall be available to the ADSSC upon request.

d) Unless otherwise stated, the Contractor shall provide a watchperson at

site during daylight hours. Should the Contractor deem it necessary to protect the site and the equipment and materials contained within during the hours of darkness then suitable watchperson(s) shall be provided. The Contractor shall ensure that all items of equipment stored on site is prevented from being damaged or stolen.

e) The Contractor shall not work on Fridays without prior approval of

ADSSC. f) All site areas shall be maintained in a clean and orderly condition, free of

waste materials, debris, and rubbish, which shall be disposed of off-site in an approved manner.

g) On completion of the installation, and prior to commissioning, all site

areas shall be swept and vacuumed, as appropriate to eliminate dust. Polythene covers shall be used to cover and protect plant and equipment from dust, to the satisfaction of ADSSC.

h) An outside storage area to receive delivered plant and equipment shall

be provided by others as detailed on the Contract Drawings. The Contractor shall satisfy himself that the area is adequate for his use at the tender stage.

i) Unless otherwise stated, Project Identification Signs shall be provided

and shall comply with the following:

i. Signs shall be prepared and painted by a professional sign painter, with a minimum of three years experience, and designed to withstand 140km/hr wind speed.

ii. The sign shall be located and anchored to the approval of ADSSC. iii. The signs shall withstand UV light, weathering, fading, and chipping

for the duration of the Works. Damage to the signs due to adverse weather conditions shall be corrected or replaced by the Contractor at no extra cost to ADSSC.

iv. The structure and framing shall be new and of steel construction, structurally adequate and embedded in a concrete foundation.

v. The sign board shall be of exterior grade plywood with medium density overlay, and have a minimum thickness of 19 mm.

vi. The sign background and lettering shall be of approved colours, and paint shall be of exterior quality. Two coats shall be applied.

vii. The sign content, graphic design, and style of lettering shall be as indicated on the Contract Drawings, and the lettering shall be sized to provide legibility at 30m distance and include:




(ADSSC)

Project number, title, logo, address, telephone number and name of ADSSC.

Logo, name and address of Consultant. Logo, names and address of the Prime Contractor and his

major Sub-contractors.

viii. Text shall be both in Arabic and English. ix. Safety Notice boards, to the approval of ADSSC, shall be erected in

prominent places at each worksite. x. Signs, framing, supports, and foundations shall be removed on

completion of the Project and the area restored to its original state.

f) Parking, comprising of a hard-surfaced shaded parking spaces for use by the Contractor, shall be provided by others as detailed on the Contract Drawings. The Contractor shall satisfy himself at the tender stage that the area is adequate for his use.

g) All construction operations and site establishment facilities shall be

confined to within the Site boundaries unless otherwise approved by ADSSC and the relevant authorities. Following such approvals, all such areas shall also be designated and treated as included within the Site.

h) The Contractor shall be responsible for safeguarding all structures and

the like near the Site. In addition, he shall ascertain from the public utility authorities, positions of all existing underground services and he shall maintain and protect or divert them as required.

11. INSTALLATION

11.1 SITE CO-ORDINATION

a) The Contractor shall coordinate the scheduling, submittal, and work of the various sections of the installation and testing process, as scheduled in the approved program of work, to ensure efficient and orderly sequence of installation of interdependent installation/construction elements. Such coordination shall include:

i. Verification of compatibility with existing plant, equipment and

buildings. ii. Coordination of space requirements, supports, and installation of

the work. iii. Ensure that routing shown for pipes, ducts, and conduit, are

followed as closely as practicable and that spaces are efficiently utilised to maximise accessibility for other installations, for maintenance, and for repairs.

iv. Coordinate locations of fixtures and outlets with the ADSSC Operation and Maintenance Section.

v. Coordinate completion and clean up of Work of separate sections in preparation for Substantial Completion and for portions of Work designated for the ADSSC partial occupancy.




(ADSSC)

vi. For operational sites, the Contractor shall ensure that his activities

will not disrupt the ADSSC activities, or the performance of the process.

vii. Prior to the Contractor mobilising on site for installation of plant and equipment, a pre-installation meeting shall be held at site with representatives of ADSSC, the Contractor and Sub-contractors (where deemed appropriate by ADSSC). The agenda shall include:

Joint inspection of Site/Works with the Civil Contractor (New

Works under construction, extensions requiring extensive Civil works), and ADSSC (Refurbishment/extension to existing operational works).

Observe and record conditions, obstructions and special features.

