WS DPR

DPR No.
: RMC/JnNURM/WS01-10/0507 Detail Project Report (DPR) for

Water Supply Projects for Rajkot City
Estimated Cost Rs.10573 lakhs Date of Preparation
Period 05-06 to 06-07 Date of Submission
Rajkot Municipal Corporation Dr. Ambedkar Bhawan Dhebarbhai Road, Rajkot 300 001 ( Gujarat India) Ph: 2224133, 2239973; Fax:+91-281-2224258 E-mail: mc_rmc@yahoo.co.in; url: www.rmc.gov.in
DPR No.: RMC/JnNURM/WS01-10/0507
Name of Project
Water Supply Projects for Rajkot City
Abbreviations
Contents
1.0 INTRODUCTION 1 1.1 Background 1.2 Need of Project 1.3 Objective 1.4 Scope & Limitation .
2.0 IBACK GROUND OF THE STUDY . 3 2.1 Sectoral Policies outlined in City Development Plan 2.2 Linkage of the objectives with CDP 3.0 CHARACTERISTICE OF THE STUDY AREA . 5 3.1 Project Area 3.2 Topography 3.3 Climate & Rainfall 3.4 Geography 3.5 Hydrology 3.6 Environmental Settings 4.0 EXISTING SYSTEM OVERVIEW 8 4.1 Water Sources 4.2 Transmission & Distribution 4.3 Scope & Limitation 4.4 Treatment Facility 4.5 Distribution Net work 5.0 POPULATION & WATER DEMAND 11 5.1 History & Growth of city 5.2 Settlement Patern 5.3 Land Use 5.4 Population Growth Rate 5.5 Population Projetcion 5.6 Demand of water 5.6.1 Alternative -1 5.6.2 Alternative -2 5.7 Future Requirements 6.0 DETAILED ENGINEERING DESIGN- CIVIL 20 6.1 New sub-head works 6.2 Augmentation of sub head works 6.3 New Head works 6.4 Transmission Main works .
Abbreviations 6.5 6.6 6.7 6.8 Source Augmentation works Distribution Networks phase-1 Civil General Design Consideration Characteristic of different pipe material
7.0 E DETAILED ENGINEERING DESIGN- MECHANICAL & ELECTRICAL ..63 7.1 Mechanical components 7.1.1 Pumping works 7.1.2 Motors 7.1.3 Valves 7.1.4 Material & workmanship 7.1.5 Inspection & Testing 7.2 Electrical Components 7.2.1 Design criteria 7.2.2 Power supply scheme 7.2.3 Protection 7.2.4 Metering 7.2.5 Cables 7.2.6 DC power supply 7.2.7 Lighting 7.2.8 Safety Earthling 7.2.9 Power Factor Improvement 7.2.10 Flow Measuring System 7.2.11 Ultra sonic flow meter 8.0 CONTROL OF UNACCOUNED FOR WATER .105 8.1 General 8.2 Guidelines to reduce UFW 8.3 Assumption of Leakage 8.4 Approach for leakage control 9.0 COST ESTIMATE . 109 9.1 General 9.2 Based for cost estimate 9.3 Development of sub head works 9.3.1 ESR & GSR at ward-6 9.3.2 ESR & GSR at ward-7 9.3.3 ESR & GSR at Ward 17 9.4 Development of New head works 9.5 Source augmentation 9.5.1 Water Supply based on Nyari-1 9.5.2 Water supply schmen based on Bhadar 9.6 Augmentation of sub head works
ii
Abbreviations 10.0 EONOMICAL & FINANCIAL ANALYSIS .130 10.1 Water Sources 10.2 Transmission & Distribution 10.3 Scope & Limitation 10.4 Treatment Facility 10.5 Distribution Net work
11.0 ENVIRONMENATAL IMPACT ASSESSMENT 135 11.1 General 11.2 EIA Methodology 11.3 Impact Identification 11.4 Impact Identification during Construction Phase 11.5 Impact Identification during operational Phase 11.6 Impact Identification during post-operational phase 11.7 Prediction of Impacts 11.7.1 Impact on Air Environment 11.7.2 Fugitive emission from crushers 11.7.3 Impact on Noise Pollution 11.7.4 Impact on Water Environment 11.7.5 Water Logging & Salinity 11.7.6 Impact on LandEnvionment 11.7.7 Impact on flora & Fauna 11.7.8 Impact on sesmicity 11.7.9 Impact on climate 11.7.10 Impact on socio-economic 11.8 Evaluation of Impact 11.9 Transmission & Distribution 12.0 SUMMING UPENVIRONMENATAL IMPACT . 145 12.1 Conclusion 12.2 Project Costing FINANCIAL ANALYSIS 146 13.1 General 13.2 Present Tariff, Billing and Collection Service Connection ENVIRONMENTAL IMPACT ASSESSMENT 148 14.1 General 14.2 EIA Methodology 14.3 Impact Identification 14.4 Impact Identification during Construction phase 14.4.1 Construction of Elevated storage Reservoir and Ground Storage Reservoir & water treatment plant 14.4.2 Environment Impact due to Labour population 14.5 Impact Identification during Operational Phase
13.0
14.0
iii
Abbreviations 14.6 14.7 Impact Identification during Post- Operational Phase Prediction of Impacts 14.7.1 Impact on Air Environment 14.7.2 Fugitive Emission from Crushers 14.7.3 Impact on Noise Environment 14.7.4 Impact on Water Environment 14.7.5 Water Logging and Salinity 14.7.6 Impact on land Environment 14.7.7 Impacts on Flora and Fauna 14.7.8 Impact on Climate 14.7.9 Impact to Seismicity 14.7.10 Impact on Socio-economic Environment 14.7.10.1 Positive Impacts on Socio-Economic Environment 14.7.10.2 Negative Impacts on Socio-Economic Environment Evaluation of Impacts 14.8.1 EIA without EMP 14.8.2 EIA with EMP Conclusions
14.8
14.9
iv
Abbreviations
Abbreviations
ALV APMC ARV BOD BPMC CA CBO CCP CDP CDS COD CUR DA FOP GIDC GMFB GOG GOI GPCB GSRTC GUD & HD GWSSB HUDCO IMR JnNURM NGO NIOH OR PF RCC REA RMC RTO RUDA SC SPM ST SWOT TDS UDPFI WPR
Annual Legitable Value Agricultural Produce Market Committee Annual Ratable Value Bio-Oxygen Demand Bombay Provincial Municipal Corporations City Administration Community Base Organisation City Corporate Plan City Development Plan City Development Strategy Chemical Oxygen Demand Capital Utilization Ratio Dearness Allowance Financial Operating Plan Gujarat Industrial Development Corporation Gujarat Municipal Finance Board Government of Gujarat Government of India Gujarat Pollution Control Board Gujarat State Road Transport Corporation Gujarat Urban Development & Housing Department Gujarat Water Supply & Sewerage Board Housing & Urban Development Corporation Infant Mortality Rate Jawaharlal Nehru National Urban Renewal Mission Non Governmental Organization National Institute of Health Operating Ratio Provident Fund Reinforced Cement Concrete Rajkot Engineering Association Rajkot Municipal Corporation Regional Transport Office Rajkot Urban Development Authority Schedule Caste Suspended Particulate Matter Schedule Tribe Strength, Weakness, Opportunities and Threats Total Dissolved Solids Urban Development Plan Formulation and Implementation Workers Participation Rate
Rajkot Municipal Corporation
1
1.1 Background
Introduction
Rajkot City with a population of one million (as per census 2001) and with an area of 104.86 Sq. Kms. is situated on the bank of river Aji. The city is falling under arid zone and monsoon is erratic. The under ground strata is hard rock and because of small confined aquifer the availability of ground water is meagre. In river Aji flow remains during monsoon only thus the river is not perennial. In view of above the water supply problem of city is very acute as the availability of water from existing sources is limited and city is dependent on outside sources viz., Narmada, Bhadar etc., Because of this, there is considerable variation in the per capita water availability even though municipal present water networks average 80 percent Rajkot's population- (90 percent in the old city area and 70 percent in the newly-merged areas). The duration of supply of water is 20 minutes a day which, the RMC contends, delivers 110 litres per capita per day (lpcd)
1.2 Need of the Project

The city is developing at a rapid pace and the population is expected to reach about 1.5 million by the year 2011. The requirement of water in the year 2011 would be about 250 MLD. City water supply is intermittent. Water is being supplied from 4.00 am to late night 11.30 pm in different zones at different time slot period. Besides, it is also observed marginal difference between water drawl from various sources and total supply to consumers, this shows leakage and unaccounted loss of water. Hence there is a need for augmenting the water supply storage capacity and filtering capacity, strengthen distribution system, and modification in main lines. Govt of India recently launched urban Infrastructure development mission for selected 63 cities of India as Jawaharlal Nehru National Urban Renewal Mission (JnNURM) which also encourages preparing Detail Project Report for water supply for Rajkot city.
1.3 Objectives
The broad objectives of the Detail Project Report (DPR) are to determine a technically and economically viable water supply project for a phased implementation to meet the requirements of the year 2021. Following are the specific objectives: 1. Assessment of the existing supply situation 2. Population and water demand projections 3. Planning for Projects identified for JnNURM 4. Project scheduling & cost estimates 5. Projects phasing 6. To prepare operational plan 7. To assess environmental and social impact
Detail Project Report for Water Supply
8. Organizational and financial studies 9. To set recommendation with respect to JnNURM reforms & sustainability
1.4 Scope & Limitations of the study

1. The study is limited to Rajkot city admeasuring area app.104.86 sq.kms. 2. The study is limited to Water supply projects for Rajkot city which are identified and outlined in City Development Plan ( 2005-2012) 3. Projects which are identified in CDP for RUDA area are excluded.
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2.1 Sectoral Policies outlined in CDP
Background of the study Background of the study
Water supply service is the highest priority for people of Rajkot .While framing any plan for city the water supply sector is being given the top priority. During 2002, RMC had prepared a water management and augmentation plan with the financial aid from Govt of India & Govt of Gujarat. Present level of water supply is 110 LPCD & it is planed to reach 135 LPCD before end of year 2007 with reduction of duration of city water supply from 18 hours to 8 to 10 hours., by augmenting existing sources, increasing storage capacity, treatment and pumping capacity as well as addition and alteration in distribution network. In accordance with suggestions of citizens, elected representatives, officials & officers of RMC and other stakeholders involved in the entire city development plan process the outcomes of water supply to entire city populations, which be fully accountable to citizens and of financial sustenance, the plan suggests, outputs of water supply of 135 LPCD with supply duration of 1 hour. It also suggests programs to reduce losses and leakages from 28% to 15 %. This will require infrastructure development fund as suggested in JnNURM projects expenses. To achieve these out comes following strategies have been formulated in City Development Plan. These are the core value of this Detail Project Report WSS1: Water Management & Augmentation Plan_ The management plan shall be designed so as to ensure water supply infrastructure provisions matches the communitys need. It shall envisage extension, augmentation and refurbishment of the system in an effective and efficient manner. It is also proposed to prepare an integrated technical & financial feasible sectoral reform plan which will fulfill this WSS2: Water Supply Operation & Maintenance Plan The plan will be designed largely by involving Private Sector for O & M operations. This may be done through a management contract with a private company, which would be solely responsible for the O & M of the system, based on agreed annual fee, with built-in incentives for improved performance. WSS3: Infrastructure Planning with Town Planning regulations & bylaws_ It is proposed to make statue provision by using GDCR, that private societies have to develop own water supply net work to get water from RMC. This will also be taken care of during preparation of Town Planning schemes. Provisions for ground water recharge and rainwater harvesting techniques in building more than 80 sq.mts had been already made in GDCR. WSS4: Institutional Strengthening & Capacity Building In order to cost effectively and customer focused manner the officials & Officers must be trained for Project Planning, Implementation, and Monitoring and Evaluation programs. It is recommended for strong database particularly to
decrease the duplication of laying of pipeline for same distribution as well as for strong readdresal system and minimizing unaccountable losses & illegal connections.
2.2 Linkage of the projects to the CDP

Projects formulated and identified in CDP for water supply focus on_ exploring new sources, optimum use of existing water resources, total water supply planning, conservation of ground water, reduction of unaccounted for water and largely on Institutional strengthen & Capacity building. The Strategic Plan for the year 2011 envisages water demand of 45 MGD (203 MLD) for 1.5 million people at a daily supply of 135 LPCD with 100% filtration and storage capacity. The distribution network is expected to cover additional 250000 households by individual water tap connection especially urban poor. Distribution losses due to Leakages and unaccounted connections will be brought to 15 % from exiting estimated 28%. From present water supply 20 minutes per day aimed to supply for one hour daily. JnNURM projects are identified as under:
No Details 200506 1000 200607 700 200708 700 Year Rs. In Lakhs 2008- 2009- 2010- 201109 10 11 12 600 0 0 0 Total 3000
3 4
5 6
Additional water head work 6 Nos.- each of_ clear water sump 10 ML capacity & ESR 25m ht. 3 ML capacity with req.pumping machinery & pump house Augmentation of existing water head works- 6 Nos.-each of_ clear water sump of 10 ML capacity Strengthing of distribution system Distribution network for development of undeveloped area Replacement of non-metallic pipe line in to metallic pipe Laying of Express feeder line for transfer of water from one zone to another zone Water supply scheme based on Narmada water for newly merged are with head works at Raiya dhar Replacement of pumping machinery at various existing head works Increasing capacity of Nyari-1 reservoir with addition & alternation in existing water treatment plant at Nyari Installation and Development of SCADA system at three stations Total Phase wise percentage
250
250
250
750
500 0
250 0
250 0
750 0
750 300
500 500
500 600
3500 1400
1050 200
500 0
500 0
1500 1000
500 1000
500 800
500 200
5050 3200
15
1500
1200
500
3215
160
160
320
300
1000
200
1500
10
100
100
200 22135 100
3175 14
3660 17
3900 18
4650 21
2650 12
2300 10
1800 8
Characteriistiic of the study area Character st c of the study area
3.1 Project Area

Rajkot is situated in the middle of the peninsular Saurashtra in central plains of Gujarat State of Western India at a height of 138 m above mean sea level. It lies between latitude 22.18 N and longitude 70.51 E. It has an area of 104.86 sq. kms Rajkot is head quarter of Rajkot District and the city is connected with other parts of the country by Rail, Road and Air. There are broad gauge railway line of Western Railway between Viramgam-Okha- Porbandar and meter gauge railway line between JetulsarVeraval-Bhavanagar. It is also well
connected by broad gauge railway line with Delhi and Bombay the important two Metropolitan cities of India. Also there are major roads and NH-8 a links Kandla, NH-8 B links Porbandar and state capital
Gandhinagar. State highways connect Rajkot to other important towns of the region like Surendranagar,Porbandar, Junagadh, Veraval, Bhavnagar, Amreli, Bhuj, Kandla, Ahmedabad,, Baroda etc., The city is also served by an aerodrome and linked by air with Baroda, Bhuj, Bombay, Delhi and Ahmedabad.
3.2 Topography
Rajkot forms central part of Saurashtra Peninsula and has a diverse landscape made up of plateau, hills, linear ridges and alluvial plains. The southern and western parts of the city are primarily covered by Deccan Traps, characterized by undulating topography with the presence of plateaus at some locations. In the northern part, topography is plain with gentle slope towards north and west. The average elevation attained in the district is 130 meters above mean sea level. The general topography of RMC area is almost undulating with level difference from 125 m to 158 m from south east to north west. The city of Rajkot is situated along the Aji River, which is seasonal in nature. The main tributary of Aji in the area is khokhadadi located on southwest side of Rajkot city. Two nos of natural water reservoirs (lakes) are located near Rajkot city viz. Lalpari and Randerda, at the distance of 4 kms and 6 kms respectively from the city. Across the river Aji , Aji reservoir is built up at a distance of 9 kms from Rajkot city and Aji II at a distance of 15 kms. In the RUDA area Nyari I and Nyari II reservoirs are constructed which are located within of 15 Kms to 30 Kms from the city. In addition to this, for draining storm water, Nos. of Natural courses exist, in RMC and RUDA areas which are ultimately meting to river Aji to drain storm water.
3.3 Climate & Rainfall

Climate: The climate in the city is hot and dry. The average maximum and minimum temperatures recorded over the last 40 years are 43.5 deg C and 24.2 deg C respectively. Rainfall: The average annual rainfall is 500mm. However, over the last 60 years, it has been below normal during 20 years. In these years, the city along with the Rajkot Urban Development Area (RUDA) faced acute water shortage. The average annual rainfall is observed about 500 mm. in the area.
3.4 Geography
Soil Type: Soil of the entire Rajkot area can be broadly classified as medium black to shallow black. The black soil, being rich in minerals and organic matter is more fertile. These soils have been formed even from granite and gneiss parent materials. The depth of the top soil is generally 25 cm to 50 cm deep. The color of soil surface varies from light gray to dark gray and is clayey in texture. The soil reaction is neutral to alkaline with Calcium Carbonate. Beyond 50 cm depth the under ground strata are soft rock & hard rock. The vegetative cover is minimal in the open area due to lack of adequate topsoil. The topsoil is underlain with hard rock formations thereby limiting the growth of vegetation in the region. .
3.5Hydrology
Ground Water Table The fluviomarine alluvium of Upper Tertiary to Quaternary age forms poor aquifer because of the predominance of argillaceous nature of formations and poor quality of ground water. The ground water occurs under water table and confined conditions. Depth of tube wells ranges from 30 to 120 meters below ground level, whereas depth to water level ranges from 20 to 100 meter below ground level. The seasonal fluctuations in the water table ranges from 1.8 to 12.0 meters. The yield from the tube wells ranges from 2.50 to 10.00 cubic meters/day. In hard rock areas the availability of ground water in a particular year is the direct response to intensity of monsoon and quick response is seen in such aquifers. In the years of normal and above normal rainfalls the water level decline. The seasonal availability of ground water also varies widely.
3.6 Environmental Setting

Water Pollution: The city lies within the watershed expansion of Aji river basin and it is network of 19 natural drainage courses, locally known as Voklas. Unfortunately, these voklas are being used for sullage disposals resulted the pollution of water Aji- river in down stream of Aji I dam, Aji-II dam which collects water from Aji dam and Nyari- river is fully polluted water dam. An analysis of different water bodies in down stream of Aji dam indicates the most of water bodies within city limit are contaminated. Pollution of under ground water due to electro-plating industries and sari-printing industries is also observed.
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4.1 Water Sources
Exiistiing System Overviiew Ex st ng System Overv ew
The Rajkot Municipal Corporation (RMC) is making great efforts to provide water supply to the citizens. RMC is drawing water from various sources viz. Bhadar, Aji-I, Nyari-I, Nyari-II, Lalpari & Randarda Lake and from Narmada canal based pipeline. The major sources are Aji-I, Nyari-I, Nyari-II and Bhadar which are described as under: Aji-I with Twine lake of Lalpari & Randarda Water Supply Scheme: This is the scheme for the purpose of water supply was constructed by the then Saurashtra State Government. This is the first water supply scheme serving Rajkot city. After the commissioning of this water supply scheme people were supplied filter water through house connection for the necessary requirement of water. This scheme was commenced in 1955 and still it is working. The availability of water from the said reservoir is for 4.5 mgd i.e. 20.43 MLD. Similarly, Rajkot Municipal Corporation is getting about 1.5 mgd i.e. 6.81 MLD from twin lakes of Lalpari and Randarda. Thus, total quantity available at Aji-I head work in normal year 20.43 + 6.81 = 27.24 MLD. Nyari-I Water supply Scheme: Due to strategy and geographic location, Rajkot has attracted so many people from outside, which resulted in higher demand for water supply. Same demand cannot be
Table: 4.1 Sources of water Sr. Particulars No 1 Distance form City 2 Dam Details Live storage Dead storage Total Storage MCFT Aji-1 5 kms. 1007 Mcft. 21 Mcft 1028 Nyari-1 8 kms. 945 Mcft. 20 Mcft. 965 NyariII 22 Km 450 45 500 Bhadar 65 kms. 7030 Mcft. 45 Mcft. 7075
fulfilled
by
Aji Hence
reservoir.
Corporation had decided to construct a dam near Rajkot city for water
supply to fulfill required additional water. demand of
In
This is the first
dam owned by Rajkot Municipal Corporation. This scheme commenced in 1975 and the population of the western part of the city is being served through the said scheme. The present availability of water from the reservoir is 4.7 mgd, about 1.0 mgd from seepage. Total 5.7 mgd i.e. 25.90 MLD, However, after detail study it is found that approximately 1 mgd of more supply would be made available if the dam height is raised by 1 mt. The proposal of raising the dam height by 1 mt at the cost of Rs.15 crores is under consideration. Thus, total quantity would be available around 7 mgd i.e. 31.78 MLD from Nyari-I side. Bhadar Water supply Scheme : To provide better sanitary facilities to the public of Rajkot by means of underground drainage Rajkot Municipal Corporation has implemented water supply scheme based on Bhadar reservoir located at 60 kms. away from Rajkot.. This scheme is major scheme for the
supply of water to Rajkot city. The scheme was completed within 135 days during the year 1988. The Bhadar reservoir is for irrigation purpose, however, Government of Gujarat has reserved 10 mgd of supply in reservoir for drinking purpose to Rajkot and accordingly every year water is being made available from the said reservoir depending upon the storage available in the reservoir. After implementation of the said scheme the existing Aji and Nyari system was interconnected with Bhadar so that water from one zone to another zone could be transferred. At present, the total availability is 45 MLD. Nyari-II Water Supply Scheme: In 1998 the city limit was extended by the government and because of which water supply demand of newly merged area had increased by 2.5 mgd. And accordingly, the State Government had given the reservation of 1.5 mgd in Nyari-2 reservoir and 1.0 mgd from seepage of Nyari-2 and accordingly to cater the demand of newly merged area namely; Nana Mava, Raiya, and Mavdi, a water supply scheme costing Rs.15 crores was implemented by Rajkot Municipal Corporation based on Nyari-II reservoir. Drinking Water from the Narmada Canal : The Government of Gujarat has planned to implement a water supply scheme based on Narmada reservoir wherein 0.86 MAF quantity has been reserved for drinking purpose for 12 Districts of State Government. The water supply project based on Narmada costing Rs.7000 Crore is under implementation with the State Government. In the above water supply project, the allocation of water for Rajkot city is 160 MLD which is to be obtained from the section-A i.e. Dhodhidhaja Dwarka pipeline project. However, the said segment of the project is yet to be implemented and as such as a temporary measure Government of Gujarat have planned to supply 75 MLD of quantity to Rajkot from the section- Maliya Jamnagar. The said segment of the project has already been implemented and based on which Rajkot Municipal Corporation has also implemented a project of storage , filtration, plant, transmission line costing Rs.15 crore to cater the demand of Rajkot city. During scarcity period Rajkot Municipal Corporation is getting water from various irrigation reservoirs namely; Aji-3, Demi-I and Demi-II, Fophal etc.
4.2 Transmission & Distribution

Water from Bhadar , after treating water at Ribda is transmitted to the underground sumps at
Table : 4.2 Zones & Storage Capacity & supply Zone ESR/ GSR Capacity Total water Supply (MLD) from each headwork ( MLD) Aji 38 37 Nyari 30 30 Gurukul 20 21 Jubillee 20 19 150 ring road 35 33 TOTAL 143 140
Gurukul
and
Jubillee
water
distribution Stations. At Aji head works, water from available Aji dam, Lalpari & Randarda lake and Narmada pipe line is being filtered at Aji and same is being stored and
transmitted to Dudhsagar sub head works, 150ring road., Mavdi headworks and Jubillee water distribution stations .
Water from Nyari-1 dam is being supplied, after treatment at Nyari filter plant to Nyari zone which includes sub zones like sojitranagar ESR etc., Water collected from Nyari-2 dam is treated at Ghanteshwar filter plant and supplied through sub-zones Bajrangwadi. Water. Main pipe lines are of Mild Steel, PS , and AC Pressure line ranges from 900 mm to 450 mm as main. Distribution networks is of AC pressure pipe line with diameter 450 mm to 80 mm. Total length of Transmission line is about 250 kms. The total distribution network length excluding the transmission lines is 1375 kms.
Table : 4.3 Water supply Distribution Net works Details Unit Number of Zones 5 Number of Sub zones 11 Mains line length 105 kms. Distribution line length 1350 kms.
A total storage capacity of
202
million liters is available in the form of underground sumps and overhead service reservoirs at various water works and other distribution stations. The storage capacity
adequacy of all the water distribution stations to the total water supply is 144 percent.
4.3 Treatment Facility

The treatment of water is carried out at Ribda, Aji , Nyari and Ghanteshwar. Ribda Filter Plant, which is about 25 kms. away from the city has 50 MLD design capacity. Aji Filter plant is located near Aji dam sit has three water treatment plants with total design capacity of 103 MLD. Nyari Filter Plant is within the city has three water treatment plants with total 32 MLD design capacity. Filter Plant at Ghanteshwar which is located near city out skirt has water treatment design capacity of 14 MLD. The total water treatment capacity is 199 MLD against total city supply of 140 MLD. This shows about 1.5 times more filtering capacity. All these WTPs are equipped with most modern facilities, which have latest kind of instrumentation devices. Under the water supply monitoring mechanism, hourly check for turbidity, residual chlorine content is done at the source. Chemical analysis and bacteriological tests are being carried out regularly. At intermediate levels a residual chlorine content is being checked regularly in each zone. At the consumer end the residual chlorine content is being maintained around 0.2 ppm.
4.4 Distribution Net work

RMC water supply distribution system is divided into 5 major zones viz., Jubilee, Gurukul, Nyari , Aji and ring road. . The details of the zonal distributions are as below: Table 4.4: Zonal Water supply System Water Supply Zone Jubilee Gurukul Nyari Aji 150ring road Ground Level Service Reservoir (GSR) 2 2 5 8 1 Elevated Storage Reservoir (ESR) 2 2 1 1 Ward Covered 1, 2, 3, 13[P], 15[P], 16 2[P], 4[P], 6, 7, 8, 9[P], 10[P] 9, 10, 11, 12, 13, 14, 21 4, 5, 6, 17, 18, 19, 20 22, 23
City distribution network comprises of 80-mm pipe to 863 mm sizes of pipeline with pipe material AC Pressure , MS . PSC as well as CI pipes. The details are as under_ Table 4.5: Existing Pipe line & Material Main Types 1. Transmission Main Details : a. 863 mm b. 900 mm c. 700 mm d. 750 mm 2. Trunk Main Details : a. 750 mm b. 600 mm c. 450 mm 3. Feeder Main Details : a. 400 mm b. 300 mm c. 250 mm d. 200 mm e. 150 mm 4. Distribution Main Details : a. 150 mm b. 100 mm c. 80 mm Losses & Leakage : No specific study is carried out by Rajkot Municipal Corporation for estimating losses & leakage. However, due to long-time experience and monitoring supply & distribution system losses & leakage are estimated about 28 %. Uncovered Area : In 1998 the city limit of Rajkot Municipal Corporation was extended by 35 Sq. Kms. By merging of surrounding area viz., Mavdi, Raiya & Nana-Mava villages & RMC had implemented a water supply scheme based on Nyari-2 reservoir in the year 1999. Presently, approximately 90% of developed area of the newly merger is being served through pipeline network & remaining area with tankers. In newly merged area as on date approximately 60% of area is green field but likely to develop within three to four years and RMC has planned to implement water supply in this region for which DPR is yet to be prepared. A. C. Pressure A. C. Pressure A. C. Pressure A. C. Pressure A. C. Pressure / Cast Iron A. C. Pressure / Cast Iron A. C. Pressure A. C. Pressure Prestressed/Hume Steel A. C. Pressure A. C. Pressure/Cast Iron M. S. Prestressed Prestressed Prestressed Pipe Material
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5
5.1 History & Growth of City
Popullatiion & Water Demand Popu at on & Water Demand
The city does not have a long history. It was founded by the then ruler of Sardhar 1608 A. D. on the west bank of the river Aji as a small fortified town. by Ruler of Sardhar Gradually, it became a Princely State in the year 1805. The British Government developed the old city area popularly known as Sadar during 1820 to 1870. The old town and Sadar area being part of the city were developing simultaneously. Both these areas were separated by North-South Railway track then existed but Both these areas merged with each other resulting in
subsequently railway track was removed.
coordinated development of the town. Hence the city developed from a village, civic development was in the process and in the course of time some of the major works came to be permanently visible. By the end of 19th century, Rajkot emerged as a premier town having a population of 36,000. At the time of Independence, Rajkot was capital of Ex-Saurashtra State and has a central location in the region being a part of Gujarat State. Its importance as a capital is attributed to geographical location, its cultural heritage and the development potential possessed by the city. The present level of
development of the city is outcome of the process of progressive development going on since decades.
5.2 Settlement Pattern