Take photographs of salient features. Identify and record the existing performance of plant, equipment

and processes that are to remain. 11.2 PROGRESS MEETINGS

a) ADSSC shall schedule and administer frequent meetings throughout the progress of the installation and testing work.

b) ADSSC shall make arrangements for meetings, prepare the agenda with

copies for participants, and will chair and preside at the meetings. c) Representatives of the ADSSC, Contractor, M&E Coordination Engineer,

Sub- contractor, Supplier, etc. as appropriate, shall attend the meetings as required by ADSSC (dependant on the agenda topics for each meeting).

d) ADSSC shall record minutes and distribute copies to all participants and

those affected by decisions made within one week after the meeting. e) Table 1 and Table 2 given at the end of this section shall be the means

of recording Minutes of Meeting held during pre-installation and coordination progress meetings.

f) Installation of plant and equipment shall be undertaken by suitably

skilled craftsmen and technicians, experienced in the installation of the types of equipment specified. Such personnel shall be approved by the ADSSC.

g) Work shall be undertaken by methods that minimise raising dust from

installation operations and positive means shall be provided to prevent air-borne dust from dispersing into the atmosphere.

h) Methods, means, and facilities shall be adopted to minimise noise

produced by installation operations. i) Methods, means, and facilities shall be adopted to prevent pests,




(ADSSC)

rodents and insects from accessing and damaging the work.

j) Methods, means, and facilities, shall be provided and adhered to so as

to prevent contamination of soil, water, and atmosphere from discharge of noxious, toxic substances, and pollutants produced by Works activities.

k) The method of working to be adopted shall be such as to permit the

satisfactory completion of the Works, accommodate the requirements of other Contractors, and limit disturbance to operational sites. ADSSC may at any time withdraw his approval to the Contractor's method of working and the Contractor shall immediately adopt another method of working, and if such change shall be required to achieve satisfactory progress or workmanship the Contractor shall have no claim against ADSSC for costs incurred by him in changing the method of working, or in the provision and use of other plant or equipment, whether permanent or temporary.

l) Notwithstanding the contents of the Conditions of Contract (in particular

those clauses referring to Progress and Delays) the Contractor shall ensure that there shall be no delay or disruption of the Works programme as a result of his requesting a change in materials programme or design, whether or not such a change is approved by ADSSC.

m) Works shall be deemed to be insured against damage in accordance

with the Conditions of Contract (in particular the clauses referring to Insurance).

n) Specialised tools and equipment, such as precision machinist levels, dial

indicators, gauges, and micrometers, shall be utilised as applicable, to achieve the required quality and accuracy of installation, free of vibration or other defects.

o) The placing of anchor bolts and other fixings shall be agreed with

ADSSC before structural concrete is altered or placed. p) Grouting shall be placed after completion and approval of initial fitting of

plant and equipment and alignment of connected piping etc. q) Unless otherwise specified, the Contractor shall be responsible for

grouting in the plant and equipment to concrete foundations and structures. Spaces under support feet, bedplates etc. shall be entirely filled with grout.

r) The edges of grouting shall be neatly finished at 45° angle, except round

exposed grout at horizontal surfaces for drainage. s) Alignment of plant and equipment shall conform to the tolerances given

by the manufacturers in the applicable installation instructions given in their instruction manuals. Such instructions shall be approved by




(ADSSC)

ADSSC.

t) Unless otherwise stated, the Contractor shall arrange for each

equipment manufacturer to provide the services of an authorised representative, especially trained and experienced in the field of the equipment supplied and installed to:

i. Ensure that the equipment is installed in accordance with the

approved manufacturer’s instructions. ii. Ensure the presence of a manufacturer representative when the

equipment is first put into operation. iii. Inspect, check, adjust as necessary, and provide written approval for

the completed installation. iv. Repeat inspections, checking, and adjustments until all problems or

defects are corrected and the equipment installation and operation are acceptable to ADSSC.

v. Witness operational demonstrations and system validation tests to the extent specified.

vi. Prepare and submit the specified manufacturers' certified report for satisfactory and safe installation.

vii. Train the ADSSC O&M personnel on the safe operation and maintenance of the Works.

viii. Should the Contractor fail to reinstate existing structures and plant and equipment adequately and promptly, ADSSC reserves the right to carry out the reinstatement by others and deduct the cost of this work from the Contract payments due to the Contractor.