In about 400 years, it has developed from a small hamlet to a prosperous town today. Up to 1820 the growth was not too rapid, but after the British government established its camp in 1822 the town opened new directions of growth. The industrial development and the urban influence of the city started with the establishment of the first textile mill in the region towards the end of 1910;. About 60 industrial units came into existence between 1900 and 1920, which induced development of the city to a great extent. Further, around the year 1940, new industrial estates, residential areas, schools, colleges, cinema houses came into being. In the earlier period, the establishment of cloth mills in the city led to the development of new residential areas like Millpara, Harishchandra Plot, Gundawadi, Kevdawadi etc. A number of transport companies established their head offices at Rajkot. The Industrial Estates known as Bhaktinagar Industrial Estate and Aji Industrial Estate were established. Trade and Industry fast developing in the city also attracted foreign investment during these periods. With increasing industrial, trade and commerce activity, there has been tremendous growth in the population of the town. The city has grown up in area from 150 hectare in 1901 to 10404 hectare in 1998. i.e. it has growth approximately 70 times of its initial size.
5.3 Land Use

Rajkot city is characterized by a pattern of multiple land uses. The total area developed for urban activities constitute 77% of the Rajkot Municipal Area. Residential use occupies about half of this area, while industries occupy a fifth and commercial zones occupy less than 2%. Although a development plan has been prepared, poor implementation and enforcement result in quite different
11
ground realities. Rajkot is plagued by problems of informal sector including slum development, illegal colonies and commercial encroachments and a lack of industrial zoning and unplanned mixed land use. The total area developed for urban activities constitute about 77 % of the city area and balances constitute activities enmarked for vacant land, water bodies and other purposes.
Land use Break Up Land Use Existing Land Use as per 2001 Area in Percent Hectare Residential 4247 40.50 Commercial 209 2.00 Industrial 628 5.99 Traffic & Transportation 1400 13.35 Public & Semipublic 149 1.42 Recreational Space 123 1.17 Agriculture 995 9.49 Water bodies 236 2.25 Vacant Land 1510 14.40 Other 988 9.42 TOTAL 10484 100 %
Residential
Proposed Land Use as per DP 2011 Area in Percent Hectare 5502 52.47 279 2.66 738 7.04 1650 249 523 800 236 -508 10486 15.74 2.38 4.99 7.63 2.25 -4.84 100 %
Uses:
The residential development is spread over 54 sq.kms. high density of residential development is found in older parts of city especially Kotak street, Raghuvir para, Ramnath para, Kumbhar
wada, Soni bazaar etc., The densities are low in the newly merged area
especially in and around
kalwad road, Raiya road, 150 feet ring road, university road and in some parts of junction area, popat para area etc. It is obvious that newly developed area where TP schemes were developed is planned. However, old city areas like Prahlad plot, Jayraj plot area are developed with a regular street pattern, well shaped plots but these area lack open space. Percentage of residential area to total area is found 51.34% while residential area to developed area is 60.23% . Commercial Use: Main commercial areas are Soni bazaar, Dharmendra road, Lakhajiraj road, area around jubilee vegetable market.etc., of old city, which is also described as city area A in GDCR; Yagnik road, Dhebar road, gondal road, Jagnath area etc., which is known as city area B etc.; and Kalwad road, amin road, university road, Raiya road, st.kabir road, pedak road etc, called Other area_ as described in GDCR. Traditionally, dana pith area was for grains & grocery whole sale and retail marketing; lakhaji raj road, kapad market and dharmendra road for clothing sale; soni bazaar for jewelry market; sadar for retail provisions stores etc., are established since long. These commercial activities demand substantial space in prime areas. The percentage of commercial area to total area is found about 1.89%, while same is to develop area seems to about 2.11%. Industrial Use: Two Industrial estates were developed by Gujarat Industrial Development Corporation. They are Bhaktinagar Industrial Estate and Aji Industrial Estate. Above which ,sorathiawadi plot area had been developed by private developers as another industrial area. Besides, National Textile mill, which is closed, occupies very prime land and is spread in huge area. Rajkot city is developed as an industrial city hence, growth of industries and residences of industrial employees
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developed simultaneously which resulted in mixed land use pattern. The percentage of Industrial area to that of total area and developed area are found 20 % & 22.28% respectively. Public Purposed Use: Main components of Pubic purpose use can be described as open space, parks & play ground, recreational space, hospital space, schools, govt. office buildings etc., The major contribution to the component is by race course complex, which has facility of international cricket stadium, indoor stadium, hockey ground, foot ball ground etc.; garden and fun world & open ground. Other such space is Shastri Maidan. The total public purposed space to total area is 9% while it is 10% against developed area.
5.4 Population Growth Rate

The population of Rajkot city is 10,02,000 as per the 2001 census. The population has grown from 36,151 in 1901 to 10,02,000 by the year 2001. with an average annual growth rate of 3.29%. During independence period Rajkot city experienced highest growth rate 99.04% in between 1941 to 1951because of large immigrants refugee from Pakistan. Also in the last decade the city registered the growth rate of 79.12% , this is attribute to the increasing the Corporation limit by merging the three surrounding village in June-1998.
Growth Rate Year Population 36151 1901 34191 1911 45845 1921 59122 1931 66353 1941 132069 1951 194145 1961 300112 1971 445076 1981 559407 1991 1002000 2001 Growth rate ---5.42 +34.08 +28.96 +12.23 +99.04 +47.00 +54.58 +48.30 +25.69 +79.12
The trend of population growth is an important indicator and base for the assessment of future requirements of basic in the area for the future.
5.5 Population Projection

Population projections for the RMC area have been done on the basis of the past growth trends. It is required to estimate separately RMC area and Newly merged area during June 1998. The population growth rate of RMC area has been given in table. It has been observed that since last 100 years, the population of Rajkot City has increased at different growth rates. The growth rate of Rajkot City from 1901 to 1941 has been calculated as very nominal i.e. 0.15 on average annually. After
Population projectios Population Projection High Medium Low
Independence i.e. after 1951, the rate of

Adopted Population Projection estimate 1,484,500 2,207,000
Year
population growth of Rajkot City has increased tremendously. Based on the above population figure for the past decades, the RMC population (excluding
2011 2021
1,570,000 2,215,000
1,484,500 2,207,000
1,490,000 2,232,000
newly merged area)has been projected utilizing ratio methods, the geometric growth method as well as
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incremental increase method and graphical method. The growth rate in higher side found as 3.11% raise per annum, medium as 3.05% and lower growth rate as 2.67%. However, Population growth rate of newly merged area found pop population growth rate as 11.79%. Therefore, combine population growth rate for RMC old area and the merged area calculated. The combined growth rate found as 4.59% for higher side, 4.05 Medium side and 4.00% for lower side estimation. Table shows population projections for the years 2011and 2021. The population for projection of population by various method is as shown in annexure.
5.6 Demand of Water

Alternative: 1
Water demand in Rajkot is assessed on the basis of 135 lpcd covering the following requirements A. B. C. D. E. F. G. Domestic Need: Comprising of water required for drinking cooking, washing, flushing toilets Institutional Needs Industrial, commercial uses as well as Construction purpose Gardening Fire fighting Requirements of live stock Likely wastage among all users and line losses The demand of water supply is based on WHO standards & Indian Standard Code of Basic Water requirement of water supply, drainage and sanitation (Indian Standard:IS1172:1983) as well as the building codes which requires minimum of 135 lpcd for all residences provided with full flushing system for toilet with the breakup of specific users. Following table shows the domestic requirement norms of WHO & Indian Standard Codes for Urban population and the adopted domestic water requirement: Table: Water Requirements Water Requirement Rates (in liters) Use Drinking Cooking Bathing Washing of utensils Washing of house Washing of clothes Flushing Total WHO standards 3 5 + 20 (ablution) 135 15 15 15 30 238 IS Codes 5 5 55 10 10 20 30 135 Adopted Water Requirement Ltrs. 5 5 55 10 10 20 30 135
Thus taking into consideration the water requirement for all such uses the water requirement norms for the urban areas of RMC has been adopted as 135 lpcd
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Alternative: 2
Alternatively, demand of water is also calculated based on consumers. For which the city base actual survey has been carried out for different categories of houses. The analyses are as under Housing Conditions : The type of housing and the economic level of a consumer is an important factor influencing consumption. People staying in houses having large number of plumbing fixtures (such as bath tubs, showers, wash basins, flushing cisterns) and having garden and lawns, would normally have higher consumption than those staying in small houses or in slums.
The areas within the walled city have very old buildings with narrow lanes demonstrating traditional planning. The newly developed area, have high rise buildings, modern row houses and individual bungalows which show modern trends. About one-fifth of the city's population lives in slums and hutments. Housing categories: No authentic data is available on various housing types, except slums (BPL survey by United Research Survey). Following housing categories have been identified by analysis of tax data and building plan permission data.
Category I II III IV V VI
Description Slums Low Rise flats High Rise Flats Traditional Row Houses / Buildings Modern Row Houses Bungalows
Slums:
Slum clearance board had identified about 74 + 10 = 84 notified slums within the Corporation limits. Besides, Below Poverty Line Survey (BPL Survey) which was carried out by United Research Organization, identified about notes about 20% city population residing in slum areas.
In Rajkot, there is a policy of giving free water through community stand posts. In the areas of the city where there is piped water supply, water supply to the slum is through tankers.
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Low Rise and High Rise Flats : Residents of this housing type are from middle and upper middle class. There are apparently to be found in low rise and high rise buildings. Typically, a flat consists of tow or three bed-rooms, a hall, a kitchen and one or tow bathrooms. The area of a flat may vary from 550 Sq. fts. to 1400 Sq. fts. Traditional Row Houses : Residents of this housing type are from the middle to the lower middle class. These type of houses are mainly to be found in the walled city area, and internal city ward area. These are mainly ground floor or GF+1 structure having an area of 400 to 900 Sq. ft. A sump is provided for storage of water and most of these houses have a bathroom and toilet facility. Modern Row houses : These are newly constructed row houses in the areas outside the walled city area and widely seen categories of houses. Residents of this housing type are from the middle & higher middle income group. These are mainly GF+1 structure having typically an area of 900 Sq fts to 2000 Sq fts. Buildings are having one hall, two or three bed-rooms, kitchen and two to three Bath / WC. A small courtyard is also provided. Bungalows : Residents of this housing type are reducing because of the land cost. Some higher income group people posses such houses. The total area of the bungalows varies from 1500 Sq fts to 3000 Sq fts. A typical bungalow consists of three bedrooms, a hall, a dining room, a kitchen, a store room, a guest room, parking space and a small garden. There are a minimum o three bathrooms. In addition to Municipal water supply, these bungalows generally have their bore well with a sump and pumping arrangements. Distribution of Housing Types: Tax data & town planning sectional building plan data were analyzed for categories of houses. Proportion of housing categories for entire city workout as follows: Distribution of Housing Types Category Slums Low Rise Flats High rise flats Traditional Row Houses Modern Row Houses Bungalows % of population 20 19 03 15 38 05
Water demand is normally classified as domestic water demand and non-domestic water demand. Domestic water demand covers the use of water for drinking, washing, bathing, flushing etc. Non-
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domestic water demand includes the water demand for educational, institutional, religious institutions, hospital, swimming pools, commercial establishments, industries and fire fighting. Water demand is necessarily assessed for 100% satisfaction of the consumers. Under
constrained resources, water is allocated to consumers and the actual water supply thus may not be able to meet the demand. Since most of the water supply schemes have to be generally designed to meet the water demand in the long run, it is necessary to estimate the water demand on a 100% satisfaction basis. Field survey for Domestic Demand:
A sample survey was carried out in various housing categories. The results are as under:
Category
Sample Size
Weighted Average Consumption (LPCD)
Slums Low Rise Flats High rise flats Traditional Row Houses Modern Row Houses Bungalows
25 250 25 75 75 100
90 120 125 115 125 150
The sample size was kept small keeping in view the time and effort required for the survey.
Adopted Domestic Water Demand:
Based on above category wise water demand figures are finally adopted for planning purpose: ( Per capita Water Demand) Category Slums Low Rise Flats High rise flats Traditional Row Houses Modern Row Houses Bungalows Average for city Water Demand 90 120 125 115 125 150
124.35
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From both the alternatives, Domestic Demand: Adopted Domestic Water Demand =135 LPCD
5.6.1 Present Water Needs ( Domestic/Non-Domestic/Industrial in MLD) 5.6.1.1 Water demand for Domestic Purpose Rajkot Municipal Corporation supplies water to domestic consumers through piped individual tap connections in older Rajkot, through community stand post in slum and backward area. The major part of RMC water supply is for domestic consumers. Individual tap connections are chargeable, while
Demand of water Description 1. No. of House Connections 2. No. of Stand Posts 3. No. of Hand Pumps by RMC 4. No. of Tankers ( 10000 Ltrs. ) Approximate 1,85,000 1150 1700 250
water supply to domestic consumers through stand post and tankers are free of cost. In normal conditions, RMC supplies water 110 LPCD while in the scarcity period; it depends upon the availability of water.
5.6.1.2 Water demand for Commercial Purpose RMC does not encourages demand from Industrial and commercial consumers, resulted in to less connections in these categories. Commercial areas include office buildings, warehouses, stores, hotels, etc. Water is required for these areas to be supplied to offices, hotels, hospitals, hostels, etc. This quantity will vary considerably with the nature of city and with the number and type
commercial establishments present in it. In case of Rajkot city, there is no dense commercial area present. As the utility of these areas is only for the day time, a lump sum amount of 10% of the total domestic water requirements may be added for the water requirements for commercial areas. 5.6.1.3 Water Demand for Industrial Use In case of Rajkot, there is no major water based industries. Thus the requirement of water is only for other non-water based small scale and medium scale industries located in RMC area as well as in RUDA area. Assuming the water requirement for industrial use as 5% of the Domestic total water requirement 5.6.1.4 Water Demand for public/semi public use This includes the quantity of water required for public utility purposes, such as watering of public parks, gardening, washing and sprinkling on roads, use in public fountains, etc. For most of the public water supply schemes in India, a nominal amount of 5% of the total domestic consumption may be added to meet this demand. As stated above, the present population of Rajkot city is 1.15 million. The city having underground drainage facility should be served with per capita supply 135 liters for smooth functioning of sewerage. Considering the above rate of water supply, the present requirement of city works out to 155 MLD. However, yet the 55% area has been covered under underground drainage facility and for
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balance area the underground drainage project is under execution and likely to be completed by middle of 2007 and as such as on date the requirement of water per capita is being considered 120 LPCD. With this, the present requirement of the city 105 MLD. Considering 28% system losses the gross requirement works out to 135 MLD which is optimal availability of water from all the reservoirs during good rainfall year. However, during scarcity condition the city supply is being curtailed up to 90 LPCD depending upon the availability of water from the all the reservoirs. The industrial as well as commercial requirement in the city is meager. About 90% population is being served through tap connection whereas few slums are being supplied water on stand post basis and the area at higher elevation where pipeline is not feasible are being supplied through tankers.
5.7 Future Requirements

Taking into consideration the water requirement for all such uses the water requirement norms and adopting 135 lpcd water requirements .Domestic water requirements have been calculated for RMC areas for the years 2001, 2005, 2010, 2015 and 2020
Future requirements of water Total Maximum permissible Water water drawl from all requirem reservoirs In MLD Year ent In MLD 2001 136 94 2005 155 170 (75 from Narmada) 2010 235 254 (160 from Narmada) 2015 275 254 (160 from Narmada) 2020 315 254 (160 from Narmada)
Daily drawl shortfall In MLD 42* 0 -21 61
Thus it is cleared from the above table from year 2015 there will be daily drawl short fall of 21 MLD & will be 61 MLD during the year 2020., which will be made available from proposed Narmada pipe line project or Morbi branch
* In 2001 , Narmada water was not available
canal of Narmada Canal System. Thus, due to Narmada the availability of water will not be a problem. RMC will move the matter with government for getting additional quantity from Narmada at appropriate time. Thus, on implementation of the Sardar Sarovar Canal based drinking water supply project by Govt of Gujarat in full phase RMC will get required quantity of water as and when needed and due to which RMC has taken up the projects of increasing the storage and filtering capacity, additional pumping machinery and transmission main so that the city dwellers may get its water requirements either in morning or in evening in adequate quantity with moderate pressure. RMC has also planned to prepare a Detail Project Report for the areas in out skirts and which are likely to develop within the period of three to four years. RMC has identified the locations of additional sub head works in the project area.
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6
6.1 New Sub-Head works
Detaiilled Engiineeriing Desiign- Ciiviill Deta ed Eng neer ng Des gn- C v
At present, the water from Aji head works is being supplied to ward no.17 to 20 and part of ward no.4, 5, and 6. Because of the non-existence of the sub head works in the system, the duration of supply from Aji zone, starts early in the morning at 4.30 a.m. to late night at 11.00 p.m. Under the circumstances, the people are getting their requirement at odd hours and also with inadequate pressure. Not only that, since the distribution system is running round the clock, the distribution losses are also significant. To over come the above problem under the Program of JnNURM, Rajkot Municipal Corporation has at first instant decided to provide 6 nos. of additional sub-head works in the city distribution. They are _ 1. Elevated Storage Reservoir (ESR) & Ground Storage Reservoir (GSR) with
pumping station & pumping machinery at ward no.6, vinod nagar 2. Elevated Storage Reservoir (ESR) & Ground Storage Reservoir (GSR) with
pumping station & pumping machinery at ward no.7 Labahadur plot 3. Elevated Storage Reservoir (ESR) & Ground Storage Reservoir (GSR) with
pumping station & pumping machinery at ward no.17 , pedakroad x green land crossing 4. Elevated Storage Reservoir (ESR) & Ground Storage Reservoir (GSR) with
pumping station & pumping machinery at ward no.16, near rail nagar Details will be submitted in phase-II program 5. Elevated Storage Reservoir (ESR) & Ground Storage Reservoir (GSR) with
pumping station & pumping machinery at ward no.12, near housing board - Details will be submitted in phase-II program 6. Elevated Storage Reservoir (ESR) & Ground Storage Reservoir (GSR) with
pumping station & pumping machinery at ward no.23
6.1.1 ESR & GSR at ward NO.6

One sub-head work is proposed to be provided in ward no.6 in T.P.Plot No. which is reserved for school and playground. The available plot size is 120 X 57 mt. Approximately 1.25 lacs present population is to be served through the proposed ESR and GSR to be constructed in the above T.P. plot As stated above, the present population of the proposed site of ESR and GSR is around 1.25 lacs and same will be about 1.60 lacs in the year 2015. Considering the supply 30 lacs gallons per capita per day, the total present requirement works out to 37.50 lacs gallons per day and that of for the year 2015 works out to 48 GPCD. Ideally 24 hours storage of future requirement of 48 lacs gallons per day is required to be provided but because of the limited space, it is proposed to provide storage of 14 hours capacity of
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ultimate stage requirement. With this the storage capacity works out to 28 lacs gallons i.e. 12.75 M.L., provide ground storage 10 M.L. and elevated stage - 3 M.L. 6.1.1.1 Proposal: In view of above, it is proposed to provide GSR of capacity 10 ml with water height 4.5 mt. and ESR of capacity 3 ml with 25 mt. staging height and with water height 6 mt in container. Water is proposed to be drawn from the existing rising main of the Maliya Branch Canal based pipeline project laid along National Highway from Aji head works to Mavdi. At off take point the size of the branch connection is proposed 500 mm dia M S / 450 mm dia D.I. (K7 category). Through above main, Water will be collected in the proposed GSR by gravity and same will be pumped by 4 nos. of Centrifugal pumping set each having capacity 942 m3/hr against the head of 35 mt. into the proposed ESR. The said ESR is proposed to be connected with the existing distribution system. Water is proposed to be supplied to part of the area 3 hours in morning and remaining area 3 hours in evening depending upon the availability of water from the Aji head works. Thus, this area will get its requirement within the period of 6 hours and for remaining 18 hours, the water will be stored into ESR-GSR. 6.1.1.2Civil Design Component: (1) Design of inlet pipe line (from off take point in Aji-Mavdi main of 850 mm dia.) 1.25 lacs o The present population of sub head work o The population for the year 2015 1.60 lacs o Considering rate of W.S. 30 GPCD o The requirement of water works are as under For 2005- 1.25 x 30 = 37.5 lacs gallon = 17.02 ML For 2015 1.60 x 30 = 48 lacs gallon = 21.79 ML o Storage capacity 13 M.L. to be filled up in 14 hours. In let pipe capacity...... 13 14 = = Assume velocity 1.2 mt/sec. The size of inlet main work out to 0.258 = A x 1.2 D= 523 mm Say 500 mm M.S. or 450 mm D.I.
0.9285 ML/hr. 0.2579 m3/ sec
o o
(3)
Size of ESR-GSR: Size of GSR . 10 ml capacity provide two compartment Capacity of one compartment - 5 ml = 5000 m3 Provide water depth 4.5 mt. Therefore area 5000 = 1111.11 sq.mt. 4.5 Provide rectangular size L X B = 1111.11 sq.mt. Assume L = 1.25 B Therefore, 1.25 B x B = 1111.11 Therefore, B2 = 1111.11 = 888.88 1.25 Therefore, B = 29.81 mt. Say 30 mt.
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o o
therefore, L = 37.50 Provide GSR size 37.5 x 30 x 4.5 = 5062.5 m3 Size of ESR . Capacity of ESR is proposed of 3 ML. Therefore, provide ESR with shaft dia. - 15.0 mt. and water depth in container 6 mt Height of ESR 25 mts..
o o o (4)
Design of pumping machinery: o Provide electrically driven C.F. sets o Total period of supply - 6 hrs. o Quantity to be supplied - 17.02 ML present = 2836.66 m3/hr 21.79 ML Future = 3631.66 m3/hr o o Provide 3 set working for present demand Say: 946 m3/hr Therefore, size 2836.66 = 945.55 3 For ultimate demand 4 sets will be working. Therefore, 946 x 4 = 3784 m3/hr > 3632 m3/hr Therefore, provide six sets each having capacity ,946 m3/hr against head of 35 mt. Therefore K.W. = 946 x 35 x 1.15 = 129.61 367.2 x 0.8 Say 130 KW Therefore, Total K.W. .. 130 x 6 = 780 KW Actual load 20 KW 800 KW For present stage 100% standby (3+3) For ultimate stage 50% standby 94+2)
o o o o
o o
(5)
Design of pipe size: o Rising main from P.H. to ESR o Total quantity 946 x 4 = 3784 m3/hr o Assume velocity 2 mt/sec. 1.051 = A x 2 d = 818 mm dia. Say 800 mm dia. for ESR Size of inlet Size of outlet Size of over flow Size of washout -
1.051 m3/Sec.
800 mm dia 850 mm dia 850 mm dia 200 mm dia
22
At present, ward no.7 of Atika area is getting it's Drinking water requirement through gurukul head works. But because of the higher elevation approximately 50% area is not getting adequate supply as water is to be supplied against gravity. For improvement in supply, it is now necessary to have an additional subhead work in ward no.7 near by pass which is having highest ground level. To transfer Narmada water in Jubilee and Gurukul zone a 700 mm dia M S transmission main is proposed to be laid along Dhebar road South. The said transmission main will work as feeder main for above proposed ESR-GSR. The present population of ward no.7 is around 60,000 souls however, approximately 50% population of the ward is not getting adequate quantity of water and as such ward no.7 is now proposed to be served partly from Gurukul head work and partly from proposed head work of near Lalbahadur Shastri society. As stated above about 30,000 present population is to be catered through new ESR-GSR. Considering population growth 2.75% every year the approximate population for the year 2015 will be around 39000 considering the rate of water supply per capita 30 gallons, the requirement works out as under: For present requirement of 2005 - 30000 x 30 = 900000 gallons = 4.086 ML For further requirement of 2015 39000 x 30 = 11,70,000 gallons = 5.32 ML Since the area is small, it is proposed to supply the water within 2 hrs duration and provide 24 hours storage. Provide 1.32 ML capacity GSR with 20 mt. staging ht and container ht. 4.5 mt. whereas a 4.0 ML capacity GSR with 4 mt water depth . 6.1.2.1 Proposal: Under Maliya canal based water supply pipeline project 850 mm dia M S transmission main has been laid from Aji to Mavdi along National Highway bypass. As per planning approx.6 to 7 mgd is to be transferred to Gurukul and Jubilee zone and as such it has been proposed to connect the Bhadar transmission main with above 850 mm dia Aji-Mavdi transmission main by 700 mm dia M S transmission main to be laid along Dhebar road south in length of 1.5 km. From above connecting main, a feeder main of 350 mm DI is proposed to be laid for collecting water in above GSR. The length of feeder main is approximately, 500 mt. Water through above feeder main will be collected in GSR of capacity 4.0 ML from where water will be pumped into the ESR by means of CF pumping sets having capacity 887 m3/hr against head of 30 mt. The ESR will be connected with existing distribution system.
6.1.2.2 Civil Design Component
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1. Design of inlet pipe line (from off take point in Aji-Mavdi main of 850 mm dia.) o o o Total requirement 5.32 ML Capacity of GSR - 4 ML with 4 mt. water depth Provide circular shape Therefore, 4 ml = 4000 m3 Therefore, area = 4000 /4 = 1000 m2 Therefore, 11/4 a2 = 1000 Therefore, d = 35.69 mt. Say 37 mt. Provide GSR having dia 36 mt. with water depth 4.0 mt. Therefore, Inlet size 350 mm dia Wash out 100 mm dia Over flow 200 mm dia.
o o o o
(2)
Provide ESR of 1.32 ML capacity with staging height 20 mt. and water depth in containing 5 mt. o Provide size of rising main 600 mm dia with velocity 2.5 mt./sec. o Therefore, size of piping for ESR will be as under: Inlet 600 mm dia M S Outlet 650 mm dia M S Overflow 650 mm dia M S Washout 150 mm dia M S Size of ESR-GSR: Size of GSR . o 4 ml capacity provide two compartment Capacity of one compartment - 2 ml = 2000 m3 Provide water depth 4 mt. Therefore area 2000 = 500 sq.mt. 4 o Provide rectangular size L X B = 500 sq.mt. Assume L = 1.25 B Therefore, 1.25 B x B = 500 Therefore, B2 = 500 = 400 1.25 o Therefore, B = 20 mt. Say 20 mt. o therefore, L = 25 o Provide GSR size 20 x 25x 4 = 2000 m3 o Size of ESR . o Capacity of ESR is proposed of 3 ML. o Therefore, provide ESR with shaft dia. - 15.0 mt. and water depth in container 6 mt o Height of ESR 25 mts.. Design of pumping machinery o Total quantity to be supplied 5.32 ML in the duration of 2 hours.
(3)
(4)
o Therefore, rate of pumping will be 5.32 /2 = 2.66 ML/hr = 2660 m3/hr. o Head = Static 20 + 5 + 4 = 29.00 +Friction & ay & Other 03.00 = 32.00 mts o Provide three sets working and one set on standby. o Therefore, 2660 / 3 = 886.66 = 887 m3/hr o Therefore, K W 112 x 4 = 448 460 KW o Say Design of pipe:
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Total discharge 5.32 ML Assume above quantity is to be received in 10 hrs. Therefore, discharge per hour 0.532 ML = 532 m3/hr = 0.1477 m3/sec. Assume velocity in pipeline 1.5 mt/sec. Therefore, 0.1477 = 1.5 A Therefore, A = 0.098 Therefore, d = 354 mm Provide size of feeder main 350 mm dia D.I.

At present the ward No. 17 & 18 are being catered from Aji head works. The location of ward No. 17 is at lower elevation, where as that of 18 is at higher elevation. Under the circumstances it is not possible to serve both the wards at a same time from Aji. Also the distance of both the wards from Aji-I is significant & as such due to leakage through the joints the pressure in the main line reduces drastically which affect adversely on supply. In view of above it has been planned to have separate sub headwork for ward No. 17 & 18 at suitable location from where both the wards could be supplied water with adequate pressure and quantity with minimum line losses. The present population of ward no. 17 is 68658 souls where as that of 18 are 53452 souls . The development in both the wards is fast due to which the population growth in last four year has been observed 4%, which is because of the development of slum pockets due to migration from villages. Now the migration process has been slow down, under the circumstances the normal growth rate of 2.75 % every year is to be taken into consideration for forecasting the future population. In view of above the future population of both the wards worked out as under: Population as per 2001 Present Population of 2005 Population for the year 2015 - 105000 souls base year - 122010 souls 4 % growth - 155563 souls 2.75% growth
In this area the slum population is significant and yet about 30% area is to be covered under sewerage system and as such the rate of W.S 25 gallons per day per capital would be sufficient. Thus the water demand works out as under. (1) For the year 2001 (2) For the year 2005 (3) For the year 2015 105000 x 25= 2.625mgd 11.91 MLD
122010 x 25= 3.05 mgd 13.85 MLD 155563 x 25 = 3.89 mgd 17.66 MLD
6.1..3.1 Proposals:
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The above area is proposed to be served through Aji Headworks. Where water from Narmada is available. In ward No. 17 under T.P. scheme is reserved for The said plot is at higher elevation & same is more suitable location for creation of sub head work for ward No. 17 and 18. In view of above it is proposed to provide ESR & GSR at above location. Ideally storage of 24 hrs is more desirable. However due to space & finance constructive, it is proposed to provide storage of 13.00 M.L instead of 17.66 M.L. Approximately 18 hrs. The water will be drawn from 600 mm dia M.S. Pipe line, which has been laid along by pass during scarcity of 1999-2001. At present through above pipeline water is being transferred to Ghanteshwar head work, but on completion of extension works of Ghanteshwar head work, the above line will be idle. The caring capacity of the said 600 mm dia graving line is around 22 MLD as such and approximately 18 hrs the full quantity will be made available at proposed ESR GSR site. In view of above water from 600 mm dia gravity main will be collected in GSL of capacity 10 ML from where water will be pumped into the ESR by means of C.F. Pumping sets having capacity 552 m3/hr against head of 37 mt. The ESR will be connected with distribution system & both wards will be supplying water by staggering. 6.1.2.2 Civil Design Component: 1. Design of inlet pipe line (from off take point in Aji-Mavdi main of 850 mm dia.) Design of Gravity main 152.40 mt o Out let level of sump at Aji o G.L. at ESR GSR site........................................... 135.00 mt o Length of Pipe Line.............................................5.0 Km Approximate. o HGL required at proposed GSR............................... 141.00 mt o o o o o o therefore, Head available 152.40 141 Therefore, net head per K.M. 5.0 x 1.1 = 2.07 mt/km = 11.4 mt 11.40
The size of gravity main 600 mm dia M.S. unlined considering value of C= 90 The carrying capacity works out as under: Q = 7.436 x 10 9 x 90 x (600) 2.63 x (2.0) 0.54 = 13.555 x 1.4812 = 20.07 Which is more than 17.66 MLD. therefore, inlet of GSR..... 600 mm dia Wash out...................... 150 mm dia overflow ...................... 300 mm dia
o o
2. Size of ESR-GSR
26
GSR o Design of storage o Provide rectangular static of GSR with two No of compartment o Capacity of GSR 10 M.L. therefore, capacity of one compartment 5 M.L. = 5000 m3 provide water depth 4.5 mt therefore, area = 5000 o Assumed L B = 1.25 4.5 = 1111.11 m2
therefore 1.25 x B2 = 1111.11 B= 29.81 mt say 30 mt. therefore L= 1.25 x 30 = 37.50 m Provide GSR with two compartment each having size 37.5 x 30 x 4.5 = 5062. 5 m3 o Provide ESR of capacity 3.0 M.L. with staging ht 25 mt & water depth in container 6 mt 3. Design of pumping machinery o o Design of pure water pumping machinery Total quantity to be pumped 17.66 MLD Duration of supply 8 hrs. therefore, Rate of pumping 17.66 x 1000 = 2207.5 m3/hr o Provide four sets working therefore capacity of one set 2207.5 = 551.87 m3/hr Say o o therefore, KW = 552 x 37 o 367.2 x 0.8 x 1.15 = 76.45 say 80 KW = 552.0 mt. therefore, total head 4.5 +25+6.0+1.5 = 37 mt
therefore 80 x 6 + 20 = 500 K.W.
4. Design of pipe: o o Design of pure water rising main Total quantity 552 x 4 = 2208 m3/hr = 0.613 m3/sec o Assume velocity 2.0 mt/sec therefore, 0.613 TT (d) 2 x 2.0 4= 0.625 o Provide size of rising main 600 mm dia. Therefore, Piping of ESR
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`Inlet outlet wash out overflow
600 mm dia 650 mm dia 250 mm dia 650 mm dia
6. 2 Augmentation Sub Head works

6.2.1 Aji subhead works The first piped water supply scheme based on Aji-I reservoir was implemented in the year 1955-56 with capacity of scheme 20.43 MLD. The scheme was implemented in two stages. The details of stage-I work are as under:
i) ii) iii) iv) v) vi)
Intake arrangement with raw water gravity main raw water sump raw water pumping machinery with 500 mm CI rising main 20.43 MLD capacity WTP 4.08 ml capacity pure water masonry reservoir Transmission and distribution system
Subsequently, in 1971-72 the extension work in filter and pure water sump was carried out. The capacity of filter was increased by 6.81 MLD whereas that of sump 1.36 ml with additional raw water pumping machinery.
The location of said head work is at high elevation of 156 m above mean sea level and because of which through above head work water is being supplied by gravity to part of city.
During course of time because of the rapid development of city, Rajkot Municipal Corporation has augmented the filtering as well as storage capacity of head work suitable to availability of water. The total availability of water at Aji head work is as under:
In good rainfall year Aji-I reservoir Lalpari Randarda twin lake Narmada water 20.25 MLD 06.81 MLD
74.00 MLD Total 101.06 MLD
The total filtering capacity at head work is as under:
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1. 2. 3.
Old filter New filter No.1 New filter No.2
27.24 MLD 11.35 MLD 65.00 MLD Total 103.59 MLD
Similarly the capacity of pure water reservoir is around 30 ML. From above headwork about 40% city area is being catered. As stated above, in the water supply scheme which was implemented, in the year 1955-56, the storage reservoirs were constructed in UCR masonry with bottom in plain c.c. Since the life span of above masonry sump has been over, the leakages from the sump has been started since long and daily about 2 to 2.5 MLD of water is being wasted from the above sump in leakages. Under the circumstances, Rajkot Municipal Corporation has decided to provide RCC cladding in mix M-25 with roof slab inside the sump so that the outer wall will work as supporting structure only. 6.2.2 Other subhead works The water supply problem of Rajkot city is very acute. till now the availability of water was limited, and also due to erratic monsoon water scarcity was frequent. Since the quantity of water is limited, to maintain the input and output Rajkot Municipal Corporation is supplying water to the city dwellers by zoning system from 4.00 a.m. to 11.00 p.m. with 800 to 900 nos. of small zones, due to which daily whole Municipal administration remains engaged with water supply only and also due continuous running of distribution system the line losses are also more.
Now the Narmada water has been made available to Rajkot by State Government and government will supply required quantity of water from canal system. Under the circumstances, Rajkot Municipal Corporation has now decided to augment the present duration of supply by providing additional ESRGSR in city which will increase the storage capacity.
For adequate distribution, in past Rajkot Municipal Corporation had created following sub head work in the system the details of which is as under: Sr No 1 Ward No 12 Sojitranagar Name of sub head work Component work ESR GSR pumping machinery with pump house 2 14 Bajrangwadi -do-dofrom Ghunteshwar Water is being supplied from Nyari headwork of head Remarks
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headwork 3 4 19 4 Dudhsagar Hudco -doESR GSR pumping machinery with pump house 5 6 17 19 Marketing yard LIG Quarter of GHB -do-do-do-do-dofrom Aji head work Water is being supplied from Aji headwork
In above all sub headwork, through express feeders water is being transferred from main head work but because of the limited storage capacity of each sub headwork the duration of supply is around 12 to 14 hours depending upon the command area of sub head work. To overcome this Rajkot Municipal Corporation has decided to increase storage capacity in form of ground service reservoir wherever the land in sub head work is available. At first instance Rajkot Municipal Corporation has planned to increase the storage capacity in three sub head work as detailed below: Sr No 1 Ward No 12 Capacity of addl. GSR in M.L. 1.1 ML After completion of work total capacity of storage in ML E.S.R. 1.45 ML GSR 2.00 ML New 1.1 ML Total 4.55 ML ESR 0.50 ML GSR 1.5 ML New GSR 3.5 ML Total 5.5 ML ESR 1.45 ML GSR 3.50 ML New GSR 3.5 ML Total 8.45 ML
14
3.5 ML
19
3.5 ML
Thus, by increasing the storage capacity and by making the required change in pumping machinery it will be possible to reduce the timing of supply hours limited to 6 to 8 hours.
Also if needed additional pipeline parallel to existing express feeder will be laid so that water could be transferred as early as possible
Further for pumping water from Bhavnagar road pumping station to existing GSR in Ward No.19 as per original project 450 mm dia AC pressure pipe of 2.7 km in length was laid. the said line is giving lot of trouble in running and gets burst frequently because of which Rajkot Municipal Corporation has suggested to replace above A C pipeline into metallic pipe.
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6.3 New Head works

The government of Gujarat have conceived a drinking water supply project based on Sardar Sarovar Canal for 135 nos. of urban town and 8600 nos. of village of State. The cost of the project is Rs.7000 crore. The phase-I of the -project has already been implemented whereas the implementation of phase-II is now started by the government and likely to be completed within couple of years. In above project, the allocation of water for Rajkot city for the year 2011 is 115 MLD whereas for the year 2021 same is 160 MLD. The above quantity is to be drawn from the section-A of the project i.e. Dhodhidhaja, Ratanpar, kalyanpar, Dwarka pipeline network. For drawing of water, in above pipeline, 3 off takes have been suggested; (1). at Ratanpar, (2). at Bedi and (3). at Nyari. The pipeline network of Dhodhidhaja, Ratanpar, Kalyanpar, Dwarka is yet not implemented, as Narmada water has not reached to Dhodhidhaja reservoir of Surendranagar District because the lift pumping stations are yet to be erected in Saurashtra Branch Canal. It is expected that the Narmada water will reach to Dhodhidhaja after about 5 years, however, as the rural and urban areas of Rajkot district, Jamnagar district as well as Kuccha district were facing acute water scarcity every year, the government of Gujarat have implemented a pipeline project of Maliya-Morvi, Hirapar, Jamnagar based on Maliya Branch Canal of Narmada work which is already completed. The capacity of the said project is 440 MLD and water is to be pumped from Maliya canal. All the civil work of MBC is already completed and GWSSB has made temporary arrangement of pumping from SBC to MBC at the place of off take of MBC in size at Dhanki. The pumping capacity is about 1000 MLD. Thus, as an interim arrangement, for Rajkot an off take has been given at Hirapar to draw 200 MLD of water from the main line work of Maliya Jamnagar pipeline section. The pipeline section Hirapar-Rajkot-Kotharia is also commissioned and from that section in phase-I Rajkot Municipal Corporation is getting 74 MLD supply at its Aji head works and Rajkot Municipal Corporation has planned to distribute said quantity among the nearby area by creating additional sub headwork in ward no.6, 7, 17 and 21. The carrying capacity of the branch line Hirapar-Rajkot-Kotharia is 200 MLD. The said branch line is crossing the proposed main pipeline Dhodhidhaja-Dwarka at village Ratanpar. Thus, till the Narmada water is not available in Dhodhidhaja, to supply water up to Dwarka the government of Gujarat has taken up the pipeline work partly from Ratanpar to Kalyanpar of various sizes of pipe. When Narmada water will be received in Dhodhidhaja the remaining portion of the pipeline between Dhodhidhaja to Ratanpar will be laid and supply of water from Maliya Jamnagar section will be shut off. At present, Rajkot Municipal Corporation is getting 74 MLD at Aji head work. After treatment the treated water is being transferred to Gauridad for Ring road zone for ward no.22 and 21 (part).
In view of above, the branch line from Hirapar to Ratanpar have a carrying capacity of 200 MLD, out of 200, 100 MLD will be pumped towards Dwarka and remaining 100 MLD will be pumped towards
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Rajkot and Kotharia. Thus, now Rajkot Municipal Corporation is in a position to draw out of 74 MLD the part requirement of 30 MLD water from proposed Ratanpar Kalyanpar pipeline of GWSSB. The size of which is 1950 mm dia. and problem of transfer of water from Aji to Gauridad will be solved.
In 1998, the boundary limit of Rajkot was extended by government merging nearby urban areas of Raiya, Nana Mava and Mavdi. To cater the additional demand of newly merged area, Rajkot Municipal Corporation has got the reservation of drinking water in Nyari-II reservoir located about 15 kms away from Rajkot. Thus, in 1998 a water supply scheme based on Nyari-II reservoir was implemented by Rajkot Municipal Corporation with drawl of 6.8 MLD directly from the reservoir and about 5.9 MLD from the seepage of the reservoir. Thus, the capacity of the system is 13.62 MLD. Under above project following works have been executed and commissioned.
1. 2.
Laying of 500 mm dia M S raw water trunk main from Rangpar to Ghunteshwar headwork. Providing and erecting submersible pumps 3 nos. each having capacity 198 m3/hr against the head of 30 mt in valve tower at Nyari-II to draw raw water.
3. 4. 5.
Construction of 13.62 MLD capacity water treatment plant at Ghunteshwar headwork. Construction of GSR of capacity 4.0 ml at Ghunteshwar. Providing and erecting pure water pumping machinery with pump house as under: 684 m3/hr against the head of 40 mt. (1+1) 270 m3/hr against head of 40 mt (2+1) 270 m3/hr against head of 20 mt. (1+1)
6. 7. 8.
Laying of 500 mm M S line from Ghunteshwar to Ring road head works. Construction GSR of 2.5 ml capacity at Ring road headwork. Construction of ESR of capacity 1.25 ml with its staging height 20 mt. at Ring road headwork.
9. 10.
Construction of pump house at Ring road headwork. Providing and erecting pumping machinery having capacity 421 m3/hr against head of 40 mt. to pump pure water from GSR to ESR at Ring road headwork.
In view of above, from Nyari-II reservoir the water is being pumped to Ghunteshwar filtration plant from where again the treated water is being pumped to Ring road head works and from ring road head works the Ward no.22 and 23 are being catered. In 1998 the requirement of water was hardly 12 to 13 MLD, however, there after there was fast development in the area and population growth have been recorded 4% to 5% per year in last decade and because of which the water supply demand of this area has been boosted from 13.62 MLD to 25 MLD. Under the circumstances, since there is no additional
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quantity of water is available in Nyari-2 and in surrounding region, the water from Sardar Sarovar pipeline project being received at Aji-I reservoir is being transferred to ring road through the existing pipeline network. Thus, water has to travel to and fro and line losses are significant. But now the government has taken up the work of Ratanpar-Kalyanpar pipeline it is now possible to draw raw water from the said pipeline. Thus instead of diverting 74 MLD of water at Aji reservoir, it is now proposed to draw 50 MLD of water from the newly proposed pipeline at Nyari off take and it is proposed to create a new head work for catering the demand of ward no.22 and 23 at Raiyadhar.
In above proposed pipeline the nearest point of off take is Nyara village, which is, located about 6.5 kms from existing Ghunteshwar head works. Earlier, it was planned to extend the Ghunteshwar head works and the Revenue department was requested to transfer land to RMC. However, in surrounding of Ghunteshwar head works no waste land is available in required quantity and as such it is now proposed to create new head work on Raiyadhar area which is just 150 mt away from Ghunteshwar. RMC has approached District Collector for transferring of about 4 hectares of land in Raiyadhar area where the land is completely waste land and technically more suitable as same is located at higher elevation.
In view of above, it is proposed to draw 45 MLD of water from Nyara to Raiyadhar where water will be pumped into the proposed filtration plant of 45 MLD capacities and from the said head works water is proposed to the supply to the residents of ward no.22 and 23 and 21 (part).
At present from Ghunteshwar head work by transferring water from Aji head work, the ward no.22 and part of the ward no.21 are being served whereas Nyari-2 water is just sufficient to cater the present demand of ward no.23 and Bajrangwadi area of ward no.14. 6.2.1 Population& Requirements The population of ward no.21, 22 and 23 as per census 2001 is 2,47,000 and present population for the year 2005 is 2,87,015 souls out of which, population of 1,37,015 is of ward no.22 and approximately 35,000 population is of ward no.21, are being served through Ring road head work. Thus, the present, total population of 1, 72,015 of ward no.22 and 21 (part) is dependent on Ring road head work. The observed growth rate is 4% which is due to rapid development, however, the said growth rate is not realistic and as such considering the growth 2.75% every year the present and future population for Ring road head work zone works out as under:
Population for the year 2005 Population for the year 2015
1, 72,015 souls 2, 19,320 souls
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Considering present rate of water supply 30 gallons per capita per day, the present demand works out to 1,72,015 x 30 = 5.16 mgd i.e. 23.43 MLD whereas that of requirement for the year 2015, 2,19,320 x 30 = 6.58 mgd i.e. 30 MLD as the underground drainage project is to be implemented by end of 2007. The rate of water supply has been considered 30 G.P.C.D. i.e. 136 LPCD. 6.2.2 Availability of water As stated above, it is possible to draw 45 MLD from Narmada pipeline from Nyara off take which will cater the areas as under:
Total availability 45 MLD 1. 2. 3.
9.91 mgd45.00 MLD 6.58 mgd29.87 MLD 3.00 mgd..13.63 MLD 0.33 mgd01.50 MLD 9.91 mgd 45.00 MLD
Demand of ward-22 and 21 (part) Demand of Ward-23 To be transferred to Nyari-I zone
At present the ward No. 23 is getting it's requirement from Ghanteshwar head works, where water is being received from Nyari-2 reservoir and is being treated through existing W.T.P. at Ghanteshwar, Water from Ghanteshwar headworks, is being pumped to existing ESR-GSR on Ring Road, from where ward No. 23 is being served & as such water has to travel to and fro, which increases the power cost as well as line losses. Under the circumstances it is desirable to provide a separate ESRGSR in the ward no.23 so that double travel of water could be avoided.
The Raiyadhar area, in Ward No. 23, is at highest elevation of 143 Mt. The average G.L. of Ward No. 23 is around 135 mt and as such if at Raiyadhar, an ESR of 20 mt staging height is constructed, with elevation of 163 mt, the whole area could be served with adequate pressure in the duration of 4 to 6 hrs. RMC has process the land acquisition proposal and within a months time the required land on Raiyadhar will be made available by collector Rajkot. Original W.S.S. of 13.62 MLD capacity based on Nyari-2 reservoir was for ward no.21 (part), 22 and 23 but now same is proposed for Bajrangwadi H.W. of ward no.14 and Sojitra head works of Ward no.12 of Nyari-I zone.
In view of the it is proposed to construct a sub head work at Raiyadhar with ESR & GSR.
The present population of ward No. 23 is around 1.15 lacs souls and same will be 1.45 lacs souls in the year 2015 considering 2.75% growth rate every year.
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The most of the resident of this area are from economically & society backward class. Most of the houses are without foundation and structurally very weak and as such in this area an underground Sewerage project is not possible during excavation as due to blasting the houses will be damaged under the circumstances the sullage water is to be disposed off through surface drainage only. Thus as per norms, the area without underground drainage system are to be served at the rate of 20 GPCD i.e. 90 LPCD.
In view of above the total requirement of Ward No. 23 works out as under : Present requirement = 1.15 x 20 =23.00 Lacs gallon per day i.e. 10.45 MLD
Future requirement the year 2015 = 1.45 x 20 = 29 lacs gallon/ day say 30 lacs gallon. Say 13.62 MLD
At Ghunteshwar the availability of water is 13.62 MLD and at Raiyadhar head works the availability of water is 45 MLD. Thus, total quantity available is around 13.62 + 45.00 = 58.62 MLD.
Considering the pumping hours 22, the design capacity of the system works out to 63.94 say 65 MLD. On implementation of Raiyadhar head works, water being received from Nyari-2 at Ghutneshwar will be distributed between 2 sub head works of Nyari zone namely, one at Bajrangwadi sub headwork in ward no.14 and another at Sojitrangar sub headwork in ward no.12. Thus, the Ghunteshwar sub head works will be made free from the supply of water to ward no.21 (part), 22 and 23. Out of 58.62 MLD, the requirement of ward no.21 and 22 for the year 2015 is 30 MLD and that of ward no.23 is 13.62 MLD the balance 15.00 MLD will be transferred to Nyari zone to cater the additional requirement of Bajrangwadi and Sojitra head works. Considering above fact, the distribution system of 58.62 MLD has been designed.
6.2.3 Project Proposal The Nyari-II reservoir is of irrigation-cum-water supply and every year from this reservoir water is being released for irrigation purpose. Under the circumstances, from February onwards it is not possible to draw 6.41 MLD of water from Nyari-II reservoir, as the location of intake works are at higher elevation and because of the technical reason, the reservoir water stops coming into the valve tower. Thus, February onwards only seepage water is being made available which also last up to middle of April. Thus, the reliability of Nyari-II reservoir of getting adequate quantity of water is up to February only. Under the circumstances, it has been planned to draw deficit quantity from Narmada pipeline project whenever the Nyari-II water is not available. Thus, the system has been designed for 65
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MLD instead of 50 MLD. Normally only 50 MLD water will be drawn but under the above circumstances, because of the non-availability of water from Nyari-II, additional quantity could be drawn from the same pipeline. As stated above, it is proposed to draw 65 MLD of water from proposed GWSSB trunk line at village Nyara. The average ground level at village Nyara is 118 mt whereas full supply level of proposed filtration plant is 148 mt. Thus, water is to be pumped from Nyara to Raiyadhar. At Nyara off take a sump of 4 ml capacity with pump house of size 20 x 15 mt is proposed to be constructed. As per economical design of rising main for 65 MLD requirements, the size of rising main works out to 1150 mm dia. M S. As stated above, now the existing headwork of Ghunteshwar is to be made free for Bajrangwadi sub headwork of ward no.14 and Sojitranagar sub headwork of ward no.12 and the quantity to be received at Raiyadhar is only for the ward no.22 and 23 and part area of ward no.21.
For Bajrangwadi H/W. The existing storage at Bajrangwadi Proposed additional storage GSR..........1.50 ML ESR...........0.50 ML GSR..........3.5 ML 5.5 M.L. The design requirement of Bajrangwadi is 6.68 MLD. & within 4 hrs water is to be distributed. Considering hours of pumps 18, at Ghanteshwar the capacity of pumping machinery works out to. 6.68 /18 x 24 = 8.90 MLD = 371 m3 / hr.
as against the capacity of existing pumps at Ghanteshwar is 493 m3/hr & hence okay. Similarly is it is also possible to transfer required 8.17 of water to Sojitra H/W from Ghanteshwar by existing pumps of capacity 270 m3/hr (2 + 1) and by proposed A.C. pipe line from Sojitra to Ring Road in length of 1.5 K.M. Thus the following works are proposed for ward no. 12 & 14 (1) Construction of additional GSR (2) At Bajrangwadi 3.5 M.L. capacity L.S. Rs.45.00 lacs
At Sojitranagar H/W. 1.1 M.L capacity L.S. Rs.13.00 lacs
Providing lowering laying & Jointing 350 mm dia A.C. Class-15 Kg pipeline From Ring Road to Sojitra about 1.5 K.M in length L.S.Rs.17.00 Lacs
(3)
Modification in pumping Machinery At Bajrangwadi and Sojitra L.S.Rs.05.00
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Rs.80.00 Lacs All existing works of Ghanteshwar are requires to be utilized without any modification. Designs for Intake Arrangement o Design of rising main from Nyara to Raiyadhar
Total flow 45 + 13.62 = 58.62 MLD Hours of pumping 22 Therefore Q design - 63.95 Say 65 MLD G.L. at Nyara S.L. at Nyara G.L. at Raiyadhar FSL of stilling chamber of filter 118.00 mt 117.00 mt 144.00 mt 148.00 mt
Therefore, static lift 148 - 117 = 31 mt Length 6500 mt. As per economical design of rising main the size works out to 1127 mm dia. Therefore, provide internal finish dia 1150 mm. M S pipe inside lined and outside gunitted.
Therefore, 65 = 7.436 x 10-9 x 120 x (1150) 2.63 x (h)0.54 65 = 100.0359 x (h)0.54 Therefore h = = 0.45 x 1.10 = 0.495 mt/km 65 100.0359
Therefore, total head: Static Friction 6.5 x 0.495 = Other Total 3.21 m 5.79 40.00 31.00 m
Now, 65 = 65000 - 2708.33 m3/hr 24 Provide 4 set working Therefore capacity of one set 2708.33 = 677.8 m3/hr 4 Provide pump capacity 700 m3/hr
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Thus, with 3 pumps running, the discharge will be 700 x 3 x 24 = 50.40 MLD When Nyari-2 water will be made available only three pumps will run and at that time the standby unit will be 100% and when Nyari-2 water will be shut off, 4 pumps shall have to be run at that time standby will be 50%. Therefore, provide six sets each having capacity 700 m3/hr against head of 40 mt (3 working + 3 standby) or (4 working + 2 standby). Kw = 700 x 40 x 1.15 = 109.61 367.2 x 0.8 Total 110 x 6 + 25 = 685 Kw Designing Distribution main Say 110 Kw
Raiyadhar Headworks to Ring Road Headworks
Total quantity to be received from Nyara - 50.00 MLD The design requirement of Ward 23 14.85 MLD -35.15 MLD Total 50.00 MLD
The requirement of ward 21 (part) 22 & Nyari zone
Assume for supply of water to ward no.23, in duration of 6 hours. Therefore, quantity to be pumped for ward no.23 14.85 x 1000 = 2475 m3/hr 6 Provide three pumps working. Therefore capacity of one pump works out 825 m3/hr (3 working + 1 standby) Assume water to be transferred to ring road headwork in 12 hours. The rate of pumping for Ring road works out to 35.15 x 1000 = 2929.16 m3/hr 12 Therefore, for initial period of six hours. The rate of pumping will be 2475 + 2929.16 = 5404.16 m3/hr and for remaining period the pumping rate will be 2929.16 m3/hr Provide 4 pumps working, the capacity of one pump works out to 735 m3/hr (4+2)
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Therefore provide pump with capacity 735 m3/hr (4 working + 2 standby) Pumping during peak (825 x 3) + 735 x 4) = 5415 m3/hr Pumping during ave. 735 x 4 = 2940 m3/hr Now: G.L. at Raiyadhar - 144.00 mt. Assume height of ESR - 20 mt Therefore, HGL at Raiyadhar 144.00 + 20.00 = 164.00 mt
FSL of Ring road GSR
136.35 mt
Required HGL at Ring road 138.00 mt Therefore, Head available 164 - 138 = 26 mt. Length of gravity main from Raiyadhar to Ring road 3.15 km Therefore, Available head loss per Km 26 = 7.5/Km 3.15 x 1.1
Therefore size of G.M. - 2929.16 m3/hr = 70.30 MLD 70.30 = 7.346 x 10-9 x 120 x (D)2.67 x 7.50.54
Therefore D = 662.34 mt. Provide size 750 mm dia M S
The carrying capacity of existing 500 mm dia with same head loss considering value of C=90 works out to
Q = 7.436 x 10-9 x 90 x (500)2.63 x (7.5)0.54 Therefore Q = 8.392 x 2.968 = 24.91 MLD Say 24 MLD.
For balance quantity additional line is to be laid along Ring Road up to head work. 70.30 - 24.0 = 46.30 MLD Therefore, 46.30 = 7.436 x 10-9 x 120 x (D)2.63 x (7.5)0.54
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D = 565.14 mm Provide 600 mm dia M S line Total head of pumps at Raiyadhar. S.L. of proposed sump 136.0 mt. FSL of ESR Therefore Static 172 - 136 = 36 mt. 144 + 20 + 8 = 172 mt.
Friction & station loss = 02 mt. Residual = 02 mt. Total = 40 mt. KW= 825 x 40 367.2 x 0.8 x 1.15
= 129.18 Say 130 Therefore 130 x 4 = 520 For ward no.23 KW = 735 x 40 367.2 x 0.8 x 1.18
= 115 Therefore 115 x 6 + 35 = 725 for ward No.21 & 22. Total KW 520 + 725 = 1245 Total quantity to be pumped 5415 m3/hr Assume velocity in header main 2 mt/sec. Therefore 5415 = 1.504 = 2 x A 3600 = 2 x (D)2 4 Therefore D = 0.978 mt. Provide size of rising main 1000 mm dia M S line Provide pipes size of ESR In let 1000 mm dia Out let 750 mm dia for Ring road Out let 700 mm dia for ward-23 Wash out 450 mm dia
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Overflow
750 mm dia
Size of connecting main with velocity 2 mt/sec. (For ward No.23) 2475 = 0.6875 m3/sec = 2 x A 3600 Therefore D = 667 Say 700 mt.
Distribution of work from existing Ghanteswar head works
At present, total income of water from Nyari-2 at Ghunteshwar headwork is 3.0 mgd in 22 hours.
Q design Therefore 3 x 4.54 x 24 = 14.85 MLD 22 Quantity transfer to Bajrangwadi 6.7 x 24 = 7.3 MLD 22 Therefore balance quantity to be transfer to Sojitra 14.85 - 7.30 = 7.55 MLD Pure water m/c 493 m3/hr - 40 mt (1+1) 270 m3/hr - 40 mt (2+1) As against quantity to be pumped 7.55 x 1000 24 = 314.58 m3/hr Say 315 m3/hr.
The said quantity is to be pumped through existing 400 mm dia A C pipeline with one pump of 493 m3/hr capacity to be run in throttle condition. Therefore, total quantity to be transferred to Ring road headwork from Raiyadhar 50.0 - 14.85 = 35.15 MLD.
With the available head of Raiyadhar ESR the carrying capacity of existing 500 mm dia M S transmission main is 24 MLD and that of proposed 600 mm M S is 46.30 MLD.
Therefore, rate of supply in 500 mm dia 24.00 MLD = 1000 m3/hr rate of supply in 600 mm dia 46.30 MLD = 1941 m3/hr
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The total requirement of ward no.22 and 21 (part) is 35.15 MLD to be supplied in 12 hours.
Therefore per hour requirement 33.15 x 1000 = 2929.16 m3/hr 12 It is proposed to cater ward no.22 with two ESRs i.e. from Raiyadhar and from Ring road. Out of 35.15 MLD, 20 MLD is to be served through Raiyadhar ESR.
Therefore, hourly requirement will be 20 x 1000 = 1667 m3/hr which could be 12 served through 600 mm dia existing line. Thus, out of total 2929 m3/hr, 1667 m3/hr is to be diverted to area and balance to be transferred to ESR. 2929 - 1667 = 929 m3/hr for Ring road ESR. Therefore, total input at Ring Road 2929 - 2000 = 1262 m3/hr The quantity to be supplied through Ring road ESR 35.15 - 20.00 = 15.15 MLD Assume duration 11 hours. Therefore hourly requirement 15.15 x 1000 = 1377.27 Say 1380 m3/hr 11 Storage at Ring road GSR 2.00 ml ESR 1.25 ml 3.25 ml = Per hourly income at Ring road From Raiyadhar 1262 m3/hr From storage 295 m3/hr Total 1557 m3/hr > 1380 m3/hr Hence O.K. However, by trial and error the city supply will be reduced upto 9 to 10 hours instead of 16 hours in a day. 3250 m3
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6.4 Transmission Mains works