(ADSSC)

Table 11.2.1

PRE INSTALLATION CONFERENCE AGENDA

No. Description Action 1.0 Apologies 2.0 Minutes of Handover Meeting 3.0 Staff Appointments 4.0 Programme 5.0 Notices of Intent 6.0 Mobilisation/Offices etc 7.0 Procedures/Requirements 7.1 Correspondence 7.2 Work Methods 7.3 Work Inspection/Approval 7.4 Work in Hazardous Areas 7.5 Access to Security Areas 7.6 Drawings 7.7 Materials 7.8 Records 7.9 Additional Works

7.10 Dayworks 7.11 Claims 7.12 Interim Valuations 7.13 Monthly Progress Reports 7.14 Quality 7.15 Insurances 7.16 Special Requirements 7.17 Safety, Security and Welfare Obligations 7.18 Progress Meeting Schedule 7.19 Immediate Priorities 8.0 Next Meeting




(ADSSC)

Table 11.2.2

CO-ORDINATION PROGRESS MEETING

No. Description Action 1.0 Minutes of Previous Meeting 2.0 Progress 3.0 Progress vs Programme 4.0 Programme 5.0 Site Safety, Security and Welfare 6.0 Staff Matters 7.0 Labour and Plant Returns 8.0 Working Hours 9.0 Co-ordination with other works

10.0 Sub-Contractors 11.0 Work Methods 12.0 Materials 13.0 Drawings 14.0 Site Instructions 15.0 Financial 16.0 Handover 17.0 Any Other Business 18.0 Next Meeting 19.0 Attachments:

20.0 Drawings:

21.0 General Comments/Remarks




(ADSSC)

12. COMMISSIONING

12.1 EQUIPMENT INSTALLATION

a) Tests shall be carried out to ensure that all equipment such as gearboxes, shafts, couplings, chain and belt drives and motors are correctly aligned and levelled before doweling and grouting takes place.

b) Before coupling bolts are inserted, alignment checks shall be carried out

to ensure that coupling concentricity and angularity are within the limits recommended by the coupling manufacturer.

c) Before chains or belts are fitted, alignment checks shall be carried out to

ensure that chain wheels, guides and pulleys are aligned within the manufacturers recommended tolerances.

d) On completion of the installation, before power is applied, and if viable,

assemblies shall be manually rotated to ensure unobstructed and safe operation.

e) Plant and process control systems and all associated electrical

equipment and control devices, shall be tested to demonstrate that the completed system operates as specified and that all protection devices are working correctly before the plant and equipment is put into operation.

f) Unless otherwise agreed with ADSSC, each manufacturer's technical

representative shall be present at the start of the operational demonstrations to examine their equipment at the beginning and end of the tests, and will supervise the start-up, calibration and adjustment procedures and other services necessary for the correct testing of the installed equipment and systems.

12.2 SITE ACCEPTANCE TESTS

a) Site acceptance tests shall commence after satisfactory completion, and approval by ADSSC, of the commissioning tests.

b) Site acceptance of plant and equipment may be dependent on the

completion of other contracts, operation of existing works, or a planned commissioning schedule for complex works, as determined by ADSSC.

c) Sewage treatment plant and sewage pumping stations shall be

commissioned with sewage or effluent, as applicable, and the Contractor shall supervise the working of all necessary engineering and technical supervision continuously to effect any adjustment that may be necessary. All equipment and components of each system shall have successfully completed the required operational demonstration before the system is validation tested. Validation testing shall be undertaken in accordance with the manufacturers’ instructions.




(ADSSC)

d) The whole of the Works and plant shall be tested over its whole working

range to demonstrate that it has been installed correctly and is safe and reliable in operation under the specified conditions at site. Unless otherwise specified, all plant and equipment shall run trouble free for a continuous period of fourteen days in automatic operation with no interruptions except for normal maintenance or corrective work. Should the plant and equipment not run trouble free or run outside the specified guaranteed duties then the the plant and equipment shall be adjusted by the Contractor and the seven fourteen day tests shall be repeated until the plant and equipment passes the test.

e) During the tests before completion all plant shall operate satisfactory.

Satisfactory operation shall mean operating safely at the guaranteed duty and efficiency without adversely overheating, overloading, vibrating or exceeding specified noise levels. During the tests simulated alarm conditions and distressed operating conditions shall be simulated to test plant control systems and protective devices for correct operation in either adjusting system functions or causing safe plant and system shutdown.