6.4.1 Bhadar water supply scheme In 1987-88 a water supply scheme based on Bhadar reservoir was implemented by Rajkot Municipal Corporation with the financial assistance from Government of India, to draw 50 MLD of supply from the reservoir. The total cost of the part-I project was Rs.1500 lacs. In the above project, following works were executed: 6.4.1.1 Valve tower in reservoir to draw raw water from the reservoir Raw water pumping machinery in form of vertical turbine pumps 6 sets each having capacity 147 liter/sec against the head of 96 mt
6.4.1.2 Transmission Main: From Bhadar Valve Tower to stand pipe to Gondal: 850 mm dia M S 900 mm dia P S 22 Kms 2.2 Km
From Gondal to Ribda filtration plant: 850 mm dia M S 20 kms
From Ribda to Gurukul head works 900 mm dia P S concrete pipe- 16 kms
From Gurukul head works to Jubilee head works 700 mm P S concrete pipes 7 kms
In between at Gondal a lift station with CF pumping machinery 6 sets each having capacity 147 lps against the head of 85 mt. has been erected.
Proposal The above water supply scheme is functioning since 1987-88 and Rajkot Municipal Corporation is drawing approximately 45 MLD of supply from the said reservoir. For treating the water at Ribda village, a filtration plant of capacity 50 MLD has been constructed. Since the lifespan of pumping machinery installed at Bhadar as well as at Gondal is already over, there is drastic reduction in the efficiency of the pumps. Under the circumstances, to get even 45 MLD of supply Rajkot Municipal Corporation has to run 5 sets on each pumping station instead of 4 sets which has increased the energy cost tremendously. Under the circumstances, Rajkot Municipal Corporation has decided to replace the
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pumping machinery at both the pumping stations. At first instance, Rajkot Municipal Corporation has replaced 3 sets at Bhadar valve tower and balance 3 sets will be replaced shortly.
The total length of transmission main is around 67 km, out of which 42 km length is M S whereas remaining 25 km length is prestressed pipeline. At the time of installation of the transmission main, inside epoxy painting work was carried out for protection against rusting. However, due to high velocity in the pipeline, the existing epoxy paint has been completely eroded and in the system incrustation has been taken place because of which there is an increase in the head in the system by about 10 mt which has also increased the energy cost.
Further, part length of the transmission main has been laid along National Highway but under the road widening program, the said National Highway 8-b between Ribda to Rajkot is being made 4 track by the National Highway Authority and the pipeline laid along that stretch i.e. the gravity main of 900 mm dia prestressed is coming in the widening area of the National Highway. Also the above pipes are with flexible joints, the rubber ring has already been worn out in the joints and because of which there is significant loss of water from the joints in the system due to leakage, which is around 5 to 6 MLD per day.
Further the alignment of transmission main is crossing railway track at village Gomta. At the time of installation the railway tracks has been crossed through existing railway culvert by detouring the alignment by 350 mt in additional length. Since the approachability of the transmission main for this segment is not there the farmers are damaging the lines frequently and as such it has been decided to lay the line straight by push through method below track near railway fatak as shown in drawing due to which there will be saving in frictional loss and losses due to damages will get reduced significantly. The work of railway crossing will be carried out by Western Railway as deposit work and remaining work of laying the pipeline will be carried out by Rajkot Municipal Corporation. As the existing system is heavily damaged, it has been decided to provide new pumping machinery and metallic transmission main.
6.5 Source Augmentation works

The capacity of Nyari-I reservoir is 945 MCFT. The catchment area of the reservoir is available and as such every year the reservoir is getting good quantity of fresh water in monsoon. Looking to the behavior of the reservoir of last 20 years, it is felt that more quantity of water will be available and with this understanding for detail study to increase the capacity of the reservoir, Rajkot Municipal Corporation had engaged a reknown consultant who has studied the behavior of the reservoir and its
44
catchment area and have opined that if dam height is raised by 1.4 mt. and length of west weir is extended further 55 mt, the maximum availability of the water from reservoir will be around 6 mgd at 90% reliability and also approximately 1 mgd of water will be available from the seepage. Thus, it has been anticipated that total availability of water from the Nyari reservoir in good rainfall year will be around 7 mgd.
For increasing the capacity of the reservoir consultant has worked out a detailed estimate which is Rs.11-00 crores, for which, Rajkot Municipal Corporation is making efforts to get loan assistance from financial Institution. The matter is under correspondence. Meanwhile, it has been decided to update the water supply system for maximum drawl of 7 mgd and accordingly the transmission main, pumping machinery, storage, filtration etc., have been planned. It is proposed to erect vertical turbine pumps in impact tower with 100% standby. The water will be pumped from reservoir with above pumps and will be transported to existing filtration plant located at 7 kms away through 700 mm dia M S transmission main. The total filtering capacity at Nyari site is 7 mgd. The capacity of existing ground storage is around 148 million liters which is more than 12 hours storage.
6.6 Distribution net work phase-1

Distribution of 45 MLD Water from Nyara head work will be pumped through 1150 mm dia M S pipeline into the proposed 45 MLD capacity water treatment plant to be constructed at Raiyadhar. The treated water is proposed to be collected in proposed GSR of 20.6 ML capacity. Again water is proposed to be pumped into the proposed ESR of capacity 3 ML and 20 mt staging height water from proposed ESR will be supplied to Ward No.23, 22 and part of 21 through various size of pipeline. Also the part of the water is proposed to transfer at Ring road and Nyari zone to cater the demand of the area located at higher elevation. The requirement of water for the year 2015 is as under: Average (MLD) Design (MLD) 30.00 32.73 13.62 14.85 6.13 6.68 8.87 9.68 58.62 MLD 63.94 MLD Say 65.00 MLD Therefore, considering hours of pumping 22, the system is to be designed for 65 MLD.
For ward no.21 (part) and ward no.22 For ward no.23 For ward no.14 of Bajrangwadi For ward no.12 of Sojitra head work of Nyari zone
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For reduction is supply hours all main storage at head work of each zone will serve as master service reservoir and sufficient storage will be created at all sub head works to supply water within duration of 4 hours to 6 hours only.
Now from existing Ghanteshwar headwork, where Nyari-2 water is being made available requirement of Bajrangwadi of 6.68 MLD will be fulfilled & balance 14.85 - 6.68 = 8.17 MLD will be transfer to Sojitra H/W of Nyari Zone, through 400 mm dia A.C. existing pipeline & 350 mm dia proposed A.C. line to be laid from Ring Road to Sojitra sub H/W. The water to be received from Narmada pipelines at Raiyadhar, H/W the requirement of ward No. 21 (part), 22 & 23 will be catered.
As stated above now the existing H/W at Ghanteshwar of Nyari-2 water is spared for Bajrangwadi sub H/W of ward 14 & Sojitra sub headwork of ward No.12. Narmada Water to be received at Raiyadhar, is to be distributed among three zones of ward 21(part) ward 22 & ward 23.
6.7 Civil General Design Consideration

General : The pure water sump and ESR shall be constructed of RC construction in M25 concrete with all the pipe works, valves, and accessories. The sump and ESR shall be watertight and to be designed to take care of vibrations on account of pumping since suction pipes are to be embedded in the sump wall. The grade of HYSD reinforcing steel in the sump structure shall be of CRS Fe-500 confirming to IS1786. The design shall take into account the worst combination of loads and forces ensuring total structural safety including seismic forces. The pure water pump house is to be located adjacent to Pure water Sump and shall be constructed in such a manner that the installation of pump sets is suitable for Centrifugal Pump. The pump house shall be adequate to accommodate/ to install required number of pump sets, valves and appurtenances, panel boards, working area for maintenance of pump sets, office accommodation, cable ducts, pump foundations, pipe supports, valve supports, floor drainage arrangement for draining the water from outside the pump house, provision for providing of suction and delivery pipe connections, etc. Provision is to be made for sufficient ventilation, lighting to the pump house with exhaust arrangement. Access between various floors shall be provided through stairs and ladders. Pump house shall also have sufficient headroom for hand operated overhead crane for loading and unloading the equipment. The pump house shall be designed so as to maintain the noise level inside pump house within permissible limits and to absorb vibrations while pumps are running.
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Design Considerations The pump house shall be of RC construction in M20 grade concrete. The grade of HYSD reinforcing steel in the sump structure shall be of CRS Fe-500 confirming to IS - 1786. It will be a RC framed structure with brick masonry walls. The roof of the pump house shall be of RC slab with waterproofing. The design of the pump house and its foundation shall take into account the worst combination of loads and forces such as service loads, wind load, uplift forces, seismic loads, dynamic forces due to vibration of pumps, ensuring total structural safety. The building plinth will be kept minimum 1000 mm above the finished grade level to the respective plot. Design Standards All designs shall be based on the latest Indian Standard (I.S.) Specifications or Codes of Practice. The design standards adopted shall follow the best modern engineering practice in the field based on any other international standard or specialist literature subject to such standard reference or extract of such literature in the English language being supplied. In case of any variation or contradiction between the provisions of the I.S. Standards or Codes and the specifications given along with the submitted tender document, the provision given in this Specification shall be followed. All reinforced concrete structural design shall generally conform to the following publications of the Indian Standards Institution: I.S. 456 I.S. 875 Code of Practice for plain and reinforced concrete Code of Practice for design loads for buildings and structures (Part 1 to 5) I.S. 3370 Code of Practice for concrete structures for the storage of Liquids (Part I to IV) I.S. 1893 I.S. 2974 Criteria for earthquake resistant design of structures Code of Practice for design and construction of machine Foundations (Part 1 to 4) All structural steel design shall generally conform to the following publications of the Indian Standards Institution: I.S. 800: I.S. 806: Code of Practice for general construction in steel Code of Practice for use of steel tubes in general building construction
Design Life The design life of all structures and buildings shall be 60 years. Design Loading All buildings and structures shall be designed to resist the worst combination of the following
47
loads / stresses under test and working conditions; these include dead load, live load, wind load, seismic load, stresses due to temperature changes, shrinkage and creep in materials, dynamic loads, impact load and other specific loads.
1. Dead Load
This shall comprise all permanent construction including walls, floors, roofs, partitions, stairways, fixed service equipment and other items of machinery.
The following minimum loads shall be considered in design of structures: 9.81 kN/m3 20.00 kN/m3
Weight of water Weight of soil (irrespective of strata available at site and type of soil used for filling etc). However, for checking stability against uplift, actual weight of soil as determined by field test shall be considered. Weight of plain concrete
24.00 kN/m3
Weight of reinforced concrete Weight of brickwork (exclusive of plaster)
25.00 kN/m3 22.00 N/m2 per mm
thickness of brickwork Weight of plaster to masonry surface 18.00 N/m2 thickness Weight of granolithic terrazzo finish or rendering screed, etc. 24.00 N/m2 per mm per mm
thickness
2. Live Load
Live loads shall be in general as per I.S. 875. However, the following minimum loads shall be considered in the design of structures: i) Live load on roofs (accessible) (Non-accessible) ii) Live load on floors supporting Equipment such as pumps, blowers, : 1.50 kN/m2 : 0.75 kN/m2
48
Compressors, valves, etc. iii) Live load on all other floors walkways, stairways and platforms.
10.00
kN/m2
5.00 kN/m2
In the absence of any suitable provisions for live loads in I.S. Codes or as given above for any particular type of floor or structure, assumptions made must receive the approval of CITY ENGINEER (Special) prior to starting the design work. Apart from the specified live loads or any other load due to material stored, any other equipment load or possible overloading during maintenance or erection / construction shall be considered and shall be partial or full whichever causes the most critical condition.
3. Wind Load
Wind loads shall be as per I.S. 875.
4. Earthquake Load
This shall be computed as per I.S. 1893 considering earthquake 2001. An importance factor appropriate to the type of structure shall be considered for design of all the structures. The supporting structure shall be constructed in RCC M:250, container and top ring beam in RCC M250. Reinforcement shall be HYSD-CRS-Fe-500 Grade confirming to IS-1786. The structure shall have to be designed with seismic forces as per zone-V. As during last earthquake in Rajkot on 26th January 2001, the magnitude of earthquake was very high.
Dynamic Load : Dynamic loads due to working of items such as pumps, blowers, compressors, switch gears, travelling cranes, etc. shall be considered in the design of structures as per manufacturers data. 5. Joints
Movement joints such as expansion joints, complete contraction joints, partial contraction joints and sliding joints shall be designed to suit the structure. However, contraction joints shall be provided at specified locations spaced not more than 7.5 m in both right angle directions for all walls and rafts.
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Expansion joints of suitable gap at suitable intervals not more than 30 m shall be provided in all walls, floors and roof slabs of water retaining structures.
Construction joints shall be provided at right angles to the general direction of the member. The locations of construction joints shall be decided on convenience of construction. To avoid segregation of concrete in walls, horizontal construction joints are normally to be provided at every 2-m height. PVC water-stops of 150 mm width shall be used for walls and 230 mm width for base slabs. Alternatively contractor can use G.I. Sheets of 18 gauge and 200 mm wide.
Expansion joints for non-liquid retaining structures shall be provided as per IS 3414.
Design Conditions for Underground or Partly Underground Liquid Retaining Structures
All underground or partly underground liquid containing structures shall be designed for the following conditions:
(i)
Liquid depth to be considered up to full height of wall and no relief due to soil pressure from other side to be considered.
(ii)
Structure empty condition (i.e., empty of liquid, any material, etc.): full earth pressure with saturation and surcharge pressure wherever applicable, to be considered.
(iii)
Partition wall between dry sump and wet sump : to be designed for full liquid depth up to full height of wall.
(iv)
Partition wall between two compartments : to be designed as one compartment empty and other full for both the directions.
(v)
Structures shall be designed for uplift in empty conditions with no live load with the appropriate water table.
(vi)
Walls shall be designed under operating conditions to resist earthquake forces from earth pressure mobilization and dynamic water loads.
(vii)
Underground or partially underground structures shall also be checked against stresses developed due to any combination of full and empty compartments with appropriate ground/uplift pressures from below to base slab. A minimum factor of 1.2 shall be ensured against uplift or floatation.
(viii)
For tender evaluation, the Soil bearing capacity is to be consider 10 MT/Sq.mt for sump and pump house foundation but on award of the work, contractor shall have to carry out detailed soil analysis & based on actual S.B.C. structure shall have to be designed.
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a. Foundations
(i)
The minimum depth of foundations for all structures, equipment, buildings and frame foundations and load bearing walls shall be as per IS 1904.
(ii)
Maximum safe bearing capacity of soil strata shall be taken as indicated in geotechnical reports.
(iii)
Care shall be taken to avoid the foundations of adjacent buildings or structure foundations, either existing or not within the scope of this Contract. Suitable adjustments in depth, location and sizes may have to be made depending on site conditions.
(iv)
Special attention is drawn to danger of uplift being caused by the ground water table. All underground structural slab wherever applicable shall be designed for uplift forces due to ground water pressure.
(v)
Where there is level difference between the natural ground level & the foundations of structure or floor slabs, this difference shall be filled up in the following ways:
In case of non-liquid retaining structures the natural top soil shall be removed till a firm strata is reached (minimum depth of soil removed shall be 500 mm.) and the level difference shall be made up by compacted backfill as per specifications. However the thickness of each layer shall not exceed 150 mm. The area of backfilling for floor slabs shall be confined to prevent soil from slipping out during compaction. The safe bearing capacity of this well compacted backfilled soil shall not exceed 100 kN/sq.m.
In case of liquid retaining structures, the natural top soil shall be removed as described above and the level difference shall be made up with Plain Cement Concrete (1:5:10)
b. Design Requirements The following are the design requirements for all reinforced or plain concrete structures:
a)
All binding and leveling concrete shall be a minimum 100 mm thick in concrete grade 1:3:6.
b)
All structural reinforced concrete for water retaining structures shall be of a minimum
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M25 grade with a maximum 20 mm aggregate size for footings and base slabs and with a maximum 20 mm aggregate size for all other structural members. For non water retaining structures the concrete shall be of M 20 grade. The structures shall have to be designed as per IS : 3370 (Part I-IV).
c)
The reinforced concrete for water retaining structures shall have a minimum cement content of 360 kg/m3 with a maximum 20 mm size aggregate and 330 kg/m3 with a maximum 40 mm size aggregate as per IS : 3370 (Part I-IV).
d)
The minimum reinforcement for water retaining structures in each direction should be 0.35% of cross section. The minimum clear cover to all reinforcement including stirrups and links shall be 50 mm for all water retaining structures.
e)
All buildings shall have a minimum 1 metre wide, 100 mm thick plinth protection paving in M15 grade concrete or stone slabs/tiles. All plinth protection shall be supported on well compacted strata.
f)
Any structure or pipeline crossing below roads shall be designed matching classification of road (anything from Class A to AA of IRC loading )
g)
All pipes & conduits laid below the structural plinth & road works shall be embedded in reinforced concrete of grade M15 of minimum thickness 150 mm.
h)
Approved quality water proofing compound (chloride free) shall be added during concreting of all liquid containing structure in the proportions specified by manufacturer or 2 % by weight of cement whichever is higher.
The wall and floor panels shall be poured in sequential order with a minimum time gap of 4 days.
The following minimum thickness shall be used for different reinforced concrete members, irrespective of design thickness:
(i) Walls for liquid retaining structures (ii) Roof slabs for liquid retaining structures (other than flat slabs) (iii) Bottom slabs for liquid retaining structures:
: :
250 mm 150 mm
200 mm
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(iv) Floor slabs including roof slabs, walkways, canopy slabs (v) Walls of cables / pipe trenches, underground pits etc. (vi) Column footings (vii) Parapets, chajja (viii) Precast trench cover : : 125 mm : : 75 mm 300 mm 100 mm : 100 mm
In Mix design, the water cement ratio should not exceed 0.45. The exposer condition to be considered severe as chlorinated water is to be stored.
The inside surface of the container of ESR and GSR shall be provided 20 mm thick water proof cement mortar plaster in CM 1:3 whereas outside surface of the GSR shall be sand faced and that of all surfaces of ESR i.e. container, shaft, etc. shall be exposed finished.
c. Standards
Materials and workmanship shall comply with the relevant Indian Standards (with amendments) current on the date of submission of the tender. All the governing items, materials, goods and equipments shall bear ISO-9001-2000 certification.
The specifications, standards and codes listed below are considered to be part of this Bid specification. All standards, specifications, codes of practices referred to herein shall be the
latest editions including all applicable official amendments and revisions.
In case of discrepancy between the Bid Specification and the Standards referred to herein, the Bid Specification shall govern. a) Materials IS : 269 Specification for 33 grade ordinary Portland cement IS : 383 Specification for coarse and fine aggregates from natural sources for concrete IS : 428 Specification for distemper, oil emulsion, colour as required IS : 432 Specification for mild steel and medium tensile steel
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bars and hard drawn steel wire for concrete reinforcement (Parts 1 & 2 ) IS : 455 IS : 458 Specification for Portland slag cement Specification for precast concrete pipes(with and without reinforcement) IS : 650 IS : 651 Specification for standard sand for testing of cement Specification for salt glazed stoneware pipes and fittings IS : 777 IS : 808 Specification for glazed earthenware tiles Specification for dimensions for hot rolled steel beam, column, channel and angle sections IS : 814 Specification for covered electrodes for manual metal arc welding of Carbon and Carbon Manganese steel IS : 1003 IS : 1038 IS : 1077 IS : 1398 IS : 1489 Specification for timber paneled and glazed shutters(Parts 1 & 2) Specification for steel doors, windows and ventilators Specification for common burnt clay building bricks Specification for packing paper, water proof, bitumen laminated Specification for Portland pozzolana cement (Parts 1&2) IS : 1566 Specification for hard drawn steel wire fabric for concrete reinforcement IS :1580 Specification for bituminous compounds for water proofing and caulking purposes IS : 1786 Specification for high strength deformed steel bars and wires for concrete reinforcement IS : 1852 Specification for rolling and cutting tolerances for hot rolled steel products IS : 1948 IS : 1977 IS : 2062 IS : 2185 IS : 2202 Specification for aluminium doors, windows and ventilators Specification for structural steel (ordinary quality) Specification for steel for general structural purposes Specification for concrete masonry units (Parts 1 & 2) Specification for wooden flush door shutters (Parts 1 & 2) IS : 2645 IS : 2750 IS : 2835 Specification for integral cement water proofing compounds Specification for steel scaffoldings Specification for flat transparent sheet glass
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IS : 3384
Specification for bitumen primer for use in waterproofing and damp roofing
IS : 3502
Specification for steel chequerred plates IS : 4021 and ventilator frames Specification for timber door, window
IS : 4350 IS : 4351 IS : 4990 IS : 8112 IS : 9862
Specification for concrete porous pipes for under drainage Specification for steel door frames Specification for plywood for concrete shuttering work Specification for 43 grade ordinary Portland cement Ready mixed paint, brushing, bituminous, black, lead free, acid, alkali, water and chlorine resisting
IS : 10262 IS : 12269 IS : 12330 IS : 12709
Recommended guidelines for concrete mix design Specification for 53 grade ordinary Portland cement Specification for sulphate resisting Portland cement Glass fibre reinforced plastics (GRP) pipes, joints and fittings for use for potable water supply
b)
Tests IS : 516 IS : 1182 Method of test for strength of concrete Recommended practice for radiographic examination of fusion welded butt joints in steel plates IS : 1199 IS : 2386 IS : 2720 IS : 3025 Methods of sampling and analysis of concrete Methods of test for aggregates for concrete(Parts 1 to 8) Methods of test for soils (Parts 1 to 39) Methods for sampling and test (physical and chemical) for water and wastewater (Parts 1 to 44) IS : 3495 IS : 3613 IS : 4020 IS : 4031 IS : 5807 IS : 7318 Method of test for burnt clay building bricks(Parts 1 to 4) Acceptance tests for wire flux combination for submerged arc welding Methods of tests for wooden flush doors Type tests Methods of physical tests for hydraulic cement (Parts 1 to 15) Method of test for clear finishes for wooden furniture (Parts 1 to 6) Approval tests for welders when welding procedure approval is not required (Parts 1 and 2)
c)
Codes of Practice IS :456 IS : 783 IS : 800 Code of practice for plain and reinforced concrete Code of practice for laying of concrete pipes Code of practice for general construction in steel
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IS : 806 IS : 816
Code of practice for use of steel tubes in general building construction Code of practice for use of metal arc welding for general construction in mild steel
IS : 817 IS : 875
Code of practice for training and testing of metal arc welders Code of practice for design loads (other than earthquake) for building structures(Parts 1 to 5)
IS : 1081
Code of practice for fixing and glazing of metal (steel and aluminum) doors, windows and ventilators IS : 1172 Code of practice for basic requirements for water
supply, drainage and sanitation IS : 1477 Code of practice for painting of ferrous metals in buildings (Parts 1 & 2) IS : 1597 IS : 1742 IS : 1893 IS : 2065 IS : 2212 IS : 2338 Code of practice for construction of stone masonry (Parts 1 &2) Code of practice for building drainage Criteria for earthquake resistant design of structures Code of practice for water supply in buildings Code of practice for brickwork Code of practice for finishing of wood and wood based materials (Parts 1 & 2) IS : 2394 IS : 2395 Code of practice for application of lime plaster finish Code of practice for painting, concrete, masonry and plaster surfaces (Parts1 & 2) IS : 2470 IS : 2502 Code of practice for installation of septic tanks (Parts 1 & 2) Code of practice for bending and fixing of bars for concrete reinforcement IS : 2571 IS : 2595 IS : 2751 Code of practice for laying in situ cement concrete flooring Code of practice for radiographic testing Recommended practice for welding of mild steel plain and deformed bars for reinforced construction IS : 2974 Code of practice for design and construction of machine foundations (Parts 1 to 4) IS : 3114 IS : 3370 Code of practice for laying of Cast Iron pipes Code of practice for concrete structures for the storage of liquids (Parts 1 to 4) IS : 3414 IS : 3558 Code of practice for design and installation of joints in buildings Code of practice for use of immersion vibrators for consolidating
56
concrete IS : 3658 IS : 3935 IS : 4000 IS : 4014 IS : 4111 Code of practice for liquid penetrant flaw detection Code of practice for composite construction Code of practice for High strength bolts in steel structures Code of practice for steel tubular scaffolding (Parts 1 & 2) Code of practice for ancillary structures in sewerage system (Parts 1 to 4) IS : 13920 IS: 4326 Code of practice for laying of glazed stoneware pipes Code of practice for Earthquake Resistant Design and Construction of Buildings IS : 4353 Recommendations for submerged arc welding of mild steel and low alloy steels IS : 5329 IS : 5334 IS : 5822 IS : 7215 IS : 9595 Code of practice for sanitary pipe work above ground for buildings Code of practice for magnetic particle flaw detection of welds Code of practice for laying of welded steel pipes for water supply Tolerances for fabrication of steel structures Recommendations for metal arc welding of carbon and carbon manganese steels IS : 10005 SI units and recommendations for the use of their multiples and of certain other units d) Construction Safety IS : 3696 IS : 3764 IS : 7205 e) Safety code for scaffolds and ladder (Parts 1 & 2) Safety code for Excavation work Safety code for erection of structural steel work
Cement & Steel makes The makes for cement shall be Ambuja, L&T, Lotus, ACC, JK/Lakshmi, Shidhdhi., Binani, The CRS - Fe-500 HYSD- Reinforcement confirming IS-1786 steel shall be Malhotra, Tata, SAIL, Punjab rolling mill, Vizak. make of steel plate shall be TATA, SAIL, ESSAR,ESPAT, JINDAL
57
6.8 Characteristics of different pipe material
Pipe materials considered for the distribution and transmission network system are Cast Iron (CI), Ductile Iron (DI), Mild Steel (MS), High Density Polyethylene (HDPE), Medium Density Polyethylene (MDPE), Polyvinyl Chloride (PVC), Asbestos Cement (AC), Glass Fiber Reinforced Plastics (GRP), Electrically Welded Steel (EWS) and Pre-stressed Concrete (PSC). The pipes have been compared on various parameters to evaluate their usefulness as a water carrying main in transmission and distribution system. The main parameters which have been discussed are available sizes and lengths, applicable IS codes, weight, flexibility, available working pressure ratings, tensile strength, impact strength, ease of tapping and repair, general availability in India, availability of plant and skilled man power for manufacturing, laying and maintenance, availability of corrosion control techniques, ease of locating underground pipes, special bedding requirements, laying speed, performance experience and basic cost economics. The list of applicable IS codes is given Table *****.
High Density Polyethylene (HDPE) : HDPE pipes are available in sizes upto 630 mm OD but
upto 315 mm OD they are commonly used. The material is light, has very good impact strength flexibility and corrosion resistance. The jointing can be cone by butt welding, insert jointing or by flange jointing. This is satisfactory but requires skilled manpower; HDPE pipes are tough and resilient and conform to the topography of land when laid above ground or in trenches. They can bend to some extent thus reducing use of specials like bends, elbows etc., thereby reducing installation cost. HDPE pipes are easy to carry and install because of their lightness. The pipe has a very high C-value. The bending material has to be free from sharp edges. Fine sand or screened excavated material is ideal. It is the costliest material as compared to other pipes available in its range. Medium Density Polyethylene (MDPE) : MDPE pipes are available in sizes from 20mm to
110mm. MDPE belongs to family of plastic pipes. A wide range of injection moulded fittings including toes, elbows, reducers, caps, pipe saddles inserts and threaded adopters are available. They have a smooth surface and hence the Hazen Williams roughness coefficient 'C' is high. The carrying capacity is not reduced with age. Special care needs to be taken about the bending material which should be either fine sand or screened excavated material. If laid over ground they should be adequately supported to prevent sagging. Also, storing of pipes need extra care. They are lighter in weight and can be carried to heights as on hills. Smaller diameter mains are coilable and can be easily bent during installation, eliminating the use of specials like bends, elbows etc. thereby reducing fittings and installation costs. They can withstand movement of heavy traffic. This would not cause any damage to
58
the pipes because of their flexural strength. They have non-adherent surface which reject any foreign material which would impede the flow. Poly Vinyl Chloride (PVC) : These are available in sizes upto 250mm i.e., for local
distribution lines but are commonly use upto 200 dia. The material is light, has fairly good impact strength, high corrosion resistance and a high C-value. The pipes are easy to carry and install because of their lightness. They need however be protected from high temperature and ultra-violet light and require proper handling and storage facilities. It is advisable not to lay PVC pipes above ground to prevent discoloration, surface cracking and brittleness. PVC pipes are also prone to rodent attack. Tapping requires saddles which is satisfactory but requires skilled manpower. The bedding material has to be free from sharp edges. Fine sand or screened excavated material is ideal. PVC is cheaper than CI and HDPE but more expensive than AC for sizes available in its range. Asbestos Cement (AC) : This is available in sizes of 80mm to 600mm suitable for the local
and trunk distribution lines. However it is commonly used in sizes of 100mm to 600 mm. It is light, has very good corrosion resistance and a high C-value. It is the cheapest available material. It has a low impact strength. It can be drilled and tapped easily, provision of saddles at the point of service connections is a preferred method to avoid possible leakages in future new connections. The pipe material is prone to attack by sulphate bearing soils. For heavy traffic, a cover of at least 1.25 m is desirable on the top of the pipe. For locating AC pipes, Sonde, an accessory to pipe-locator, is inserted inside the pipe and locator is moved along the pipe alignment. Glass Reinforced Fiber Plastic (GRP) :This is available in sizes of 400mm-2400mm suitable
for local and trunk mains and has been introduces in India a few years back. The commonly used size range is 400mm-2000mm. M/s Graphite Vicarb with their factory located at Nasik manufactured this pipe with foreign collaboration for the first time in India. Some more manufacturers of this pipe are now in the market. These pipes have been in use abroad for many years with satisfactory performance. The pipe is light, has good impact strength and has very good corrosion resistance. The bending of these pipes have to be carried using granular material compacted to specific Proctor Density. This can be achieved with proper supervision and control during lying. Joining methods consist of double bell coupling, flanged jointing, mechanical coupling and butt strapping which is satisfactory but requires skilled manpower. It has superior C-valve and therefore needs to be compared on carrying capacity
basis for cost comparison. On this, basis, it is more or less on par with internally coated CI and internally coated and externally gunited MS for 500 mm and larger sizes. The pipe has greater durability and high resistance to internal and external corrosion unlike CI and MS which would require coating to resist corrosion. Cast Iron (CI) : It is available in sizes of 80mm 100mm suitable for local and trunk
distribution mains though the commonly used range is 100 mm 1000mm. It is widely used in the water supply systems in India because of its longer life. There are examples of cast iron mains in India
59
which continue to give service even after a century of use though with reduced carrying capacity. CI pipes can be used in soils and waters of slightly aggressive charactive. It would e preferable to have inside mortarlining of this material. This will also improve its C-value. Adequately trained manpower is available in India for laying and jointing of CI piles. Locating underground CI pipes is easy with a pipe locator. Old worn out CI pipes have salvage value. Mild Steel (MS): This can be manufactured from mild steel plates for required sizes. However,
it is not normally used in the local distribution lines. It is mostly used as trunk distribution mains and transmission mains in the water supply systems in India. The material has high impact strength due to its high ductility. Specials of all kinds and be fabricated without difficulty. Due to elasticity, MS pipes adopt themselves to changes in relative ground level without failure and hence are suitable for lying in ground liable to subsidence. MS pipe with flexible joints provides additional safeguard against failure. MS pipes being flexible are best suited for high dynamic loading. Because of its low resistance to corrosion, MS mains need protection from corrosion internally and externally. The internal coating would improve the C-valve. Skilled manpower is available for laying and jointing of MS pipes. Tapping and repairs are easy. When a pipeline has to lay over waterway or railway, MS pipes are most suitable due to their flexibility and light weight compared to CI / PSC pipes. When internally coated and externally gunited it marginally differs in cost as compared to internally coated CI pipe. Electrically Welded Steel (EWS) : EWS pipes are available ready from manufacturers in sizes
suitable for local distribution and transmission lines. The characteristics are similar to MS pipe as discusses above. Basic cost wise it is slightly cheaper than MS. However, transportation cost (from manufacturer to city and then to site) of large diameter pipes is higher than MS pipes. Ductile Iron (DI) : Ductile Iron, also called nodular iron or spherical graphite iron has superior
mechanical characteristics. Ductile iron differs from cast iron by its greater tensile strength and by its significant proof stress and elongation after yield. For protection from corrosion inside and outside linings are provided. Cement mortar lining with a seal coat of asphalted material is typically applied. Polyethylene internal linings and epoxy coatings and linings are also used for special applications. Laying and joining techniques are similar to CI. The pipe has high impact strength due to its ductility. Thus it has the durability of CI and the ductile strength of MS. However it needs proper bedding and backfilling for sizes 700mm and above due to its this wall design. An Indian firm has started manufacturing these pipes in India recently Technical literature on these pipes was collected from this firm. Pre stressed Concrete (PSC) : In India, Pre-stressed Concrete pipes are manufacture in sizes
between 400 mm and 1400 mm though at few places a size of 1500 mm has also been manufactured. The range of 400-1200 mm is most common. These pipes are used for trunk distribution mains and transmission mains and not commonly used in the local distribution lines due to difficulty in tapping. The C-value of PSC pipe is higher than that of CI. Its attraction lies in the fact that it is cheaper material
60
compared to CI. It nees high degree of quality control during its manufacture. Lying of this pipe with rubber rings also calls for skilled expertise and supervision. This expertise is available only with reputed contractors. Rubber rings have to be of good quality and storing the same without exposure to light is necessary. In addition to producing pipes of standard specifications, reputed manufacturers can produce PSC pipes as per the specifications of the customer.
Techno- Economic Comparison

The techno-economic comparison of pipes of different materials based on various parameters is presented in Table Final selection of pipe material depends upon the type of use it is going to be subjected to and the cost economics. Various related aspects are covered in the following paragraphs. Granular bedding would be required for HDPE, PVC and GRP. Costs are worked out accordingly. It is also necessary to compare the cost on a carrying capacity basis because the 'C' values vary for different materials. For local distribution lines the candidate materials are HDPE, PVC, AC, CI, MS/EWS, DI and MS/EWS, DI and PSC. These aspects involved in pipe material selection were discussed in details with SMC.
Local Distribution Lines

Local distribution lines defined as the pipelines from various service reservoirs to consumers. The sizes of these line range from 150 mm to 1400 mm. The materials available in this range are HDPE, PVC, AC, CI, MS/EWS, DI and PSC. Cost of AC pipes is the lowest followed by PVC, PSC, PSC, MS and CI, AC pipes can be drilled and tapped easily leading to unauthorized connections. The life of AC pipes is shortened and the pipe suffers from frequent bursts. The same therefore are not
recommended, PSC pipes are available from 400mm size but it is difficult to provide branch lines and house service connections and hence not recommended for local distribution. PVC pipes can lead to leakage losses due to rodent attack. They can be easily tapped and encourage unauthorized connections. The life of PVC pipes is comparatively less. They are not therefore recommended. MS pipes are more economical than CI and DI pipes. MS are comparable with CI and DI on other aspects. CI ahs merits such as its good performance record, availability of reputed manufacturers and skilled manpower for lying jointing and operation and maintenance and ease of making connections. For lower sizes, the costs of CI & DI pipes are comparable and the actual costs may vary as per the market conditions. Another significant factor is the time of supply and laying. Considering these aspects, it was decided to leave the choice open between CI & DI pipes for sizes below 800 mm. Final decision between CI & DI pipes is to be made after inviting competitive tenders. For higher diameter mains internally mortatrtarline and externally gunited MS pipes are recommended.
Transmission Mains
61
The pipes carrying water from Treatment Plants to Service Reservoirs re defined as transmission lines. The required sizes of mains for Rajkot city transmission system vary from 750mm to 2000mm. The materials available in this range are GRP, CI, MS/EWS, DI and PSC. PSC piles are very attractive from the economic point of view. However, because of its special bedding requirements in black cotton soil difficulty of giving branch connections and maintenance requirements, use of PSC pipes was ruled out. In the higher diameter range, MS pipes are cheaper compared to CI, DI and GRP pipes. GRP pipes are good in corrosive soils and water. But experience on the use of GRP pipes is less in India. Laying standards are to be strictly followed to achieve uniform and firm bending material throughout the length of pipe. GRP pipes are slightly more expensive than MS pipes, however has superior corrosive resistance and 'c' value. It is proposed to use GRP pipes on experimental basis in one stretch. The supply to Reservoirs from Treatment Plants is pumped throughout the service area. Hence for pumping mains MS pipes with internal mortarlining and external gunting are recommended as MS pipes with welded joints are better suited to withstand water hammer because of flexibility. Comparison of pipe material for selection of pipes for different purpose are as shown in annexure
62
7
1.1.
Dettaiilled Engiineeriing Desiign-- Mechaniicall & Ellecttriicall De a ed Eng neer ng Des gn Mechan ca & E ec r ca
7.1 Mechanical Components