If any defect is detected during the ‘Tests on Completion’ or during the maintenance period (which shall be a period of 12 months or as defined by the particular specification), the faulty equipment shall be rectified immediately by the Contractor at his expense. If the fault cannot be rectified the Contractor must replace the defective equipment which must also be proven to be free from defect.

f) All the Works shall be examined at the conclusion of the ‘Tests Before

Completion’ to establish that all the plant and equipment is free from damage and undue wear. This inspection shall be considered as part of the ‘Tests before Completion’. The plant shall be considered to have failed such tests if there is any detectable damage or undue wear.

g) The Contractor shall correct all defects and malfunctions disclosed by

tests using approved methods and new materials for repairs as required and within the time for tests specified in the Contract and at his expense and in the time stipulated in the Conditions of Contract. If the fault cannot be rectified, the Contractor must replace the defective equipment that shall also undergo all the preceding tests.

h) All flow metering systems, liquid level/differential measuring systems,

pressure measuring systems, dissolved oxygen measuring systems, chemical metering and mixing systems and any other metering or measuring system shall be tested across their entire operating range, minimum through average to maximum flows. Low-low and high-high level alarms and system reaction shall also be tested where equipment or instruments are required to react to such conditions.

i) Remotely controlled plant and equipment shall demonstrate suitable

operation both from local controls and remote controls. As a minimum, these procedures shall include fully opened and fully closed positioning




(ADSSC)

and shall demonstrate the ability of each valve to hold the set position under operating conditions throughout the specified operating range of the process.

j) Variable frequency Equipment shall demonstrate accurate response to

speed controlling devices and controls within the specified operating range. During such tests, actual output shaft speed shall be validated by mechanical measurement of shaft speed to compare actual speed with equipment instruments.

k) Instruments, gauges and other sensors and display devices forming part

of the completed installation shall be properly calibrated before the tests begin and may be used to measure and record the test data. The Contractor shall provide any other test equipment required for the duration of the tests.

l) The Site Acceptance Tests shall be carried out under the control of the

Contractor's staff and the supervision of ADSSC. m) The Contractor shall make all arrangements to conduct an Integrated

Site test. The preferable source of power to conduct the test shall be that supplied by the Authority’s Electric Power Network. In the absence of a delayed Authority’s Electric Power Network connection, the Contractor shall arrange for a mobile generator to be used for the duration of the test. The hire cost of such a generator shall be proven to be at competitive market prices, and approved by ADSSC before proceeding.

n) The Contractor shall prepare pre-commissioning and testing reports to

ADSSC for approval prior to any site test to be witnessed by ADSSC. The Contractor shall allow one week for ADSSC to review such reports which shall show that the plant and equipment has been installed correctly and given a pre-run to show mechanical and electrical integrity.

12.3 TRAINING

a) The Contractor shall provide training during the commissioning and Tests on Completion in the operating and maintenance of the plant and equipment for up to five personnel. Training shall be undertaken using the services of qualified personnel from the various system supplier/equipment manufacturers. The training shall include instructions covering basic system operation theory, routine maintenance and repair, safety, and "hands on" operation of the equipment and associated materials. The training program shall be submitted to ADSSC fourteen days before the start of the tests before completion for approval by ADSSC.

b) Training shall include instructions covering basic system operation

theory, routine maintenance and repair, safety, and "hands on"




(ADSSC)

operation of the equipment and associated materials. The training program shall be submitted to ADSSC for approval fourteen days before the start of the ‘Tests before Completion’.

c) Training shall be undertaken using the services of qualified personnel

from the various system supplier/equipment manufacturers.

d) Where specified, for particularly complex equipment and systems, the Contractor and the vendor/manufacturer shall provide a quality control and training programme for ADSSC personnel to be held at suitable locations outside the U.A.E. The programme shall be submitted to ADSSC for approval and be designed to provide training in the proper operations and maintenance of the equipment and components.

12.3 PUMPSETS AND AIR BLOWERS

a) Tests shall be carried out to ensure that pumps have been correctly levelled and aligned before such units are grouted or doweled in position.

b) Before the coupling bolts are inserted, alignment checks shall be carried out to ensure that the coupling concentricity and angularity are within the limits recommended by the coupling manufacturer.

c) On completion of the installation a head/quantity specific power

consumption tests shall be carried out on each pump, singly, in pairs, three pumpsets in parallel and four pumpsets in parallel as appropriate, and the results plotted on suitable graph paper. The instruments to be used for these tests shall be those installed on site as part of the contract.

d) The whole of the pumping installation shall be tested over its whole

working range to demonstrate that it has been erected correctly and is reliable in operation under conditions at site. Unless otherwise specified, all plant shall run for a continuous period of seven days automatic operation, with rotation of standby pumpsets to give equal running times of the whole plant.

e) During the Tests on Completion all valves, pumps, blowers etc shall

operate satisfactorily. Satisfactory operation shall mean operating at the guaranteed duty and efficiency without adversely overheating, overload, vibration or noise.

f) All of the Works will be examined at the conclusion of the Tests on

Completion to establish that all of the plant is reasonably free from damage and wear.

g) If any vibration is detected of the pumpsets during commissioning or

during the maintenance period the fault shall immediately be rectified by the Contractor at his expense.