Horizontal Centrifugal Pump
The pumping unit shall consist of a horizontal split-case, double-stage, single suction impeller directly connected through a flexible coupling to a horizontal induction motor. The pump shall be designed such that the rotating element can be removed without disturbing the pipe work or the pump motor. 1.2. The pumps shall be designed to operate satisfactorily without detrimental surges, vibration, noise, or dynamic imbalance over the required head range. The head-capacity curve of the pump shall have a continually rising head characteristic with decreasing capacity over the whole range of total head. The shut off head of the pump shall be at least 120 % of the total head. The Contractor shall guarantee that adequate required Net Positive Suction Head (NPSH) is available to ensure that pumps can operate without cavitations under the worst operating conditions. The required NPSH at duty point and throughout the range shall be at least 1.0 M, and 0.5 M, less than the available NPSH respectively at the lowest water level in the sump. Each pump must be capable of running satisfactorily in parallel with other sets in the system without throttling and by itself, without cavitations or overload under all operating conditions within the system resistances indicated. The unit shall be designed to operate safely at the maximum speed attainable in the reverse direction of rotation due to water returning through the pump at times when the power supply to the motor is interrupted and the discharge valve fails to close. The first critical speed of the pump set shall be at least 30 % above the operating speed. Pumps shall run smooth without undue noise and vibration. The velocity of vibration shall be within the 4.5 mm/sec. Noise level shall be limited to 85 dBA at a distance of 1.86 m. Automatic float type air valve with cock shall be fitted in the highest part of the casing to assist priming. 1.8. Small bore pipe work shall be provided for gland water drainage. Gland water drainage shall be piped to the drainage channel. All the pumps shall be supplied with machined pads to allow the fitting of portable vibration monitoring transducers. The pump casing shall be of the single suction type. Either single or double volute type could be adopted, to produce smooth flow with gradual changes in velocity. Unbalanced, hydraulic, radial thrust acting upon rotating elements shall be kept minimum.
1.3.
1.4.
1.5.
1.6.
1.7.
1.9.
1.10.
63
1.11.
Flanges shall be machined on faces and edges and conform to ISO 7005, IS 6392 BS 4504. Back faces of flanges shall where necessary be machined to ensure they are parallel to the front faces and that flange bolts can be fitted flush to the flanges. The casing shall be provided with removable and renewable wearing rings where there are close-running clearances between the impeller and the casing. Suitable tapped holes shall be provided for air vents and for drains. The casing shall be so constructed that the drains will unwater the entire casing. One tapped hole shall be provided in the discharge flange and the suction flange for connection of pressure gauges. The casing stuffing box and gland shall be designed to be suitable for easy maintenance of the conventional gland pickings. The impeller shall be the enclosed type and shall be fastened to the shaft in such a manner as to make it readily removable. The water passages of the impeller shall be hand finished to remove rough spots and excessive irregularities. For pump of 2000 cum/hr and larger capacity, removable and renewable wearing rings shall be provided on the impeller. Materials and hardness of the casing and impeller wearing rings shall be selected to ensure that they are not susceptible to galling and premature wear. The shaft shall be provided with replaceable stainless steel sleeves with proper hardness where it passes through the stuffing boxes and water passages. Water deflectors shall be provided on the shaft to prevent water from passing along the shaft and entering the pump bearings. A stationery guard shall be provided for the coupling conforming to all relevant safety codes and regulations. Guard shall be designed for easy installation and removal, complete with necessary support, accessories and fasteners. The stuffing box shall be provided with a readily accessible soft pickings of conventional type. The material of packing shall be of technically advanced and commercially available type.
1.12.
1.13.
1.14.
1.15.
1.16.
1.17.
1.18.
The pump shaft shall be supported by two bearings of anti-friction type, one located on each side of the pump. Bush bearing will not be accepted. The bearings may be of the oil or grease lubricated, ball or roller bearing type. One bearing on the pump shall be of the thrust type, designed to withstand the unbalanced axial hydraulic thrust. Suitable fittings shall be furnished for the type of lubrication provided. Bearings shall have a minimum life of 40,000 hours of operation.
1.19.
Bearings shall be grease / oil lubricated type. Pocket for measurement of the bearing temperature shall be provided in the bearing housing. Seals shall be provided to prevent loss of lubricant and entrance of moisture and dirt.
1.20.
64
1.21.
The pumping unit shall be provided with a base plate. The base plate shall be of sufficient size and rigidity to maintain the pump and motor in proper alignment and position. All contact surfaces between the pump and base plate and between the motor and base plate shall be machined. Means shall be provided for transmitting the entire load due to discharge shutoff pressure to the concrete structure. Induction Motor Design Requirements The motors shall generally conform to IS: 325 or relevant equivalent internationally approved standards. Additionally the specific requirements mentioned in the following clauses shall also be met. Performance and Characteristics Motors shall be capable of giving rated output without reduction in the expected life span when operated continuously under the following supply conditions: a) Variation in supply voltage b) Variation in supply frequency c) Combined voltage and frequency variation + 10% + 5% 10%
2. 2.1. 2.1.1.
2.2. 2.2.1.
2.2.2.
LV motors shall be suitable for star- delta starting. HV motors shall be suitable for flux compensated magnetic amplifier ( FCMA ) in the neutral side of the star point of the motor. The Power rating of the motor shall be the larger of the following : a) 115% of the power input to the pump at duty point at a speed corresponding to the frequency of 48.5 Hz.
2.2.3.
b) Maximum power input while operating solo or in parallel within maximum and minimum system resistances corresponding to the speed at 50Hz. 2.3. 2.3.1. Insulation Any joints in the motor insulation such as at coil connections or between slot and winding sections, shall have strength equivalent to that of slot sections of the coil. The insulation shall be given tropical and fungicidal treatment for successful operation of the motor in hot, humid and tropical climate. The motors shall be provided with class F insulation with temperature rise limited to that of class B insulation. Motors shall be given power house treatment. This comprises an additional treatment to the winding over and above the normal specified treatment. After the coils are placed in slots and all connections have been made, the entire motor assembly shall be impregnated by completely submerging in suitable insulating compound or varnish followed by proper baking. At least three such submersions and backings shall be applied to the assembly.
2.3.2.
65
2.4. 2.4.1.
Constructional Features The motor construction shall be suitable for easy disassembly and reassembly. The enclosure shall be sturdy and shall permit easy removal of any part of the motor for inspection and repair. Motors weighing more than 25 kg shall be provided with eyebolts, lugs or other means to facilitate safe lifting. The rotor bars shall not be insulated in the slot portion between the iron core laminations for squirrel cage motors. Terminal Box Terminal boxes shall be of weather proof construction designed for outdoor service. To eliminate entry to dust and water, gaskets of neoprene or approved equivalent shall be provided at cover joints and between box and motor frame. It shall be suitable for bottom entry of cables. It shall be capable of being turned through 360 degrees in steps of 90 degrees. The terminals shall be of the stud type with necessary plain washers, spring washers and check-nuts. They shall be designed for the current carrying capacity and shall ensure ample phase to phase and phase to ground clearances. Suitable cable glands and cable lugs shall be supplied to match specified cables. Accessories Two independent earthling points shall be provided on opposite sides of the motor, for bolted connections. These earthing points shall be in addition to earthing stud provided in the terminal box. H.V. Motors Motors shall be capable of starting and accelerating the load with the applicable method of starting, without exceeding acceptable winding temperatures, when the supply voltage is 80% of the rated voltage. Motors shall be capable of satisfactory operation at full load at a supply voltage of 80% of the rated voltage for 5 minutes, commencing from hot condition. The locked rotor withstand time under hot conditions at 110% rated voltage shall be more than starting time at minimum permissible voltage by at least two seconds or 15% of the accelerating time whichever is greater. The locked rotor current of motors shall not exceed 600% of full load current of motors which is inclusive of 20% tolerance. Motors when started with the drive imposing its full starting torque under the specified supply voltage variations shall be capable of withstanding at least two successive starts from cold condition and one start from hot condition without injurious heating of windings. The
2.4.2.
2.4.3.
2.5. 2.5.1.
2.5.2.
2.6. 2.6.1.
2.7. 2.7.1.
2.7.2.
2.7.3.
2.7.4.
66
motors shall also be suitable for three equally spread starts per hour under the above referred supply conditions. 2.7.5. The three phases shall be segregated by metal barriers within both line and neutral terminal box. The earthing pads shall be of non-corrodible metal, welded/brazed at two locations on opposite sides. The pad size shall be 75 x 65 x 25 mm with two holes drilled at 40mm centers, tapped & provided with suitable bolts and washers for connecting the earthing strip. At least six resistance type temperature detectors for the stator winding each having D.C. resistance of 100 ohms at 0 degrees Celsius, embedded in the stator winding at locations where highest temperatures may be expected, shall be provided. The material of the RTDs shall be platinum. Motors shall have space heaters suitable for 240V single phase 50Hz AC supply. These shall be placed in easily accessible position in the lower part of motor frame. Provision shall be made to measure temperature of bearing by inserting hand held temperature measuring device. Motors shall have drain plugs so located that they will drain water, resulting from condensation or other causes from all pockets in the motor casing. Pockets shall be provided for the measurement of bearing temperature. L.V. Motors Motors shall be suitable of starting and accelerating the load with the applicable method of starting, without exceeding acceptable winding temperatures, when the supply voltage is 85% of the rated motor voltage. The locked rotor current of the motor shall not exceed 600% of full load current (subject to tolerance as per the applicable standard). Motors shall be designed to withstand 120% of rated speed for two minutes without any mechanical damage, in either direction of rotation. Stator leads shall be brought to the terminal box as insulated cable through a suitable barrier and terminated in clamp type terminals. Valve General Valves shall be as per Internationally recognized standards. Flanges shall be machined on faces and edges to ISO 7005, IS 6392 or BS 4504. Valves shall be double flanged type and the face shall be parallel to each other and flange face should be at right angles to the valve centerline. Back side of valve flanges shall be machined or spot faced for proper seating of the head and nut.
2.7.6.
2.7.7.
2.7.8.
2.7.9.
2.7.10. 2.8. 2.8.1.
2.8.2.
2.8.3.
2.8.4.
3. 3.1. 3.1.1.
3.1.2.
67
3.1.3.
Valve buried or installed in underground chamber, where access to a hand wheel would be impractical, shall be operated by means of extension spindle and/or keys. Valve shall be suitable for frequent operation as well as operation after long periods of idleness in either open or closed position. The valve stem, thrust washers, screws, nuts and all other components exposed to the water shall be of a corrosion resistant grade of stainless steel. Valves shall be free from sharp projections. Butterfly, non return valves and rising spindle sluice valves shall be provided with bypass arrangement. This may be integral with valve or connected between pipes. Butterfly Valve Resilient seated butterfly valve shall be as per IS 13095/ BS 5155. Valve shall be suitable for mounting in any position. The valve seat shall be of integrally cast or replaceable design. When the valve is fully closed, the seal shall seat firmly so as to prevent leakage. The seat surfaces shall be machined smooth to provide a long life for the seal. All fasteners shall be set flush so as to offer the least resistance possible to the flow through the valve. Valve shall be suitable for throttling purpose. All valve, spindles and hand wheels shall be positioned to give good access for operational personnel. Valve of diameter 450 mm and above shall be provided with enclosed gear arrangement for ease of operation. The operation gear shall be such that they can be opened and closed by one man against an unbalanced head 15% in excess of the maximum specified rating. Valve and any gearing shall be such as to permit manual operation in a reasonable time and not exceed a required rim pull of 400 N. All hand wheels shall be arranged to turn in a clockwise direction to close the valve, the direction of rotation for opening and closing being indicated on the hand wheels. Non-Return Valve The valve shall be suitable for mounting on a horizontal pipeline and flow direction shall be clearly embossed on the valve body. Valves shall possess high speed closing characteristics and be designed for minimum slam condition when closing. Dual plate check valves shall conform to API 594 and API 598. They shall have metal to metal sealing. The spring action shall optimize the equal closing rates of each plate especially when the friction coefficients are uneven due to one plate resting upon one
3.1.4.
3.1.5.
3.1.6. 3.1.7.
3.2. 3.2.1.
3.2.2.
3.2.3.
3.2.4. 3.2.5.
3.2.6.
3.2.7.
3.6 3.6.1
3.6.2
3.6.3
68
another. The plates shall not drag on the seat while opening. The plates shall not vibrate under full or partial flow condition. 3.6.4 In case of the nozzle check valve, the disc shall be correctly positioned at all times to achieve fully non-slam closure. The spring shall be fully shielded from the flow stream by the central flow diffuser. Tilting disc non-return valve shall incorporate a double offset shaft with a variable angle tilt disc configuration. Sealing shall be metal to metal. The disc shall be stable and shall not vibrate under full or partial load conditions. Valve of diameter greater than 450 mm shall be provided, in addition to others, feet and jacking screws. Hinge pins / shaft shall preferably be square in section to ensure positive location of flaps and provide for secure fixing. Isolating Cocks For isolation of small bore pipe work tapings for instrumentation equipment etc., and for individual component isolation, the cocks shall be stainless steel, 0.25 turn ball or plug valve with the operating handle arranged to indicate the open and closed positions. Where specified, means shall be provided for securing the valve body to a front panel or near surface. 5 5.4 Pipe work All pipes, fittings, bolts, nuts, jointing materials and appurtenances for piping to be required for execution of the Works shall be manufactured and erected in accordance with the erection plans, specifications and directives of the Employer. All pipe work and fittings shall be to a class in excess of the maximum pressure attained in service including any surge pressure. The pipe work installation shall be so arranged to offer ease of dismantling and removal of pumps or other major items of equipment. Stainless steel AISI 304 expansion bellows which can take radial and axial misalignment of minimum 1 percent of valve nominal size with tie rods shall be included in the suction and delivery pipe work of all pumps as well as on delivery header for easy dismantling. All loose flanges shall be secured to fixed flanges by suitable tie-bolts. All pipe work shall be adequately supported with purpose-made fittings. When passing through walls, pipe work shall incorporate a puddle flange. Flange adapters and unions shall be fitted in pipe work runs, wherever necessary, to permit the simple disconnection of flanges, valves and equipment. The final outlet connection of the pipe work shall match the connecting point of the transmission main. 5.6 Flanged joints shall be full face, fabric reinforced rubber gaskets, pierced to take the bolts, and the face of all flanges shall be machined to give a true angle of 90o to the center line of the pipe or fittings. All necessary supports, saddles, slings, fixing bolts and foundation bolts shall be supplied to support the pipe work and its associated equipment in an approved
3.6.5
3.6.6
5.5
69
manner. Valves, meters and other devices mounted in the pipe work shall be supported independently of the pipes to which they are connected. 5.7 The whole of the jointing work and materials necessary to fix and connect the pipes, including adequate and efficient pipe support shall be included in the Contract. The Contractor shall be responsible for ensuring that the internal surface of all pipe work is thoroughly clean before and during erection and before commissioning. Cleaning shall include removal of all dirt, rust, scale and welding slag due to Site welding. Before dispatch from the manufacturers works, the ends of the pipes, branch pipes, etc., shall be suitably capped and covered to prevent any accumulation of dirt or damage. This protection shall not be removed until immediately prior to connecting adjacent pipes, valves or pumps. All small bore pipes shall be blown through with compressed air before connection is made to instruments and other equipment. No point of passage of pipes through floors or walls shall be used as a point of support, except with the approval of the Employer. 5.8 Material of steel pipes and fittings shall conform to IS:2062. Fabrication and testing shall be in accordance with IS:3589 for pipes and IS:6392, ISO 7005 or BS 4504 for flanges. Minimum corrosion allowance shall be 2mm for pipes and fittings which are not mortar lined.. All the underground buried mild steel piping shall be protected by the application of hot coal tar enamel and fiber glass wrapping. The coating shall consist of one coal tar primer coat, one coal tar enamel coat, wrapping of fiber glass and one more coat of enamel and then final wrap of enamel impregnated fiber glass. Fire Extinguishers The fire extinguishers shall be of carbon dioxide type - 3.0 kg - with ISI mark/ Tariff Advisory Committees approved make. MATERIALS AND WORKMANSHIP 1. 1.1. Introduction This part of the Specification sets out the general standards of materials to be supplied and the workmanship required to be ensured by the Contractor. All component parts of the Works shall, unless otherwise specified, comply with the provisions of this part or be subject to the approval of the Employer. Particular attention shall be paid to a neat, orderly and well arranged installation carried out in a methodical competent manner. Reference Specifications and Standards Where reference is made in the Specification to a British Standard Specification (hereinafter abbreviated to `B.S) issued by the British Standards Institution of 2, Park street, London W.I., or to an Indian Standard Specification (I.S.) issued by the Bureau of Indian Standards, (earlier known as Indian Standard Institution), Manak Bhavan, 9 Bahadur shah Zafar Marg, New Delhi 110 002, or American Society for Testing and materials (ASTM) issued by ASTM 1916 Race Street, Philadelphia, P.A., 19103, U.S.A. or American national Standards
5.9
2. 2.1.
70
Institute (ANSI) issued by ANSI 1430, Broadway, New York, N.Y., 10018, U.S.A. or Japanese Industrial Standards (JIS) issued by Japanese Standards Association, 4-1-24, Akasaka, Minato-Ku, Tokyo 107, Japan or to any other equivalent Standard it shall be to the latest revision of that Standard at the Tender opening date. 2.2. The Contractor may propose at no extra cost to the Employer, the use of any relevant authoritative Internationally recognised Reference Standard. All details, materials and equipment supplied and workmanship performed shall comply with the specified Standards. If Tenderer offers equipment to other Standards, the equipment/material should be equal or superior to those specified and full details of the difference shall be supplied. In the event of conflict between this Specification and the Codes for equipment, provisions of this Specification shall govern. Certain specifications issued by national or other widely recognised bodies are referred to in this Specification. In referring to the Standard Specifications the following abbreviations are used : IS ANSI API ASME ASTM AWS AWWA ISO DIN BS IEC IEE IEEE NEMA AGMA 3. 3.1. : : : : : : : : : : : : : : : Indian Standard American National Standards Institute American Petroleum Institute American Society of Mechanical Engineers American Society of Testing and Materials American Welding Society American Water Works Association International Organisation for Standaridisation Deutsches Institute fur Normung British Standard International Electrotechnical Commission Institution of Electrical Engineers Institute of Electrical and Electronic Engineers National Electrical Manufacturers Association American Gear Manufacturers Association
2.3.
2.4.
Materials - General All materials incorporated in the Works shall be the most suitable for the duty concerned and shall be new and of reputed make/approved quality, free from imperfections and selected for long life and minimum maintenance. Non-destructive tests, if called for in the Specification,
71
shall be carried out. All submerged moving parts of the Plant, or shafts and spindles or faces etc. in contact with them shall be of corrosion resistant materials. All parts in direct contact with various chemicals, shall be completely resistant to corrosion, or abrasion by these chemicals, and shall maintain their properties without aging due to the passages of time, exposure to light or any other cause. 4. 4.1. Workmanship - General Workmanship and general finish shall be of first class quality and in accordance with best workshop practice. All similar items of the Plant and their component parts shall be completely interchangeable. Spare parts shall be manufactured from the same materials as the originals and shall fit all similar items. Machining fits on renewable parts shall be accurate and to specified tolerances so that replacements can be readily installed. All equipment shall operate without excessive vibration and with minimum noise. All revolving parts shall be truly balanced both statically and dynamically so that when running at normal speeds at any load up to the maximum there shall be no vibration due to lack of balance. All parts which can be worn or damaged by dust shall be totally enclosed in dust proof housings. All materials incorporated in the Works shall be the most suitable for the duty concerned, free from imperfections and selected for long life and minimum maintenance. All necessary accessories required for satisfactory and safe operation of the Plant shall be supplied by the Contractor unless it is specifically excluded from his scope. Suitable provision by means of eyebolts or other means are to be provided to facilitate handling of all items that are too heavy or bulky for lifting and carrying by two men. If, after installation, the operation or use of the materials or equipment furnished by the Contractor proves to be unsatisfactory. The Employer shall have the right to operate or use such materials or equipment until correction of defects, errors or omissions, by repair or by partial or complete replacement, can be made without interfering with the plant operations. Except for any warranty provided for elsewhere in this Contract or unless otherwise agreed upon in advance, the period of such operation or use, pending correction of defects, will not exceed 1 year. Welding Welding shall comply with the latest revision of the BS 5135 Code. Welders shall be qualified in accordance with the requirement of the appropriate section of BS 4871. The Engineer shall have the right to call for further qualification from time to time from any welder who in the opinion of the Engineer, does not produce weld in accordance with the qualification. Each welder shall be assigned a number and letter. Each weldments shall clearly be identified as to its welder marking the welders Code adjacent to the welds. A record chart shall be maintained for each welder showing the procedures for which he has qualified, the date of such qualification, the type of defects produced and their frequency.
4.2.
4.3.
4.4.
5. 5.1. 5.2.
72
The Engineer shall disqualify the welder whose Work requires a disproportionate amount of repairs. All procedures where required shall be qualified as per BS EN 283-3 . 5.3. Inspection and quality of surveillance shall not be limited to the examination of finished welds. The techniques employed shall be based on methods which are known to produce good results and which have been verified at Site by actual demonstration. Haphazard striking of the electrodes for establishing an arc shall not be permitted. The arc shall be struck either on the joint or on a starting tag. The starting tag shall be of the same material or a material compatible with the base metal being welded. In case of any inadvertent strike on place other than the welding, the area affected shall be ground flushed and examined by liquid penetration method. Generally, a stringer bead technique shall be used with a slight oscillation of necessary to avoid slag and to minimize the number of beads needed to fill exceed 3 times the wire diameter. Vertical welds shall be made in upward direction. For all pipes above 300 mm dia., welding shall be done whenever possible, by 2 welders working simultaneously along both sides of the pipe. The root pass shall have less than 1.5 mm internal reinforcement. Defects like icicles, burn through and excessive such back, etc. shall be cause for rejection of welds. Final welds shall be suitable for appropriate fabrication of the non-destructive examination of the weld. If grinding is necessary, the weld shall be blended into the parent metal without gouging or thinning of the parent metal in any way. Uneven and excessive grinding may be a cause for rejection. Fillet weld shall preferably be convex and free from undercutting and overlap at the toe of weld. Convexity and concavity shall not exceed 1.5 mm. The leg lengths shall not exceed the specified size by more than 1.5 mm. All attachments such as lugs, brackets and other non pressure parts shall also be done by qualified welders in accordance with the design details and materials specifications. Temporary attachments shall be removed in a manner that will not damage the parent metal. Areas of temporary attachments shall be dressed smooth and examined by ultrasonic or liquid penetration methods. All tack welds shall be made using qualified procedure and welders, the number of size of tack welds shall be kept as small as to consist of adequate strength and joint alignments. All tack welds shall be examined visually for defects and if found defective shall be completely removed. As welding proceeds, tack welds shall be either removed completely or shall be properly prepared by grinding or filling their starting ends so that they may be satisfactorily incorporated in the welds. Unacceptable defects shall be removed by grinding machine or chipping or gouging. Flame gouging may be permitted provided gouged surfaces are ground at least by 1.0 mm below the deepest indentation.
5.4.
5.5.
5.6.
5.7.
5.8.
5.9.
73
5.10.
All weld repairs shall be carried out using the approved welding procedures and welders. Re-welded areas shall be re-examined by the methods specified for the original welds and repair procedures shall be duly qualified by the Engineers Representative. Pre-heating and Post-heating Treatment Pre-heating and post heating treatment shall conform to the relevant application Codes. Preheating not exceeding 121 deg. C for all carbon steel construction above 25 mm thickness would be mandatory. Such pre-heating would be maintained during flame cutting, flame or arc gouging, welding and repairs and may be done by gas heating by gas torches/gas rings with neutral flame. The temperature shall be checked by temperature indicating crayons. However, such pre-heating will not be necessary for welds less than 6 mm size. In large diameter pipe fabricated out of plate materials, production control test plates in accordance with the BS 4870 part 1 Table 6 to represent 30% of the long seams and each welders performance would be mandatory. Electrodes All electrodes shall be stored in their original sealed containers under dry conditions. Electrodes shall remain identified until consumed. All electrodes shall be dried before use. Drying ovens shall be provided in Work areas for drying purposes. Electrodes withdrawn from oven shall be promptly used and excess unused electrodes shall be promptly returned to oven. Examination/NDT/Radiography The various stages of examination and types shall be as stipulated in the respective fabrication Codes. Radiographic examination shall be carried out as per provisions of BS 2600 or BS 2910.; Ultrasonic tests where called for shall be carried out as per provisions of BS 3926; magnetic particle tests shall be carried out as per BS 6072. Liquid penetration tests shall be carried out as per BS 6443.
6. 6.1.
7. 7.1.
8. 8.1.
9. 9.1.
Stainless Steel Welding All welding consumable such as electrodes, filler weirs, argon gas for shielding and purging shall be of high quality and the proposed brand shall be furnished for approval of the Engineer. Weld deposits shall have similar or higher physical properties and similar chemical composition to the members joined. All electrodes shall be purchased in sealed containers only and stored in their packing intact. The packets opened shall be consumed as early as possible. The electrodes removed from the containers shall be kept in holding ovens at temperatures recommended by electrode manufacturer. Special care shall be taken in avoiding mixing of electrodes in the oven. The electrodes and filling wires shall be free from rust, oil, grease, earth and other foreign matter.
9.2.
74
9.3.
Argon gas with purity 99.5% shall be used for shielding and purging. The purity of gas shall be certified by the gas manufacturers. Non destructive examination of the welds shall be carried out to ensure quality of weld. The electric current for welding shall be direct current, straight polarity (electrode negative). The welding current shall be kept minimum possible to ensure minimum heat affected zone in the parent material. Other side of the weld joint shall be periodically flushed with argon gas. Castings Cast iron shall be of standard grey close-grained quality. The structure of the castings shall be homogeneous and free from non-metallic inclusions and other injurious defects. All surfaces of castings which are not machined shall be smooth and shall be carefully fettled to remove all foundry irregularities.
9.4. 9.5.
10. 10.1.
10.2.
Minor defects in depth not exceeding 12.5 percent of total metal thickness and which will not ultimately affect the strength and serviceability of the casting may be repaired by approved welding techniques. The Engineer shall be notified of large defects and no repair welding of such defects shall be carried out without prior approval of the Engineer. If the removal of metal for repair should reduce the stress resisting cross section of the casting by more than 25 percent, or to such an extent that the computed stress in the remaining metal exceeds the allowable stress by more than 25 percent, then casting shall be rejected. Test coupons cast simultaneously with the main castings shall be identified to check physical, chemical analysis of casting. Major defects on casting are not acceptable. Castings repaired by welding for minor defects shall be stress-relieved after such welding. Non-destructive tests as directed by the Engineer will be required for any casting containing defects whose extent cannot otherwise be judged, or to determine where repair welds have been properly made. Forging All major stress-bearing forging shall be made to a Standard Specification. Forging shall be subjected to magnetic particle testing or dye penetration test at the areas of fillets and change in section. The testing shall be conducted after rough machining (10 microns). Any defect which will not machine out during the final machining, will be gouged out fully, inspected by dye penetration or magnetic particle inspection to ensure that the defect is fully removed and repaired using an approved repair procedure. Any indication, which proves to penetrate deeper than 2.5% of the finished thickness of the component, shall be reported to the Engineer giving the details like location, length, width and depth. For the magnetic particle inspection the choice of wet or dry particles shall be at the Contractors discretion. All forging shall be demagnetised after test and shall be heat treated for the relief of residual stresses. Design Life
11. 11.1.
11.2.
12.
75
12.1.
The Works as a whole shall be new, of sound workmanship, robustly designed for a long reliable operating life and shall be capable of 24 hours per day continuous operation for prolonged period in the climatic and working conditions prevailing at the Site, and with the minimum of maintenance. Particular attention shall be given to temperature changes, the stability of paint finish for high temperatures, the rating of engines, electrical machinery, thermal overload services, cooling systems and the choice of lubricants for possible high and prolonged operating temperatures. The Contractor shall be called upon to demonstrate this for any component part either by service records, or evidence of similar equipment already installed elsewhere or relevant type tests. Routine maintenance and repair shall as far as possible not requires the services of highly skilled personnel. The Plant shall be designed to provide easy access to and replacement of component parts which are subject to wear, without the need to replace whole units. No parts in contact with water shall have a life from new to replacement or repair of less than five years. Design features shall include the protection of Plant against damage caused by vermin, dirt, dust and dampness and to reduce risk of fire. Plant shall operate without undue vibration, and parts shall be designed to withstand the maximum stresses under the most severe condition of normal service. materials shall have a high resistance to change in their properties due to the passage of time, exposure to light, temperature and any other cause which may have a detrimental effect upon the performance or life of the Works. Plant located outside lockable areas/building shall have additional features to prevent unauthorized operation. Lubrication A complete schedule of recommended oils and other lubricants shall be furnished by the Contractor. The number of different types of lubricants shall be kept to a minimum. The schedule and the name of the supplier of the lubricants shall be submitted to the Engineer. Contractor shall indicate indigenously available equivalent lubricants, with complete specification, to enable the Employer to arrange for regular supply. Where lubrication is effected by means of grease, preference shall be given to a pressure system which does not require frequent adjustment or recharging. Frequent, for this purpose, means more than once in a month and grease systems having shorter periods between greasing should be avoided. Where necessary for accessibility grease nipples shall be placed at the end of the extension piping, 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. All grease nipples shall be of the same size and type for every part of the Plant. Arrangements shall be provided to prevent bearings being overfilled with either grease or oil. Where more than one special grease is required, a grease gun for each special type shall be supplied and permanently labelled.
12.2.
12.3.
12.4.
13. 13.1.
13.2.
13.3.
13.4.
76
13.5.
Oil containers shall be supplied complete 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 levels shall be clearly visible in the sight glass type from the normal access floor to the particular item of Plant and they shall be easily dismantled for cleaning. All sight glasses shall be firmly held and enclosed in metal protection in such manner that they cannot be accidentally dislodged. All lubrication systems shall be designed so as not to cause a fire or pollution hazard and particular care shall be taken to prevent leakage of lubricants and to avoid leaking lubricants coming into contact with any electrical equipment, heated surfaces or any other potential source of fire. Name Plate Each item of the Plant shall have permanently attached to it in a conspicuous position, a nameplate and rating plate. Upon these shall be engraved or stamped, the manufacturers name, type and serial number of Plant, details of the loading and duty at which the item of Plant has been designed to operate, and such diagrams as may be required by the Engineer. All indicating and operating devices shall have securely attached to them or marked upon them designations as to their function and proper manner of use. Name plates, rating plates and labels shall be of a non-flame propagating materials, either non-hygroscopic or transparent plastic with engraved lettering of a contrasting colour. Fixing shall be by means of non-corrosive screws; drive rivets or adhesives shall not be used. Warning labels shall be provided where necessary to warn of dangerous circumstances or substances. Inscriptions or graphic symbols shall be black on a yellow background. Instruction labels shall be provided where safety procedures such as wearing of protective clothing are essential to protect personnel from hazardous or potentially hazardous conditions. These labels shall have inscriptions or graphic symbols in white on a blue background. Nuts, Bolts, Studs and Washers Nuts, bolts, studs and washers for incorporation in the Plant shall conform to the requirements of the appropriate standard. Nuts and bolts shall be of the best quality of specified grade, machined on the shank and under the head and nut Fitted bolts shall be a light driving fit in the reamed holes they occupy, shall have the screwed portion of such a diameter that it will not be damaged in driving and shall be marked in a conspicuous position to ensure correct assembly at Site. Washers, locking devices and anti-vibration arrangements shall be provided where necessary. Jointing hardware for the entire Plant shall be provided with sufficient spares to cater for site losses.
13.6.
14. 14.1.
14.2.
14.3.
14.4.
15. 15.1.
15.2.
15.3.
77
15.4.
Where bolts pass through structural members taper washers shall be fitted, where necessary, to ensure that no bending stress is caused in the bolt. Where there is a risk of corrosion, bolts, nuts and studs shall be designed so that the maximum stress does not exceed half the yield stress of the material under any conditions. All bolts, nuts and washers which are subject to frequent adjustment or removal in the course of maintenance and repair shall be made of nickel-bearing stainless steel. The Contractor shall supply all holding down, alignment and leveling bolts complete with anchorages, nuts, washers and packings required to attach the Plant to its foundations, and all bed plates, frames and other structural parts necessary to spread the loads transmitted by the Plant to concrete foundations without exceeding the design stresses. Allowance for Wastage The Contractor shall supply reasonable excess quantities to cover wastage of those consumable which will be normally subject to waste during erection, commissioning and setting to Work. Painting General The Contractor shall be responsible for the cleaning, preparation for painting, and priming or otherwise protecting, as specified, all parts of the Plant at the place of manufacture prior to packing. Parts may be cleaned but surface defects may not be filled in before testing at the manufacturers works. Parts subject to hydraulic test shall be tested before any surface treatment. After test, all surfaces shall be thoroughly cleaned and dried out, if necessary by washing with an approved de-watering fluid prior to surface treatment. Except where the specification provides to the contrary all painting materials shall be applied in strict accordance with the paint manufacturers instructions.
15.5.
16. 16.1.
17. 17.1.
17.2.
17.3.
All protective coatings shall be suitable for use in warm humid climates. All primers, under coats and finishes shall be applied by brush or airless spray, except where otherwise specified. Consecutive coats shall be in distinct but appropriate shades. All paints shall be supplied from the store to the painters, ready for application, and addition of thinners or any other material shall be prohibited. Painting at Place of Manufacture Steel and cast iron parts shall be sand blasted to near white cleaning before painting. Edges, sharp covers etc. shall be ground to a curve before sand blasting. A primer coat of a zinc rich epoxy resin based coating with at least a 75 microns dry film thickness is to be provided. In addition the parts are to be provided with adequate number of coats of coal tar epoxy polyamine coating to a dry film thickness of 175 microns including primer coating.
18. 18.1.
78
19. 19.1.
Painting at Site Immediately on arrival at the site, all items of Plant shall be examined for damage to the paint coat applied at the manufacturers works, and any damaged portions shall be cleaned down to the bare metal, all rust removed, and the paint coat made good with similar paint. After erection, such items which are not finish painted shall be done so and, items that have been finish painted at the manufacturers works shall be touched up for any damaged paint work. For finish painting, two coats of synthetic enamel conforming to IS: 2932 shall be applied. Dry film thickness of each coat shall be at least 25 microns. The dry paint film thickness shall be measured by Electrometer or other instruments approved by the Employer. In order to obtain the dry film thickness specified, the Contractor shall ensure that the coverage rate given by the paint manufacturer will enable this thickness to be obtained. Strength of adhesion shall be measured with an adhesion tester and this value shall not be less than 10 kg/cm2. Painted fabricated steel work which is to be stored prior to erection shall be kept clear of the ground and shall be laid out or stacked in an orderly manner that will ensure that no water or dirt can accumulate on the surface. Suitable packings shall be laid between the stacked materials. Where cover is provided, it shall be ventilated. Noise and Vibration The Contractor shall provide a quiet installation. All items of Plant and equipment shall be carefully chosen with a view to minimising sound levels. The Contractor shall provide and fix all material for the prevention of transmission of noise and vibration through the structure. Where appropriate all fans, A/C package units compressors, and other motive Plant shall be mounted on resilient mountings. All rotating Plant shall be statically and dynamically balanced.
19.2.
19.3.
20. 20.1.
20.2.
21. 21.1.
Galvanising Wherever galvanising has been specified the hot dip process shall be used. The galvanised coating shall be of uniform thickness. Weight of zinc coatings for various applications shall not be less than those indicated below: a) Fabricated steel Thickness less than 2 mm but not less than 1.2 mm Thickness 2 mm and above b) Fasteners Up to nominal size M10 Over M10 270 gms/sq.m 300 gms/sq.m 340 gms/sq.m 460 gms/sq.m
79
21.2.
Galvanising shall be carried out after all drilling, punching, cutting, bending and welding operations have been carried out. Burrs shall be removed before galvanizing. Any Site modification of galvanised parts should be covered well by zinc rich primer and aluminum paint. Support For Pipework & Valves All necessary supports, saddles, slings, fixing bolts & foundation bolts shall be supplied to support the pipe work. Valve and other facilities mounted in the pipe work shall be supported independent of the pipes to which they connect.
22. 22.1.
INSPECTION AND TESTING AT MANUFACTURERS PREMISES 1. 1.1. General All inspection and testing shall be carried out in accordance with the Specification and in absence of Specification relevant Indian Standard or internationally approved equivalent standard. The Contractor shall carry out at the place of manufacture tests of the Plant /Equipment at any part of the Works. The Employer shall be entitled to attend the aforesaid inspection and/or tests by his own duly authorized and designated representatives. The Employer and his duly authorised representative shall have access to the Contractors premises at all suitable times to inspect and examine the material and workmanship of the mechanical and electrical plant and equipment during its manufacture there. If part of the plant and equipment is being manufactured on other premises, the Contractor shall obtain permission for the Employer or his duly authorised representative, to inspect as if the plant and equipment was manufactured on the Contractors own premises. Testing (including testing for chemical analysis and physical properties) shall be carried out by the Contractor and certificates submitted to the Engineers Representative who will have the right to witness or inspect the above mentioned inspection /testing at any stage desired by him. The procedure for the testing and inspection to be carried out during or following the manufacture of the materials to ensure the quality and workmanship of the materials and to further ensure that they conform to the Contract in whatever place they are specified shall be as described below. The Contractor shall give the Employer at least 21 clear days notice in writing of the date and the place at which any plant or equipment will be ready for inspection/testing as provided in the Contract. The Employer or his duly authorised representative shall thereupon at his discretion notify the Contractor of his intention either to release such part of the plant and equipment upon receipt of works tests certificates or of his intention to inspect. The Employer shall then give notice in writing to the Contractor, and attend at the place so named the said plant and equipment which will be ready for inspection and/or testing. As
1.2.
1.3.
1.4.
1.5.
1.5.1.
80
and when any plant shall have passed the tests referred to in this section, the Engineers Representative shall issue to the Contractor a notification to that effect. 1.5.2. The Contractor shall forward to the Employer 3 duly certified copies of the test certificates and characteristics performance curves for all equipment. If the Engineers Representative(s) fails to attend the inspection and/or test, or if it is agreed between the parties that the Employers Representative(s) shall not do so, then the Contractor may proceed with the inspection and/or test in the absence of the Engineers Representative and provide the Employer with a certified report of the results thereof as per (b) above. If any materials or any part of the works fails to pass any inspection / test, the Contractor shall either rectify or replace such materials or part of the works and shall repeat the inspection and/or test upon giving a notice as per (a) above. Any fault or shortcoming found during any inspection or test shall be rectified to the satisfaction of the Engineer before proceeding with further inspection of wiring of that item. Any circuit previously tested, which may have been affected by the rectification work, shall be re-tested. Where the plant and equipment is a composite unit of several individual pieces manufactured in different places, it shall be assembled and tested as one complete working unit, at the makers works. Neither the execution of a inspection test of materials or any part of the works, nor the attendance by the Engineers Representative(s), nor the issue of any test certificate shall relieve the Contractor from his responsibilities under the Contract. The test equipment, meters, instruments etc., used for testing shall be calibrated at recognised test laboratories at regular intervals and valid certificates shall be made available to the Engineers representatives at the time of testing. The calibrating instrument used as standards shall be traceable to National/International standards. Calibration certificates or test instruments shall be produced from a recognised/Laboratory for the Engineers consent in advance of testing and if necessary instruments shall be recalibrated or substituted before the commencement of the test. The Contractor shall not pack for shipment any part of the Plant until he has obtained from the Employer or his authorized representative his written approval to the release of such part for shipment after any tests required by the Contract have been completed to the Employers satisfaction.
1.5.3.
1.5.4.
1.5.5.
1.5.6.
1.5.7.
1.5.8.
1.5.9.
The following Testing shall be carried out for all the equipment as applicable a) Visual Inspection. b) Material Certificates for all the specified material shall be furnished. c) Welding Qualifications
81
d) Dimension Checking e) Stage Inspections (in process inspection) f) Dynamic balancing for all rotating parts g) Hydrostatic / Leak testing for all pressure parts, Pneumatic Leak Test wherever applicable h) Operation check i) Liquid penetrant tests or magnetic particle tests for all machined surfaces of pressure parts. Ultrasonic test for forging materials viz., Plates of thickness 20mm and above for pressed / formed parts such as heads, etc. Plates, flanges and bars of thickness / dia 40mm and above used for fabrication of pressure and load bearing members and rotating parts.
j)
k) Radiographic testing for all but welded parts, as per applicable codes. l) 1.6. Hardness tests for all Hardened surfaces.
The Contractor shall maintain proper identification of all materials used, alongwith reports for all internal / stage inspection work carried out, based on the specific job requirement and or based on the datasheets / drawings / specifications. Inspection and Tests Horizontal Centrifugal Pump All pumps shall undergo witness performance tests at the pump manufacturers Works. NPSH test shall be undertaken to verify that the pumps meet the. Plots of pump head shall be made for various NPSH values. Pump casings shall be subject to hydrostatic pressure testing as an assembly at 150% of the pump shut-off head or 200% of the pump rated head whichever is higher. The hydrostatic pressure shall be held for not less than 30 minutes . Impeller and pump rotating assembly shall be dynamically balanced as per ISO 1940 / Gr. 6.3 / VDI 2060. Standard running test shall be conducted as per BS 5316 Part 2 Class B / ISO 3555 at the rated speed at manufacturers works to measure the capacity, total head, efficiency and power. However, no negative tolerance shall be permitted on the tested pump efficiency. Coating / painting shall not be applied on the impeller and casing prior to testing. These tests shall form the basis for pump acceptance except for vibration and noise. The pump shall be tested over a range comprising shut off head to maximum flow.
2. 2.1. 2.1.1. 2.1.2.
2.1.3.
2.1.4.
2.1.5.
82
Minimum seven readings approximately equidistant shall be taken for plotting the performance curve. The following formula shall be taken for computing the power input to the pump:
Power input to the Pump in kW :
QxH 367.2 x p
where,
Q = Discharge in cm/hr H = Total head in mwc p = Efficiency of pump.
If the vibration, noise level readings taken during performance test show higher than that permitted, vendor shall guarantee to show that the values shall be maintained at site after erection. Any cost of rectification needed on this count shall be borne by the Contractor. 2.2. 2.2.1. Induction Motor Routine Tests
All routine tests shall be carried out as per the latest edition of IS 325. 2.2.2. 2.2.3. Acceptance Tests Deleted. Type tests
The following type tests shall be carried out on one motor of each rating: a) Temperature rise test b) Momentary overload test c) Vibration measurement test d) Noise level test e) Over speed test f) Full load test to determine efficiency, power factor and slip g) Starting current, starting torque and pullout torque at reduced voltage 2.3. 2.3.1. Valve During testing there shall be no visible evidence of structural damage to any of the valve component. Motorized valves shall be tested with their actuators, with a differential head equivalent to their maximum working pressure, to prove that the actuators are capable of opening and
2.3.2.
83
closing the valves under maximum unbalanced head condition within the specified opening or closing period. 2.3.3. The following test shall be carried out for butterfly valves: a) Seat leakage test at rated pressure b) Body hydrostatic test at 1.5 times the rated pressure c) Disc strength test at body test pressure d) Valve operation with and without actuator 2.3.4. The following test shall be carried out for sluice valves: a) Seat leakage test at rated pressure b) hydrostatic test at 1.5 times the rated pressure c) Valve operation 2.3.5. The following test shall be carried out for non-return valves: a) Seat leakage test at rated pressure b) Body hydrostatic test at 1.5 times rated pressure c) Operation 2.4. 2.4.1. Pipework Testing of pipes and fitting shall be carried out in accordance with relevant Indian Standard and internationally approved standard. Pipes, fittings and expansion bellows shall be hydrostatically tested for 1.5 times the rated pressure. H.O.T. Crane The cranes shall be completely assembled in the Contractors or subcontractors Works and shall be subjected to the tests as specified in IS 807/IS 3177 or relevant internationally approved standard. The Contractor shall provide the test weights.
2.5. 2.5.1.
INSTALLATION, TESTING AND COMMISSIONING 1. 1.1. Erection - General The Contractors staff shall include adequate and competent erection engineers with proven, suitable, previous experience on similar contracts to supervise the erection of the Works and sufficient skilled, semi-skilled and unskilled labour to ensure completion of Works in time. The Contractor shall not remove any representative, erector or skilled labour from the Site without prior approval of the Engineers Representative. The Contractor shall ensure that no installation or erection work shall commence until full and unconditionally approved working drawings, signed and stamped by the Employer are available at Site.
1.2.
84
1.3.
The Contractors erection staff shall arrive on the Site on dates to be agreed by the Engineer. Before they proceed to the Site, however, the Contractor shall first satisfy himself, as necessary, that sufficient plant of his (or his sub-contractors) supply has arrived on Site so that there will be no delay on this account. One erection engineer who shall be required to be the Contractors representative shall be conversant with the erection and commissioning of the complete Works. Should there be more than one erector, one shall be in charge and the Contractor shall inform the Engineers Representative in writing which erector is designated as his representative and is in charge. Erection engineer is to report to Project Manager. The Contractor shall be responsible for setting up and erecting the plant to the line and levels of reference and of the positions, levels dimensions and alignment, appliances and labour in connection therewith. The checking of setting out of any line or level by the Engineer or Engineers Representative shall not in any way relieve the Contractor of his responsibility for the correctness thereof. Erection of Plant shall be phased in such a manner so as not to obstruct the work being done by other contractors or operating staff who may be present at the time. Before commencing any erection work, the Contractor shall check the dimension of structures where the various items of Plants are to be installed and shall bring any deviations from the required position, lines or dimensions to the notice of the Engineer. Plant shall be erected in a neat and workmanlike manner on the foundations and at the locations shown on the approved drawings. Unless otherwise directed by the Engineer, the Contractor shall adhere strictly to the aforesaid approved drawings. If any damage is caused by the Contractor during the course of erection to new or existing Plant or buildings or any part thereof, the Contractor shall, at no additional cost to the Employer, make good, repair or replace the damage, promptly and effectively as directed by the Engineer and to the Engineers satisfaction.
1.4.
1.5.
1.6.
1.7.
The Contractor shall align all equipment and holding down bolts and shall inform the Employer before proceeding with grouting-in the items concerned. The Contractor shall ensure that all equipment is securely held and remains in correct alignment before, during and after grouting-in. The approval by the Employer of the Contractors proposals for rigging and hoisting any items of the Plant into final positions shall not relieve the Contractor from his responsibility for damage to completed structures, parts or members thereof or other installed equipment. He shall at his own cost make good, repair or replace any damaged or injured items, whether structural, electrical, architectural, or of any other description, promptly and effectively to the satisfaction of the Employer.
1.8.
1.9.
No Plants or other loads shall be moved across the floors of structures without first covering the floors with timber of sufficient size so that applied loads will be transferred to floor beams and girders of steel or concrete. If it is required to reduce bending stresses and deflection, the beams and girders shall be provided with temporary supports.
85
1.10.
During erection of the Plant the Engineer will inspect the installation from time to time in the presence of the Contractors Site representative to establish conformity with the requirements of the Specification. Any deviations and deficiencies found or evidence of unsatisfactory workmanship shall by corrected as instructed by the Engineer. Levelling and Grouting of Machinery He shall undertake sufficiently in advance chipping of any unevenness of concrete on foundations, anchor bolt pockets, cutouts etc., to achieve uniform level of reference for erection. All concrete surfaces receiving grout shall be hacked as required to ensure better bonding with grouting. Contractor shall undertake the inspection of all components to be erected sufficiently in advance to check their soundness and conformity to drawings and the inspection records shall be signed by the Engineer as approval for undertaking the installation of the components. Any damage, shortfalls etc. shall be made good to the satisfaction of the Engineer. All grout for equipment shall be carried out using non-shrinkable continuous grout materials with suitable frame work of at least 12mm thickness. Surfaces to receive the grout shall be hacked and roughened and laitance shall be removed by wire brushing or blast of air. Concrete surface shall be blown off by compressed air before commencing grouting. Grouting shall be done in one continuous operation from one side such that grout flows in a single wave until grout reaches all confined spaces with no air pockets and air form all confined spaces is expelled. A hydro static head of 150 mm shall be maintained during grouting operations. All grouting shall be carried out in the presence of the Engineers Representative. All lines and levels shall be checked up after grout is set. Block outs shall be closed using cement concrete of the same grade as that of the parent structure. Records, Procedures and Reports The Contractor shall maintain records pertaining to the quality of installation/erection work and inspection, testing, compliance with all technical requirements in respect of all his works as described in the previous paragraphs. The reporting formats shall be in the approved formats. The Contractor shall submit such records to the Engineer after the completion of any particular work before submitting the bill of supply/progress of work. Such report shall comprise shop inspection reports, shop testing reports, material test reports, based on which despatch clearances are provided, all the quality control reports of welding, erection and alignment records. All the above mentioned records shall be submitted in the final form duly countersigned by the Engineers Representative attesting conformity to specifications and his approval of installation, and duly incorporating all the additions, alternations, and information as required by the Engineer, on the basis of preliminary reports giving the progress of the work. Such records notwithstanding, any records submitted earlier with bill of supply/progress etc.,
2. 2.1.
2.2.
2.3.
3. 3.1.
3.2.
86
shall be duly bound and submitted to the Engineer in six copies by the Contractor on his notification of the mechanical completion of erection. 4. 4.1. General Preparations before Completion of the Plant The following documents should be completed in accordance with the Contract schedule before completion of erection. The Employer and the Contractor shall preserve and control these documents in a safe and appropriate place on Site in order the both parties personnel can make use of them at any time. Technical Documents a) Operation and Maintenance manual b) Design documents including the Contractors design data, drawings and Specifications. c) Tools and test equipment list d) Spare parts list e) Lubricant list 4.1.2. Procedures a) Mechanical testing procedure b) Electrical testing procedure c) Instrumentation testing procedure d) Detailed Precommissioning and Commissioning procedure e) Detailed Performance Test procedure 4.1.3. General and Coordination Documents. a) Detailed organisation charts for Precommissioning and Commissioning showing lines of authorities and responsibility, and functions of all key personnel. b) The job description of the members of the team. c) The scheduled dates of assignment of each member to Precommissioning and Commissioning Organisation. d) A detailed schedule showing the time sequence which the Contractor anticipates to follow for the various steps in Completion of Erection, Precommissioning and Commissioning of each unit and equipment. e) The regulations for safety, hygiene and discipline. f) The practical organization of the relationship (meetings, reports, etc.) between the Contractor and the Employer at the phases of Precommissioning and Commissioning. g) Emergency communication route.
4.1.1.
87
4.2. 4.2.1.
Manpower Required manpower shall be provided as agreed between the Contractor and the Employer in a Manpower Mobilization Plan which shall include the number and qualifications of the operator and maintenance personnel to be furnished by the Employer for the Plant. Completion of Erection The completion of Plant under erection by the Contractor shall be deemed to occur, if all the units of the Plant are structurally and mechanically complete and will include among other such responsibilities the following: Plant in the Scope of the Contract has been erected, installed and grouted as per specifications. Installation checks are completed and approved by the Engineer. The erected Plants are totally ready for commissioning checks. At the stage of completion of erection, the Contractor shall ensure that all the physical, aesthetic and workmanship aspects are totally complete and the Plant is fit and sound to undergo tests on completion and subsequent pre-commissioning checks. Upon achieving the completion as described above, the Contractor shall notify the Engineer by a written notice intimating completion of erection and notify the Engineer for inspection. The Engineer / Engineers Representative shall proceed with the inspection of such units within 14 days of such a notice. The Engineer shall certify completion when there are no defaults in the Works or The Engineer shall inform the Contractor list of deficiencies for rectification hereinafter referred as Punch list and the Contractor shall complete the rectification work within a jointly agreed period before precommissioning activities and obtain the Engineers acceptance or approval of the same before proceeding with the same. The Engineer may inform the Contractor that the works are accepted with the Punch list (items which do not hamper operability, safety or maintainability) and allow the Contractors to proceed with the pre-commissioning checks when the Contractor under-takes to complete such outstanding works within an agreed time during defects liability period. Taking over shall be based on rectification of all deficiencies as advised by Punch lists.
5. 5.1.
5.1.1.
5.1.2. 5.1.3. 5.2.
5.3.
5.3.1. 5.3.2.
5.3.3.
5.4.
The erection period indicated by the Contractor would be deemed to cover all the activities upto Completion as stipulated in previous paragraphs, notice of completion by the Contractor, inspection by the Engineer for Completion, and Contractor rectification of all deficiencies as noticed by the deficiency/Punch list, and acceptance by the Engineer of such rectifications, prior to Tests on Completion.
88
5.5.
Minor defects, which in the opinion of Engineer which do not hamper operability and maintability will nor be taken into account for deciding Mechanical Completion. Such defects shall be rectified concurrent to commissioning checks before Tests on Completion. However, the Engineers decision in this regard is final. The commissioning period as notified by the Contractor shall be deemed to occur beyond the date of Completion and shall include all periods of precommissioning, trials and Tests on completion. It is in the Contractors interest to offer the section/units/systems, progressively under identified milestones within overall erection period, duly completed for rectification of any deficiencies pointed out by the Engineer and to achieve Mechanical Completion before undertaking the tests on Completion within the specified erection period. The Engineer also reserves the right to withhold the cost as estimated to be equivalent to the rectification of deficiencies pointed out to the Contractor until such a time such deficiencies are rectified to the satisfaction of the Engineer. Precommissioning After the Completion of erection, Precommissioning activities listed below shall be carried out to make the Plant ready for Commissioning. All instruments, materials and provisions necessary for conducting site tests shall be provided by the Contractor at his own cost. Upon completion of erection of each piece of equipment, facility or discrete part of the plant, mechanical checks and tests shall be carried out according to the Contractors check list. The mechanical checks and tests shall be to establish that: The Plant is erected in accordance with the Contractors construction drawings, pipework drawings, instrument diagrams, etc. issued for the Plant. The materials are installed and mechanically function in accordance with the Contract and
5.6.
5.7.
6. 6.1.
6.2.
6.2.1.
6.2.2.
6.2.3. 6.3.
Applicable codes as listed in the Contract are followed for Materials and workmanship. Items such as painting, thermal insulation and final clean-up which do not materially affect the operation or safety of the Plant will be excluded. All these items shall be listed and completed after Precommissioning or Commissioning at the discretion of the Contractor, but before acceptance. The Contractor shall prepare and maintain at Site test forms and records which shall include : Description of type of test or check, Date and times of test or check, Identification of equipment and facilities,
6.4.
6.4.1. 6.4.2. 6.4.3.
89
6.4.4. 6.4.5.
Test pressure, test data and results, including remarks, if any, Signature of the Contractors personnel attesting to data recorded, if any.
Checks, tests and records thereof shall be carried out by the Contractors construction forces. 6.5. Wherever the Employers witness or attesting of the check or test is required, the Employers personnel shall attend such check and test. For this purpose, the Contractor shall keep the Employer informed of a day-to-day test plan schedule. The test plan schedule may be revised from time to time to reflect the actual progress of the work and test. Any items found incomplete or requiring repair or adjustment shall be marked as such on the test records and then reported by the Contractor to the Employer and the Contractors personnel in charge of the relevant construction area. Checking procedures shall be repeated until all the items on the check list are cleared. A complete set of test records shall be handed over to the Employer on completion. The tests on the different Mechanical and Electrical equipment shall include but not limited to : Pumps, Piping and Valves a) 1.5 times the shut off pressure or twice the working pressure whichever is higher to test the soundness of the joints. Provision of the necessary pumps, gauges, blank flanges, tappings etc. for carrying out these tests shall be included in the Contract. b) Leakage tests shall be carried out on all erected pipework, pumps and valves immediately after erection and where possible before being built in. c) Operating tests shall be conducted on valves. d) The pumpset shall be tested for performance. The vibration and noise levels shall be checked to be within the specified. e) The pump shall be tested through the operating range as per BS 5316 Part 2 Class B / ISO 3555 with all working (excluding stand-by) pumps at a time, for all the pumps. However, no negative tolerance shall be permitted on the tested pump efficiency. 6.9.2. Pump motors
6.6.
6.7. 6.8. 6.9.
6.9.1.
Condition of winding insulation be tested and insulation values shall be restored to required level by suitable heating arrangements locally. 6.9.3. Cranes
The crane and lifting tackle shall be tested to 125% of the safe working load. The Contractor shall arrange the test load. Deflection and speed tests shall also be conducted.
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6.9.4.
Sluice Gate
Leakage test shall be performed by the Contactor after installation of the Sluice Gates. Under the design seating head and unseating head the leakage shall not exceed the limit specified in IS:13349, Class 1 for shop testing. 6.10. Instrumentation The tests on the instrumentation equipment shall include but not be limited to : a) All cables shall be tested for polarity, continuity and insulation resistance. The common mode d.c. voltage at each signal input terminal shall be measured and recorded. b) The pre-commissioning tests on the various main categories of plant shall be as listed below: c) The resistance of each electronic loop shall be measured d) Electronic equipment shall have been energised for at least 24 hours before testing begins e) The zero setting of each display instrument including any local indicator on or associated with a transmitter shall be checked f) The correct calibration of each items in each control or monitoring loop shall be checked by the introduction of appropriate signal at each source, at five cardinals points of the range for increasing and decreasing signals 6.10.2. The following tests methods shall be used: a) Pressure operated devices dead weight testers or portable calibrators b) Level operated devices actual level variation or simulation thereof. Instrument zero reading shall be checked against a bench mark: c) For controlling devices the Contractor shall demonstrate the correct operation of the loop including the regulating devices. Each automatic controller shall be set to the appropriate estimated values of the terms. Which shall be optimised during the plant start-up. Each control valve shall be optimised during the plant start-up. Each control valve shall be checked by operation of the manual control on the associated controller and the correct stroking verified. Valve positioners, electronpeumatic converters and gauges shall be checked during these tests. d) All systems shall be checked for fail-safe operation. e) Initiating devices not covered by the foregoing e.g. plant stop/start controls shall be checked in conjunction with the testing of the associated switchgear and machine. 6.10.3. The Contractor shall also demonstrate the data transfer as per data transfer schedule between Pumping Stations.
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7. 7.1.
Commissioning After the completion of Precommissioning activities the final checks and preparations necessary for start-up of the plant shall be carried out. The Contractor shall submit to the Employer a written Notice of Mechanical Completion which shall include : Identity of a part of the Plant considered mechanically complete, A copy of all relevant completed test reports, The date on which the completion of the tests was achieved, Check list, and A request for issuance of a Mechanical Completion Certificate in respect of that part.
7.1.1. 7.1.2. 7.1.3. 7.1.4. 7.1.5.
7.2.
Within fourteen (14) days from the date of receipt of the Contractors written Notice, the Employer shall : In the case of acceptance, issue a Mechanical Completion Certificate. In the case of Objection, submit a rejection Statement setting forth remaining items to be completed or defects or deficiencies to be corrected before Mechanical Completion status can be accepted. When the Employer rejects the Contractors Notice the Contractor shall take any necessary action to complete or correct the items marked and give the Employer a second Notice of Mechanical Completion. After the issuance by the Employer of a Mechanical Completion Certificate, Commissioning activities listed below shall be carried out to enable the start-up and operation of the Plant. Procedures are described as below :
7.2.1. 7.2.2.
7.3.
7.3.1.
Commissioning Procedure shall be carried out in a methodical sequence as follows a) Warming up, b) Start-up, c) Initial running, d) Operability adjustment, e) Stable operation f) Final adjustment
7.3.2.
At all stages of commissioning sequence, the Plant shall be operated at optimum Plant conditions. To ensure this, the Contractor may make minor adjustment to the conditions indicated in the Operation and Maintenance Manual as necessary.
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7.3.3.
The Contractor shall check the operating conditions of the Plant by constantly monitoring operating data. The Contractor shall specify for each discrete part of the Plant the operational data to be recorded and the manner in which the data is to be taken. All the operating data shall be recorded by the Employer on the forms to be mutually agreed. A copy of the operating log and analytical data from initial operation through to the completion of Performance Test shall be made available by the Employer to the Contractor for evaluation.
7.3.4.
7.3.5.
7.2 Electrical Components