(ADSSC)

h) If the default cannot be rectified, the Contractor must replace the

defective pumpset with another new pumpset, which must also be proven to be vibration free.

i) Pumps shall be tested to verify that the duty and efficiency is in

accordance with the manufacturer's works test data. 12.4 ELECTRIC MOTORS

a) Tests shall be carried out to ensure that motors have been correctly levelled and aligned before grouted or doweling into position.

b) Before the coupling bolts are inserted, alignment checks shall be carried

out to ensure that the coupling concentricity and angularity are within the limit recommended by the coupling manufacturer.

c) Before the coupling bolts are inserted a rotation check shall be carried

out to confirm that the motor rotates in the desired direction. All safety procedures shall be complied with prior to and during this test.

d) Before initial energising, testing shall include, but not be limited to the

following:

i. Insulation resistance tests. ii. Polarisation index test (where required by the Contract or found

necessary due to low winding insulation levels). iii. Confirm that protection devices work correctly and give the

appropriate alarm and trip signals to the control equipment (winding temperature, bearing temperature, vibration etc.).

12.5 PERFORMANCE TESTING OF PROCESSES

a) The Contractor shall employ the services of an approved independent certified testing laboratory/laboratories to perform performance testing and control testing of systems incorporated into the work or provide an on-site laboratory as required.

b) ADSSC reserves the right to directly employ services of an independent

testing agency or laboratory to perform specified testing.

The Employment of a testing agency or laboratory in no way relieves the Contractor of his obligation to perform the Work in accordance with the requirements of the Contract Documents.

c) Laboratories shall be accredited to a recognised international standard

and shall submit a valid accreditation certificate to be approved by ADSSC, before the testing program is approved.

d) Testing Equipment shall be calibrated at reasonable intervals in

accordance with the manufacturer's recommendations.




(ADSSC)

e) Tests to verify compliance with the Contract requirements shall conform

to the approved QC procedure and undertaken by the qualified personnel specified in the Contract. Substitutions to the personnel specified in the Contract shall be submitted to ADSSC for approval, and shall be at least equal in experience and qualifications to those specified in the Contract.

f) The Contractor shall promptly notify ADSSC of any observed

irregularities or non-conformance of Work or Products during testing. g) The Contractor shall perform additional tests, at no extra cost to the

Contract, as required by ADSSC to prove full compliance of the performance of the completed Works.

h) After each test, the Contractor shall promptly submit six (6) copies of a

test report to ADSSC. The report shall include the following as a minimum:

i. Date issued. ii. Project title and number. iii. Name of inspector. iv. Date and time of sampling or inspection. v. Identification of product and specifications section. vi. Location in the Project. vii. Type of inspection or test. viii. Date of test. ix. Results of tests. x. Interpretation of test results. xi. Conformance with Contract Documents.

12.6 PROVISIONAL ACCEPTANCE

a) The Contractor shall submit written certification that Contract Documents have been reviewed, the Works has been inspected, submittals required by governing or other authorities have been submitted and that work is complete and in accordance with the Contract Documents and ready for ADSSC review. The Contractor shall remove all unused materials and equipment from site before the Provisional Acceptance Certificate is issued.

b) On acceptance of the Works, the Contractor shall submit the Final

Account identifying total adjusted Contract Sum, previous payments and sum remaining due.

13. OPERATIONAL AND MAINTENANCE MANUALS

13.1 GENERAL

a) Operating and Maintenance Manuals (O&M Manuals) shall be provided in both electronic and paper format in accordance with Section 16670: Documentation format.




(ADSSC)

b) All printed matter shall utilise a uniform type and size of type with the

exception of manufacturer's standard literature. Wherever possible, use shall be made of photographs, charts, exploded diagrams and other pictorial aids to assist in explaining maintenance procedures and principles of operation. All irrelevant literature shall be deleted by means of a single diagonal red line.

c) The O&M Manuals shall include the following information as a minimum:

i. The extent of supply and general overview of the scheme. ii. Process description and process control philosophy. iii. General description of the plant and equipment supplied. iv. Updated technical data sheets for all plant and equipment duly

completed with as-built details and certified for all major plant and components.

v. Health and Safety Statement, Certificates, requirements and precautions.

vi. Step-by-step operating instructions for the plant as a whole to include as a minimum:

Manual, Semi-Automatic and Automatic operation. Start up and shut down procedures. Recovery from failure. Operational procedure during partial closedown for

maintenance work. Protective devices, stating all trip settings. Schedules of settings for all adjustable or programmable

devices (timers, pressure switches, etc.). Calibration procedures for all instruments, controllers, meters,

recorders, indicators etc. that require calibration, including calibration records with calibration revalidation authority where applicable.

Software details (Program listing, I/O Schedules, Register listings, etc.). A hardcopy and softcopy of all software applications together with source code, where applicable, and user manual.

The original software, together with associated interface cables, hardware/software key, and all other accessories required to establish on-line communication with all programmable controllers supplied under the contract.

Plant failure troubleshooting chart. Maintenance schedules, including operators checklists. Lubricants, capacities and approved alternatives. Plant management procedures and optimisation. Hazardous Operations. Confined Spaces. Potentially Explosive Atmospheres. List of consumables with part numbers and alternatives. Corrosion protection system supplier, stating repair procedures. A schedule of serial numbers and rating plate data for all items




(ADSSC)

supplied.

Index of suppliers. Edited individual equipment manufacturers manuals. Performance curves and test certification. Full set of "as constructed" mechanical and/or electrical

drawings plus civil/structural arrangements. Certified engineering calculations where applicable and asked

for by ADSSC. Safety instructions and safety manual for the completed

installation.

d) Within each volume of the Manual, individual sections shall be segregated by section dividers.

e) Each volume shall contain a detailed index sheet. f) Where engineering modifications are required, the site manual shall be

marked up immediately and revised drawings issued.

g) The Contractor shall provide a Planned Maintenance system documentation for all equipment.

h) Documentation sheets shall be provided for each item, even where

identical items are utilised. i) Planned Maintenance data sheets shall be completed for all items of

Plant (Equipment, Structures and Buildings). j) The Contractor shall list the recommended planned maintenance for

each item of plant. k) The Contractor shall provide adequate training in the safe and proper

operating and maintenance of the plant and equipment to the satisfaction of ADSSC. Training shall be undertaken during the site testing and commissioning periods, and the Contractor shall allow for training up to six personnel from ADSSC.

14. IDENTIFICATION

14.1 GENERAL

a) Pipes, valves, pumps, compressors etc shall be colour coded. The coding shall indicate the contents of the pipelines, purposes of the valves etc. and show whether or not the fluids being handled are dangerous.

b) Tape banding of pipes of the appropriate colour shall be spaced at 3m

intervals and at every valve or junction. Direction of flow arrows shall be provided together with process stream contents.




(ADSSC)

c) Lagged pipework shall be colour coded prior to lagging. Lagging surface

shall be continuously colour coded. d) Stainless steel shall not have any paint system applied to its surface but

imperfections and heat-affected zones shall receive a suitable treatment to give a high quality, uniform surface appearance.

e) CE/UL labels shall be fixed on all electrical equipment, components and

accessories. f) The Contractor shall provide and fix necessary diagrams and/or

instructions, notices for all systems. They shall be located adjacent to the appropriate items of Plant. Such notices shall be protected from the environment by glass or clear plastic covers as approved by ADSSC.

14.2 NAMEPLATES

a) The Contractor shall supply and fix name and rating plate(s) to each item of plant.

b) The plates shall be engraved or stamped with, but not limited to:

i. Manufacturer's name. ii. Type and serial number of the Plant. iii. Details of the loading and duty at which the item has been designed

to operate. iv. Sufficient detail to allow the assembly to be readily identified in

correspondence and when ordering spare parts.

c) Additional information shall be engraved on the plate as specified in specific sections of this specification.

d) A schedule of plant nameplates shall be provided at the detailed design

stage to enable these numbers to be allocated. e) The plates shall be robust, weatherproof and resistant to cracking and

fracture. f) Colourfast numbering and lettering, in block capitals and/or symbols,

shall not be less than 5mm high, engraved in both Arabic and English. g) The plates shall include a maintenance reference number obtainable

from ADSSC, for the item of plant to which they are fixed. h) All plates shall, where practicable, be mechanically fixed to plant. The

use of other fixings shall be subject to specific written approval of ADSSC.