Design Criteria for Electrical Equipment a) Load Factor i) ii) iii) b) Main motor : : 0.9 : 1.0 0.9
Auxiliary load suction valve motors etc : Lighting load
Diversity Factor i) ii) iii) Main motor : : 1.5 : 1.20 1.0
Auxiliary load, suction valve motors etc : Lighting load
c)
Power Factor of H.V. Motors
As per Manufacturers Catalogue
d) e) f)
Efficiency of H.V. Motors Power factor of L.V. Motors Efficiency of L.V. Motors
: : :
- do - do - do -
Power Supply Scheme
a)
The source of power supply to these pumping stations will be through one no. 11 kV, (for loads upto 2500 kVA) overhead line from Gujarat Electricity Board.
b)
Two transformers of 11kV/0.433 kV for pumping station at Ward No.6, including auxiliary load of pumping station and lighting load for staff quarters are recommended to meet the load requirement. The capacity of transformers
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shall be designed such that in the event of outage of one of the transformers, the other transformer shall supply the full load of the pumping station. c) Transformer sizing shall consider the following : i) The load of all the normal working pumps and auxiliaries of the pumping station, which will be ON simultaneously. ii) Each transformer shall be rated for full working load of the pumping station. iii) Normally both transformers, shall share the total load (each transformer loaded to about 50% of its capacity).This will ensure the running of the stand by pump in addition to normal working pumps in the event of compensating the loss of pumping, followed by a prolonged power failure. iv) During the outage of one of the transformers, the other transformer shall supply the total working load of the pumping station. The additional load requirement of starting of stand by pump (to compensate the loss of pumping, followed by a prolonged power failure) shall be met by over loading the transformer within the limits as specified in IS:6600 Guide for Loading of Oil-Immersed Transformers. d) The short circuit apparent power of the system at the proposed main substations shall be as follows as per IS:2026 (Part I). 11 kV system 3.3kV system 415 kV system e) : : : 350 MVA 150 MVA 20 MVA
Pumping stations with L.V motors shall have two main step down transformers of 11kV/ 0.433 kV with on load tap changers for a range of -10% to +10% in steps of 1.25%. The power for main pump motors as well as for other loads such as exhaust fans, control valves, lighting etc. shall be supplied at 415 V.
f)
Power factor correction capacitors shall be provided and their capacity shall be adequate to correct the power factor upto 0.95 at full station load.
h)
Suitable metering facility shall be provided for monitoring purposes.
Protections
Following protective relays are proposed for incomer, transformers, motors and other plant feeders. a) Incomer i) Inverse time phase over current relays
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ii) iii) iv) b)
Inverse time earth fault relay P.T. fuse failure relays Under voltage relay
Main Transformers H.V. side : i) Inverse time over current relays with instantaneous over current element ii) Instantaneous earth fault relay
iii)
Transformer Buchholz/gas pressure relay with alarm and trip contacts
iv)
Winding Oil temperature indicators with alarm and trip contacts
L.V. side (3.3 kV) (NOT APPLIABLE)
i) ii) iii)
Inverse time phase over current relays Inverse time earth fault relay. Restricted earth fault relay.
L.V side (415 side) 415 V L.V. incomer Air Circuit Breaker shall be provided with built-in C.T. operated thermal magneto release adjustable between 0-1 sec to 0.3 sec delay (independent of current) c) 3.3 kV Plant Feeders i) Inverse time phase over current relays with instantaneous over current relay.
ii)
Inverse time earth fault relay.
d)
3.3 kV Plant Feeders to Aux. transformers (H.V. side of transformers) i) Short circuit protection in all three phases through.
e)
Motors: H.V.Motors and L.V Main Pump Motors i) ii) iii) iv) v) Thermal overload protection in two phase for trip. Locked rotor protection in two phase with a common timer for trip. Short circuit protection in all the three phases. Instantaneous unbalance single phasing protection. Earth fault relay connected to core balance C.T. for trip.
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vi)
Temperature monitoring by RTD elements embedded in stator windings and bearing temperature indicators provided on both the bearing.
L.V. Auxiliary Motors : i) Overload protection by thermal (bimetal) relays in all the three phases to trip ii) Metering Short circuit protection in all the three phases through fuses
The following metering shall be provided. a) Incomers : i) ii) iii) iv) v) vi) b) Ammeters in all the three phases Voltmeter with selector switch Frequency meter kW & kWH meter Power factor meter Trivector meter
Main Transformers H.V. Side i) Ammeters in all the three phases
L.V. Side: i) c) Ammeters in all the three phases
H.V. Feeders: i) Ammeter in all the three phases.
d)
L.V. Feeders: i) Ammeter in all the three phases
Switchgear:
a)
L.V. Switchgear
i)
415 V Power control centres, power distribution boards etc. shall be of fixed, compartmentalised double front construction, excepting circuit breaker modules which shall be of drawout type and single front construction.
ii)
The degree of protection for switchgear shall be IP 54 for indoor installation and IP 55 for outdoor installation.
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iii)
H.V. indoor switchgear circuit breakers shall be suitable for 110V D.C. control power supply. Others shall be suitable for 110V/230V A.C. control power supply which shall be derived either through potential transformers or between phase and neutral.
b)
H.T. Switch Gear
H.V and L.V Motors a) Induction motors up to 200 kW shall be suitable for 415 V, 3 pH, 50 Hz supply. Motors rated above 200 kW shall be suitable for 3.3 kV, 3 PH, 50 Hz supply. Fractional H.P. motors meant for unidirectional rotation shall be suitable for 240 V, 1 pH 50 Hz supply. b) Totally enclosed fan cooled (TEFC) L.V. motors with I.P 54 enclosure shall be used in dry indoor locations, whereas totally enclosed fan cooled, weather proof with IP 55 enclosure L.V. motors shall be used in outdoor locations. c) H.V motors shall have closed air circulation air cooled (CACA) arrangement.
d)
All motors rated 55 kW and above shall be provided with space heater suitable for 240 V, 1 pH, 50 Hz supply.
e)
At least six resistance type tempearature detectors for the stator winding, each having D.C resistance of 100 ohms at 0 C, embedded in the stator winding at locations where highest temperatures may be expected, shall be provided for H.V pump motors.
f)
H.V pump motors, bearings shall be provided with dial type thermometers having two separate NO contacts, for alarm/tripping of the motor.
g)
Each motor shall be provided with start/stop facility near the motor as well as on the panel, however, no power isolation near motor is envisaged.
h)
H.V motors shall be suitable to FCMA in neutral soft starting, where as L.V main motors rated upto 200 kW shall be suitable to star/delta starting. Valve motors shall be suitable to DOL starting.
i)
Flux compensated magnetic amplifier (FCMA) type soft starters in the neutral side of star point side of the stator shall be provided for 3.3 kV motors starting.
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Cables : a) The H.V. Power supply from main sub-station to various plant sub-stations and to the equipment shall be done by using aluminum conductor, XLPE insulated, PVC sheathed and armoured type. The L.V power cables shall be aluminium conductor, PVC insulated, PVC sheathed and armoured type. The control cables shall be copper conductor, minimum 1.5 sq.mm PVC insulated. PVC sheathed and armoured type. b) All power cable sizes shall be based on continuous current carrying capacity, permissible voltage drop and short circuit rating. The voltage drop shall be limited to 3%. For short circuit rating of H.V. cables, the fault clearing time shall be 0.5 second for H.V. plant feeders and 0.16 second for equipment feeders. For S.C. rating of H.V. cables the fault clearing time shall be 0.5 second for L.V. incomers and 0.16 second for L.V. outgoing feeders to equipment. c) Rating factors for variation in ground temperature, variation in ambient air temperature, grouping of cables, depth of laying etc. shall be based on the cable manufacturer's recommendations/catalogues. D.C. Power Supply a) One set of 110V D.C, maintenance free rechargeable sealed lead acid batteries of adequate A.H capacity shall be provided for control of H.V. switchgear in pumping stations as well as emergency lighting in main operating area. b) Batteries shall be provided with battery charger cum DC distribution board. Battery charger shall include a boost charger and a float charger, indicating lamps and annunciations. Lighting The lighting system will comprise the following : a) Normal A.C. lighting. All indoor and outdoor areas will be provided with A.C. lighting and the same will be available as long as A.C. supply is healthy. b) Emergency D.C. Lighting for Switchyard and substation area. Switchyard, main substation area and control room will be provided with D.C. emergency lighting of about 10% of normal A.C. lighting. These lights will be made "ON" automatically on failure of A.C. supply. These lights will be fed from 110V D.C. Batteries through battery charger-cum D.C. distribution board.
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c)
Emergency D.C. Lighting for other areas. In other areas, at important locations, built in battery operated instalite fixtures will be provided which will come in service when A.C. supply fails.
d)
The wiring for lighting circuits shall be done by wires run in PVC. conduits for indoor areas. For outdoor lighting, wiring shall be done by armoured cables.
e) Sr.No
The illumination levels for various areas shall be as follows : Area Illumination Level (Lux)
i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv)
Pump house Battery room Machinery service area Offices/conference room H.V./L.V. switchgear rooms Plant/Switchyard control rooms Chemical/general stores Chemical plant room Cable basement All other indoor areas Outdoor platforms and walkways Building entrances Outdoor plant areas Switchyard and transformer yard i. General ii. On equipment
200 lux 150 lux 150 lux 300 lux 200 lux 300 lux 150 lux 200 lux 100 lux 100 lux 50 lux 100 lux 20 lux
10 lux 30 lux 10 lux
xv) f)
Roads (Secondary)
Lighting distribution board shall be provided and it shall supply power to various local lighting panels.
g)
Lighting panels shall be provided in various areas and circuit wiring to the lighting fixtures shall be made from these lighting panels. Lighting panel shall comprise of 63A TPN MCB with ELCB for incomer and 16A/10A MCBs for each out going single phase circuits.
h)
Lighting fixtures and fans will be grouped on the circuit wherever required. However, separate circuits shall be used for receptacles wiring.
i)
For the purpose of calculating connected loads of various lighting circuits, a multiplying factor of 1.25 will be assumed to the rated lamp wattage for
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mercury vapour, sodium vapour and fluorescent lamp fixtures to take into account losses in the control gear. Also a loading of 100 watts and 500 watts shall be assumed for single phase 5 Amps and 15 Amps receptacles respectively. j) Lighting fixtures, receptacles, switches, conduits and junction boxes shall be properly earthed using 12 SWG G.I. wire unless specified otherwise. k) Receptacles of 5A and 15A, single phase, 3 pin shall be provided with switch. Receptacles in offices and control rooms shall be decorative type and in other areas shall be industrial type. Three phase receptacles shall be associated with TPN switch housed in the same enclosure. The receptacle shall become live only when the associated switch in "ON" position. The enclosure for all outdoor receptacle shall be provided with degree of protection of IP-55. l) Generally maintenance factor of 0.8 shall be considered for lighting fixtures.
Safety Earthing & Lightning Protection
a)
The soil resistively of the plant area has not yet been measured, the same should be carried out during detailed engineering by successful bidder.
b)
After soil resistively measurement; length of conductor, no. of earth electrodes and no. of test pits shall be finalized.
c)
The material of earthing conductors will be as given below :
i)
Conductors above ground shall be Galvanised steel to prevent atmospheric corrosion
ii)
Conductors buried in ground or embedded in concrete shall be mild steel.
d)
The maximum values of the earth fault current for the design of the earthing system shall be considered as below:
i) ii)
11 kV system 3.3 kV system
: :
19 kA 27 kA
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iii)
415 V system
30 kA
e)
Fault clearing time for sizing the earthing conductor shall be taken as three (3) seconds.
f)
Maximum allowable temperature rise for steel welded joints will be taken as 500C and ambient temperature as 45C.
g)
Plant earthing system will be designed such that overall earthing resistance is less than one (1) ohm.
h)
In case of different electrical systems operating at different voltages in an area/plant, the main earthing conductor for each system shall be decided on the basis of maximum fault current in that system. Earthing system for different systems shall be interconnected by interconnections of maximum size conductor.
i)
In outdoor sub-station area, main earthing conductors will be planned for most economic earthing of the equipment, keeping the potential gradients at earth surface within maximum allowable limit. Step and touch voltages shall be within permissible limit. Main earthing conductors in outdoor areas shall be buried 600 mm below finished ground level. Earthing conductor around the building shall be buried in earth at a minimum distance of 1500 mm from the outer boundary of the building.
k)
Main earthing conductors inside the building will be planned such that various equipment are connected to earthing system in most economical and reliable manner.
l)
Earthing conductors shall be provided around the outside edge of switchyard fence at a distance of approximately 1000 mm and every alternate fence post shall be connected to the grid by one lead and gates by flexible braid to the earthed post.
m)
Minimum 6000 mm spacing between rod/pipe electrodes and 8000 mm spacing between plate electrodes shall be provided.
Power Factor Improvement
a)
Capacitors for H.T motor shall be provided with manual switching across motor terminals to improve power factor upto o,95
a)
Capacitors for 415V motor shall be provided on 415V bus with automatic switching to improve power factor upto 0.95.
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Flow Measuring System (General): (a) Flow measuring system shall consist of flow sensor / transducers, flow computer and flow transmitter, digital flow indicator and integrator and any other item required to complete the system. (b) Flow transducers shall be rugged in construction and shall be suitable for continuous operation. Flow transducers shall have waterproof construction and shall be suitable for installation on underground / above ground pipelines. Insertion / removal of flow sensors shall be possible when pipelines are pressurized and should be leak proof at 1.5 times the working pressure at that location. Multi channel instruments shall have facility of measuring different flows in single path measurements. With a different set up, the same instruments shall measure flow in a single pipeline with multi-path sensor arrangement with higher accuracy of measurement. (c) To avoid the effects of disturbances in the velocity profile, a straight and uninterrupted run, upstream as well as downstream from the location of the flow sensor shall be provided, as required by the flow meter manufacturer. (d) Contractor shall finalize the exact location of flow transducers in consultation with Engineer's Representative. (e) The flow transmitter shall be suitable for field mounting and shall accept input from the flow transducer. It shall process the input signal and provide 4-20 mA DC out put proportional to flow rate. flow transmitters shall have LCD display to indicate instantaneous flow rate. The flow range shall be adjustable. The flow meters shall be suitable for measuring flow at velocities of water from 0 to 4 m/sec. (f) Flow measurement shall not be affected by physical properties of water viz. temperature , pressure, viscosity, density etc., within given limits. Contractor shall provide compensating electronic circuits, if required. (g) Contractor shall construct a suitable concrete chamber for enclosing flow transducer to be mounted on underground pipelines. A concrete cabin shall be constructed above the chamber for housing the flow transmitter. A concrete cabin shall be constructed for housing the flow transducer and the flow transmitter to be mounted on surface pipelines. (h) The Insertion / Retraction assembly, head of the flow transducers shall be made up of anticorrosive material. Ultrasonic flow meter: (a) (b) Ultrasonic Transducers shall work on transit (time of flight) time principle. Ultrasonic flow meters shall consist of multi-path flow transducers as described below:
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i)
Upto 1200 mm Line size
Two path measurement (Four Transreceiver Transducers) Four path measurement (Eight Transreceiver Transducers)
ii)
Above 1200 mm Line size
(c)
The transducer probe shall be of the wet insertion type with facility for online insertion and retraction assembly.
(d)
The flow computer shall be microprocessor based and shall have facilities for on-line diagnosis, entering pipe size, engineering units, measuring span etc.
(e)
The contractor shall measure the exact inside diameter of the pipe at the location of flow transducer and this data shall be used for flow computation.
2. 2.1
Flow Meters: Ultrasonic flow meters shall be provided on inlet and discharge header of the pumping station. Flow meter shall be of a multi-path, multi-beam type.
2.2
The flow meter shall permit the removal of the sensors for maintenance without draining down or depressurizing the line.
2.3
The flow computer shall be microprocessor based and shall have self-diagnosis facilities.
2.4 (a) i
Ultrasonic Flow Measuring System: General Service Flow measurement pumping station. on discharge header of
ii
Meter size
800 mm dia discharge header of the pumping stations 0-4000-m3/hr
iii iv
Range setting
Overall accuracy of measure-ment 1% of full scale loop
v (b) i
Quantity Flow Sensor / Transducer Type
1 No
Multipath, Insertion type (Clamp-on type not acceptable)
ii
No.of paths
Four paths (8 transreceiver transducers) for discharge header of the pumping station
iii iv v
Measuring principle Weather protection class
Transit time (Time of flight) IP 68 of IS: 13947 (Part-I)
Provision for online removal / Required
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insertion of flow sensors without depressurization of the line vi Accessories Prefabricated integral cables for connecting sensors and transmitter. Insertion / Retraction assembly (c) i Flow computer and transmitter. Type Multi channel indicating type having back-lit LCD / LED display ii iii iv v (d) i ii iii iv Input Output Zero and span adjustment Weather protection class Flow indicator and integrator. Type Display Digit Height No.of digits for Flow Indicator Flow integrator v vi vii Input zero and span adjustment Manual integrator viii Engineering units for - Flow rate indicator - Flow integrator ix Communication port CUM/Hr ML RS-232 (for re-transmitting values of integrated flow) x Battery back up for integrator Retransmitted out put Required 4-20 mA Proportional to Flowrate rest facility for 4 digits 6 digits 4-20 mA DC (Isolated) from flow transmitter Required flow Required (shall be key operated) Electronic Digital, seven segment back lit LCD/LED display. 14 mm or higher. From ultrasonic flow sensors 4-20 mA DC (isolated) Required IP 65 of IS: 13947
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8
8.1 General
Controll of Unaccounted for Water Contro of Unaccounted for Water
Definition: The term unaccounted for water (UFW) represents the difference between net production (the volume of water production at sources) and consumption ( the volume of water that can be accounted for by legitimate consumption, whether metered or not) a. Water consumed but not recorded by consumer meters or otherwise accounted for other public uses. This is refer to as non-physical loss and is reflected in lost revenue. it includes water consumed through illegal connections b. Water lost through leakage, also referred to as physical loss. This is a resource loss and is reflected in the cost of production.
8.2 Guidelines to reduce UFW