14.3 TAGS

Metal Tags shall be of Stainless Steel with stamped letters; tag size shall be




(ADSSC)

minimum 40mm square with smooth edges.

14.4 STENCILS

a) Stencils shall be produced with clean cut symbols and letters of the following sizes:

i. 20-30mm Outside Diameter of Insulation or Pipe: 200mm long

colour field, 15mm high letters. ii. 40-50mm Outside Diameter of Insulation or Pipe: 200mm long

colour field, 20mm high letters. iii. 65-150mm Outside Diameter of Insulation or Pipe: 300mm long

colour field, 30mm high letters. iv. 200-250mm Outside Diameter of Insulation or Pipe: 600mm long

colour field, 65mm high letters. v. Over 250mm Outside Diameter of Insulation or Pipe: 800mm long

colour field, 90mm high letters. vi. Ductwork and Equipment: 65mm high letters.

b) Stencil Paint shall be semi-gloss enamel, colours conforming to BS4800. 14.5 PIPE MARKERS

a) Pipe marking colours shall conform to BS4800. b) Plastic pipe markers shall be factory-fabricated, flexible, semi-rigid

plastic, preformed to fit around pipe or pipe covering; minimum information indicating flow direction arrow and identification of fluid being conveyed.

c) Plastic tape pipe markers shall be flexible, vinyl film tape with pressure

sensitive adhesive backing and printed markings. d) Underground plastic pipe parkers shall be bright coloured continuously

printed plastic ribbon tape, minimum 150mm wide by 4mm thick, manufactured for direct burial service.

14.6 INSTRUCTION NOTICES

a) The Contractor shall supply all necessary diagrams and instructions and notices for special systems.

b) All diagrams, instructions and notices shall be located and fixed adjacent

to the appropriate items of plant. 14.7 SAFETY WARNING SIGNS AND NOTICES

a) Signs and Notices specifically required for Safety and Warning purposes shall comply with the requirements of ADSSC.




(ADSSC)

b) Any items of equipment that start automatically shall have permanent

warning signs affixed to them with the legend in English and Arabic stating “Warning Equipment Automatic Starting, Isolate Elsewhere”.

14.8 IDENTIFICATION COLOURS

a) The following colours to BS 4800:1989 shall be used for mechanical and electrical equipment.

b) For equipment not listed, the colour shall be agreed with ADSSC.

14.9 COLOUR SCHEDULE FOR PLANT AND EQUIPMENT

Table 14.9.1

COLOUR NO.

BS 4800 COLOUR DESCRIPTION (FOR GUIDANCE ONLY)

1 00 A 05 Light Grey

2 10 B 17 Stone

3 06 C 39 Mid Brown

4 06 D 43 Light Orange

5 00 E 53 Black

6 04 E 53 Red

7 08 E 51 Mid Yellow

8 18 E 51 Sky Blue

9 18 E 53 Mid Blue

Or RAL Alternative.

Table 14.9.2

COLOUR NO.

RAL 841 HR COLOUR DESCRIPTION (FOR GUIDANCE ONLY)

1 7035 Light Grey 2 7030 Stone Grey 3 8025 Mid Brown 4 2008 Light Orange 5 9005 Black 6 3020 Red 7 1018 Mid Yellow 8 5015 Sky Blue 9 5024 Mid Blue




(ADSSC)

14.10 IDENTIFICATION COLOURS FOR PLANT AND EQUIPMENT

a) Colour number from

ITEM COLOUR SCHEDULE No.1

Pumps (Centrifugal) 7 Pumps (Screw) 5 Motors 9 Gearbox 7 Couplings and flywheels 6 Baseplates and Mounting Stools 1 Drive Shafting 6 Diesel Engine 4 Alternator 9 Shaft and coupling guards SELF COLOUR Exhaust Pipes POLISHED ALUMINIUM Control, Switchgear, Distribution and Mimic Panels 8 Main Valve Handwheels 6 Lifting equipment, including rails, beams, bogies, gantry girders, crab, blocks, and control cabin if any. 6 Handrails, walkways and steel supporting structures 1 Open Mesh flooring SELF COLOUR Daily Fuel Storage Tank 3 Bulk Fuel Storage Tank 3 Coolers for generators 5 Transformers 8 All other exposed Metalwork 9




(ADSSC)

14.11 IDENTIFICATION COLOURS FOR PIPELINES

a) All main and auxiliary service pipes and valves shall be painted in accordance with the following schedule.

Table 14.11.1

FLUID COLOUR DESCRIPTION (FOR GUIDANCE ONLY) BS 4800

Raw Sewage Stone (with Dark Green Bands)

10 B 17(14 C 39)

Secondary effluent Supernatants and Liquors

Medium Green 14 E 53

Final effluent Light Green 14 E 51

Potable water Sky Blue 18 E 51

Air White 00 E 55

*Oxygen White with danger bands 00 E 55*

*Gas (Methane) Violet with danger bands 24 C 39*

*Chlorine Yellow with danger bands 10 E 53*

Electrical Conduits Orange 06 E 51

Fuel oil Brown 06 C 39

Lub.oil Light Brown 06 C 33

Raw sludge Black 00 E 53

Digested sludge Dark Grey 00 A 13

Activated sludge Medium Grey 00 A 09

Pipes carrying gases and dangerous chemicals are to be banded at regular intervals and at valves with danger symbol (Black 00 E 53) diagonal stripes on Yellow (08 E 51) background 150mm wide.

14.12 PREPARATION

a) Surfaces shall be degreased and cleaned to receive adhesive for identification materials.

b) Surface preparation shall be in accordance with Section 09900 for

stencil painting.




(ADSSC)

14.13 INSTALLATION

a) Nameplates shall be installed with corrosive-resistant mechanical fasteners, or adhesive. Sufficient adhesive shall be applied to ensure permanent adhesion and shall be sealed with a clear lacquer.

b) Tags shall be installed with corrosion resistant chain. c) Stencil painting shall be in accordance with Section 09900. d) Plastic pipe markers shall be installed in accordance with manufacturer's

instructions. e) Plastic tape pipe markers shall be installed completely around the pipe in

accordance with the manufacturer's instructions. f) Underground plastic pipe markers, shall be installed 150 to 200mm

below finished grade, directly above buried pipe. g) Air handling units, pumps, heat transfer equipment, tanks, and water

treatment devices shall be identified with plastic nameplates or stencil painting. Small devices, such as in-line pumps, may be identified with tags.

h) Control panels and major control components outside panels shall be

identified with plastic nameplates. i) Thermostats relating to terminal boxes or valves shall be identified with

nameplates. j) Valves in main and branch piping shall be identified with tags. k) Air terminal units and radiator valves shall be identified with numbered

tags. l) Automatic controls, instruments, and relays shall be tagged and

referenced to control schematics. m) Concealed or exposed piping shall be identified with plastic pipe

markers, plastic tape pipe markers or stencilled painting. Tags shall be used on piping of 20mm diameter and smaller. Service, flow direction and pressure shall be identified in clear view and aligned with axis of piping. Identification points shall not exceed 6m intervals on straight runs including risers and drops. They shall be adjacent to each valve and tee and be at each side of penetrations of structures or enclosures, and at each obstruction.

n) Ductwork shall be identified with plastic nameplates or stencilled

painting. Air handling units shall have an identification number and area served. Identification shall be provided at air handling units, at each side of penetrations of structures or enclosures, and at each obstruction.




(ADSSC)

o) Ceiling tags shall be provided to locate hidden valves or dampers above

T-bar type panel ceilings. They shall be located in the corner of a panel closest to the equipment.

14.14 SCHEDULES

a) When identifying specific equipment, the Contractor will provide an appropriate schedule.

The following may assist in developing such a schedule:

i. Equipment type. ii. Identification size/colour. iii. Background size/colour. iv. Lettering.

15. WARRANTY

15.1 GENERAL

a) During the guarantee period, a warranty check of each system required to be validation tested shall be performed twice by qualified technical representatives of the various system manufacturers, including manufacturers of equipment components within systems. Checks shall be detailed and complete, requiring not less than 8 hours at the site, and shall be performed under the observation and to the satisfaction of ADSSC. All costs for in-service checks shall be included in the Contract Price.

b) The Contractor shall notify ADSSC in writing at least ten days prior to the

start of each warranty check and obtain his approval of the proposed dates.

c) At the time of each warranty check, each qualified technical

representative shall review the O&M Manual and the pertinent operational and maintenance problems encountered, and furnish technical advice and recommendations to ADSSC.

d) The initial warranty check shall be performed approximately six months

after final acceptance of the plant. The second warranty check shall be performed within thirty days of the end of the contractual guarantee period.

e) The Contractor shall submit a written report of each warranty check,

signed by the appropriate manufacturer or his representative, to ADSSC within ten days following the check. The report shall describe the checking procedure in detail, and shall restate all advice and recommendations given to ADSSC.

END OF SECTION