World Bank provides following suggestion to reduce UFW:
1.
Accountability is the most important factor that will induce management of an utility to take the necessary actions and for them to fall into place in the right sequence
2.
Water service should be adequately priced so that it will pass right signal to both the utility and the users to act promptly in keeping UFW at the lowest cost-effective level.
3.
Reduction of commercial losses is very important because it helps improve the revenue stream almost immediately. Hence, both utilities give the highest priority to the commercial system (accounting for all users, universal metering and maintenance, billing and collection) which are tightly controlled operations. A well operated and maintained commercial system is the life-blood for the organization
4.
Reliable information and consumption and their evolution over time are critical to a reliable assessment and monitoring of UFW and identification of the correct actions to keep it under control. This information is also critical for the optima; operation of the distribution system
5.
Reduction of physical losses has a lesser impact on net revenue; at least in the short run 9varible production costs are often not significant). However, in the medium and long term, such reduction post-pones the need for additional capacity and eases pressure of financing new works. In addition, broken pipes that remain un repaired project a bad image of the utility among consumers.
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6.
Reduction of both physical and commercial losses is under taken concurrently. UFW is the result of a combination of factors, not the result of a single one. Therefore, the components of an UFW reduction program and their costs and benefits should be carefully determined to arrive a cost-effective strategy.
7.
UFW programs should be routine and institutionalized operation programs and not sporadic exercises to be undertaken.
8.3 Assumption of Leakage

During 1976 and the during 1985 leak detections studies were carried out by private consultant for Rajkot city. The study were carried out at all different places by inserting pitot tubes at different locations and pressure measurements were observed for online and off-line situation. Leak and loss detection were found about 18 % of total supply. However, then after more three sub head works and additional distribution network for about 35 sq.kms. are added in to the system to the system but no specific study has been carried out. Therefore, it is attempted here to calculate UFW with the help of imperial arithmetic procedure. As described in the chapter of water demand, the detail of number of connections and total supply can be enumerated as under: Details Domestic water supply Water Supply through community stand posts Water Supply through tankers Commercial, Industrial Supply, Garden, Institution and Fire brigade Total Average Actual Supply from various zones Assumed Loss & Leakages in Percentage Number Water supply in Water supply in Million Liters Lakhs Gallons 188000 103.40 227.78 1150 2.3 5.06 100 5% 1 5.10 111.80 140.70 26% 26% 2.20 11.23 246.27 310
From the above assessment it is inferred that leak age is quite high about 26%. The reasons for the leakage are identified as under: 1. There are more than 1250 valves operated daily to make intermittent zone wise water supply for twenty minutes daily. It is observed that because of the often and daily operation lead the valves to leak. It is estimated that more than 3% water is lost at valve leakages. 2. The city water supply distribution network is largely through AC pressure pipes. These pipes do not have rigid joint and it breaks occasionally. The leakage from these the lines are estimated about 14%.
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3.
The storage tanks at all head works have been repaired recently and almost all tanks leakages are stopped. However possibility of some leakage at treatment plant and isolated places is seen. It is estimated such losses about 3 to 4%
4.
There is no special round the clock cell in the RMC to monitor illegal connections and un authorized water trapping. Losses due to such illegal connection taps are estimated about 10 to 12 % .
8.4 Approaches for Leakage Control

It is recommended that a systematic approach for leakage control be undertaken for the city. As it is also part of Rajkot CDP water supply strategies and also it is set out comes to cut down losses up to 14 to 15% of total water supply before end of 2007 as part JnNURM projects. Leakage control forms a significant portion of the wider function area of Operation and Maintenance of the system , Mapping & record keeping, Network Analysis, Maintenance event analysis are required for O & M and leakage control. IEC (Information, Enforcement and Communication) Program is recommended. The leakages in the distribution system proposed to be reduced by following action: 1. 2. 3. 4. 5. Replacing the valves which are mal-functioning and also replacing the gland of each valves. Replacing the non-metallic pipes with flexible joint into metallic pipe with rigid joint. By reducing the hours of supply A special drive to locate the unauthorized connections Immediate repairs during the break down of pipeline.
1.Replacing the valves which are mal-functioning and also replacing the gland of each valves. In the distribution system, sluice valves are required to be provided at various sections so that water could be supplied by zoning. Since this region is falling under arid zone, it is not possible to supply water round the clock and because of which the method of adopting supply by zoning is essential. Under the circumstances, few valves are required to be operated daily twice in a day. If the quality of valves is not good, the leakage starts from the gland of the valve. In RMC for distribution work, as far as possible, the valves of only either Kirloskar Make or IVC make are being used which gives guarantee for one lac operation without leakage. For reduction of leakages, RMC has now planned to identify such leaking valves and replacing the gland kit etc. If with this arrangement, leakage will not be stopped, RMC will replace the valve.
2.Replacing the non-metallic pipes with flexible joint into metallic pipe with rigid joint. Because of the financial constraint with all local bodies, the pipe material for distribution system is generally Asbestos cement which is being jointed with rubber rings. In due course of time, due to chlorinated water, the rubber ring gets damaged and vibration due to vehicular traffic, the nuts and
107
bolts of the joint gets loosened and ultimately the joints start leaking. If pressure is very high, such leakages damage the pipes also. Under the circumstances, it is advisable to replace the non-metallic pipe into the metallic pipe where joints are rigid and there is no any adverse effect on vehicular traffic as well as chlorinated water. RMC will carry out the detailed leak detection survey and will replace such heavily leaked distribution main into metallic pipe.
3.By reducing the hours of supply Till date, the availability of water was limited. Also the storage and filtering capacity were inadequate. Under the circumstances, to maintain input and output, RMC was compelled to continue the city supply for duration of 18 hours in a day i.e. from early morning 4.0 O'clock to late night at 11.00 p.m. Thus, in intermittent supply, the distribution system runs for longer period with pressure and because of which the leaking joints are activated. To avoid this, it has been planned to increase the filtering as well as storage capacity and also the pumping arrangement. Storage is planned to have 72 hours so that during the peak hours, the supply and demand could be met with and water supply to the city could be curtailed up to 6 to 8 hours from 18 hours duration which will have a significant effect on control of leakages. 4. A special drive to locate the unauthorized connections As stated above, RMC has covered almost 90% developed area of the city with distribution network. The sizes are ranging from 80 mm to 1000 mm. There is laid down criteria in RMC for getting house connection for water supply. However, the unauthorized construction activities in the city are considerably on higher side. Such unauthorized houses or complexes are not entitled for getting the water connection because the plan is not as per the prevailing TP rules. Rajkot is spread over in the area of 104 sq.km. People residing in such unauthorized houses are taking the water connection overnight from the nearby pipeline. It has been anticipated that about 15000 such connections are existing in the city. In past, RMC had given the incentive to the people for regularization of unauthorized connections but the response was very poor. For identifying an unauthorized connection, a special drive is required to be made for which RMC has planed out the program and will disconnect all these connections at the earliest, so that the quantity of unaccounted water could be reduced. 5.Immediate repairs during the break down of pipeline. As stated above, most of the pipelines are Asbestos cement. Some times due to surge or air locking, the pipes gets burst or joints gets heavily leaked. RMC do have a special gang for attending such emergency repairs, however, the information system is still not perfect and because of which such leakages takes time for repairs. During break down significant quantity of the water is being wasted, however, RMC will strengthen the communication arrangement and will attend such damages within half an hour so that leakage could be stopped immediately.
108
9
9.1 General
Cost Estiimate Cost Est mate
Preliminary cost estimates for various components of proposed water supply projects are presented here. The proposed works are divided in phase wise manner and it is scheduled to complete within seven years. The proposed works are categorized as follows : 1. Development of new sub head works : It includes construction new 6 ESR / GSR with pumping station & allied work 2. Augmentation of sub head works: It consists of construction of new 6 GSR with necessary augmentation of pipes & pumps. 3. Development of new head works: Consists of water treatment plant, raw water transmission mains, pumping stations, ESR & GSR, staff quarters etc. 4. Transmission system :Consists of replacement of existing transmission mains, laying of express feeder lines, special etc. 5. Distribution New work : Pipe, valves and special etc.
9.2 Based for Cost Estimate

1. Development of new subhead works & Augmentation of Head work Bases for calculation of Elevated storage reservoir & ground storage reservoir are considered as per actual constructed amount. Similarly, pumping machinery & electrical-mechanical work at new sub-head works have also been adopted basis on actual contracted amount.
2. Development of new head works: Based on the actual market rate a unit cost of Rs.6.50/MLD has been adopted for treatment plants on actual (recently contracted other similar work by Rajkot Municipal Corporation Electrical & mechanical works at pumping stations, an average cost rate of Rs.25000/KW has been adopted on basis of experience on similar jobs.
3. Transmission mains: It has been finalized to use metallic pipes. For mild steel, the rates are derived from prevailing rate of raw material i.e. M.S. plate. The present prevailing rate of M.S. pipe without lining & coating is around Rs.36/kg whereas for completed item the rate is around Rs.55/kg. Regarding DI pipes the rate contract of GWSSB is being followed for completed the item. And the rest of labour work Rajkot Municipal Corporation current SOR is being followed.
109
4. Distribution Network: It is proposed to use MS, DI and AC pressure pipe depending upon the capacity and size. It has been planned to provide DI pipe within range of 200 mm to 450 mm size. Above 450 mm dia size mild steel, is being preferred as pipe material whereas, below 200mm dia size AC class-III has been suggested. For MS pipe rates are derived from prevailing market rate whereas for DI & AC pressure pipe rate contract of GWSSB / RMC is being followed for all labour components / excavation, lowering, laying etc. current similar work of Rajkot Municipal Corporation has been adopted.
9.3 Development of sub heads 9.3.1 ESR & GSR at ward : 6

Sr No 1 Construction of RCC ESR having capacity 3 ml with 25 mt. staging height considering market rate Rs.5.0 per liter cost works out to 3 ml X 5.0 =Rs.150-00 lacs. 2 Construction of RCC GSR 10 ml capacity having water depth 4.5 mt in two compartment considering market rate Rs.1.2 per liter, cost works out to 10 ml X 1.2 =120 lacs 3 Cost of valves, specials, inlet, outlet over flow washout piping for ESRGSR etc. L.S. 4 5 Construction of pump house having size 25 x 15 .. 1 no. L.S. Accepted value of Tender value 495.00 Description of Item Amount in Rs. lacs.
Providing, erecting, commissioning of electrical driven Centrifugal pumping sets having capacity 942 m3/hr against head of 35 mt. total 6 sets. Considering Rs.20,000/- per KW, the amount works out to = 800 x 20000 = 160-00 lacs
Providing and erecting feeder main line 500 mm dia M S / 450 mm dia D.I. 1200 mt. in length. L.S.
7 8 9
GEB charges
L.S.
25.00 10.00 110.00 640.00 032.00 Total Rs. In Lakhs (Say) 675-00
Cost of compound wall and area development L.S. Cost of feeder main for distribution Total
10
Add 5% Contingency
110
9.3.2 ESR & GSR at ward : 7

Sr 1 Description of Item Accepted value of tender for following works Construction of ESR having capacity 1.38 ml with staging height 20 mt including inlet, outlet, washout and over flow arrangement Construction of 4.0 ml capacity RCC GSR with inlet, outlet, overflow and washout arrangement Providing, laying and jointing 700 mm dis M S pipe from existing 850 mm dia Narmada main to point of crossing at Bhadar main 1.5 km in Providing, lowering, laying an jointing of 350 mm dis DI pipe line 500 mt in length for inlet to sump Construction of pimp hoise of size 25 x 15 mt. Providing and erecting pumping machinery 900 m3/hr against head of 36 mt. Cost of GEB charges Cost of compound wall and area development Cost of feeder main Total Amount in Rs. lacs
Accepted value of Tender value 350.00
2 3 4
20.00 11.00 50.00 431.00
9.3.3 ESR & GSR at ward : 17

1 Job connection with existing 600 mm dia M.S. Gravity main laid on by pass & laying of 600 mm dia connecting line with road crossing by pass through method L.S. Construction of ESR 3 M.L. capacity with staging ht 25 mt at the rate of Rs.5/ht. Construction of P.H. size 25 x 15 at the rate of Rs.4000/m2 Cost of special valves & piping for ESR & GSR Cost of 10 M.L. capacity GSR at the rate of Rs. 1.20 / lit
Accepted value of Tender value 432.00
Providing & erecting C.F.Pumping M/C six sets each having capacity 552 m3/hr Total K.W. 500 at the rate of Rs. 20,000/K.W. 2 G.E.B connection charges Rs.15.00 lacs 3 Compound wall & area -----4 Cost of Distribution main L.S. Rs.15.00 lacs Rs.382.00 lacs Rs.844 Lacs
111
9.4 Development of New head works

Raiyadhar Head works Cost - estimate for intake work- part-1
1 Providing and erecting 1200 mm dia M S pipeline 30 mt along with 1200 mm dia butterfly valve chamber and water meter at off take from main line of 1850 mm dia. L.S. 2 3 Cost of 4 ml capacity RCC raw water GSR L.S. Cost of 1150 mm dia 8 mm thick M S pipeline inside lining 12.5 mm thick and outside guniting 40 mm thick including excavation, bedding, refilling, lowering, laying and jointing by welding etc complete 6500 mt at the rate of Rs.14,840/- per mt. 4 Construction of RCC pump house size 25 x 15 at the rate of Rs.4000 per sq.mt. L.S. 5 Providing and erecting pumping machinery having capacity 700 m3/hr against the head of 39 mt. total 6 sets (4 working, 2 standby), total kw 685 at the rate of Rs.25000 per KW 6 7 8 9 10 11 Power connection charges L.S. Cost of valves and valve chambers L.S. Cost of CC encasing and thrust block L.S. Cost of compound wall area development approach road etc Cost of staff quarter Land Acquisition Total 15.00 lacs 20.00 lacs 10.00 lacs 20.00 lacs 7.00 lacs 7.15 lacs 1290.00 lacs 171.25 lacs 15.00 lacs 48.00 lacs 964.60 lacs 15.00 lacs
112
Cost estimate for Raiyadhar Head works- Part 2

For treatment, storage and distribution of 45 MLD of water among ward no.21 (part), 22 and 23 at Raiyadhar head work following works are proposed:
A. Cost Estimate for Raiyadhar Headworks 1 Providing and constructing water treatment plant of capacity 50 MLD LS 2 Construction of pure water RCC GSR having water depth 3.5 mt capacity 20.6 Mt L.S. 3 Construction of pump house having size 37 x 20 at the rate of Rs.4000/m L S 4 5 Construction of ESR having capacity 3.0 ML and stage height 20 mt LS Providing and erecting pumping machinery having capacity 825 m /hr against head 40 mt (3+1) for ward-23 and capacity 735 m3/hr against head 40 mt (4+2) for Ring road. Total KW 1250 at Rs.25000/KW 6 L.S.
3 2
350.00 lacs
236.70 lacs
29.60 lacs
150.00 lacs 312.50 lacs
Providing, lowering, laying and jointing M S pipeline for various sizes including excavation, refilling, bedding etc. 1200 mm 200 mt.for inlet to sump L.S. (Gravity) 1000 mm dia 210 mt. for rising main L.S. (Gravity) 700 mm dia 1200 mt. for ward no.21 L.S. (Gravity) 750 mm dia 1200 mt. for ward-22 L.S. (Gravity) 600 mm dia 2000 mt. for ward-22 L.S. (Gravity) 108.30 lacs 27.09 lacs 35.80 lacs
116.10 lacs
154.80 lacs 7 8 Cost of valves and job work Area development L.S. Compound wall and internal roads and area lighting LS GEB connection L.S. Staff quarter LS Approach road L.S. Total 55.00 lacs 15.00 lacs 15.00 lacs 1680.09 lacs 40.00 lacs 20.00 lacs 15.00 lacs
113
Say Thus, total cost of project: Intake work Rs.1290.00 lacs Filtration, storage, distribution etc. Rs.1680.00 lacs ------------------------------------Total Rs.2970.00 lacs Add 5% physical contingency Rs. 149.00 lacs Total Rs.3119.00 lacs Say Rs.3120.00 lacs
1680.00 lacs
9.5 Source Augmentation

9.5.1. Water Supply scheme based on Nyari Reservoir
Sr. Item 1 Providing and erecting vertical turbine pump having capacity 970 cu.mt./hr against head of 28 mt. two sets and trimmer pump having capacity 490 cu.mt./hr against head of 28 mt. two sets; one working and one standby. 2 Supplying, lowering, laying and jointing 700 mm dia. M S pipeline including excavation, refilling, bedding etc. 7 Kms. 3 Repairing work of existing valve tower and bridge 4 Other misc. items like job connection, road crossing etc. 5 500 mm dia rising main 6 Panel room 7 Replacement of pure water machinery at Nyari head works, supply ,erection testing and commissioning of CF pumping machinery having capacity 190 LPS against 40 mt. head ( 3+1 = 4 sets ) 8 Providing , erecting EOT crane in valve tower at Nyari Total Amount
Accepted value of tender Rs. 688 Lakhs
Accepted value of tender Rs. 48 Lakhs Rs.4.85 Lakhs Rs.740.85 Lakhs
114
Rajkot Municipal Corporation Abstract Form Name of work :- Supplying, lowering, laying and jointing 700 mm dia. M S pipeline including excavation, refilling, bedding etc. 7 Kms. Sr. No. 1. Qnty. Description Rate Total amount P.No.B-1 S.No.1,2 average. S.O.R.No. (Year 04-05)
5760.00Excavation for pipeline 39.50 m3 2,27,520.00 cu.mt. trenches including all safety provisions using site rails and stacking excavationed stuff upto a lead of 90 Mt. cleaning the site etc.comp. upto 1.50 mt. depth soil soft murrum and hard murrum (average rate). 1 x 8000 x 1.60 x 1.50 = 19,200.00 cu.mt. Therefore, 30% of total Cu.mt. = 5760.00 cumt.
2.
13440.00 cumt.
--do-In soft rock and hard rock (overage rate) 1 x 8000 x 1.60 x 1.50 = 19,200.00 cumt. Therefore, 70% of total Cumt.= 13,440.00 cumt.
107.50 m3
14,44,800.00 P.No.B-1 S.No.3,4 average.
3.
6500.00--do-210.00 m3 cumt. For upto depth of 1.50 to 3.00 mt. in hard rock with blasting or by chiseling only. 1 x 8000 x 1.60 x 0.50 = 6400.00 L.S = 100.00 6500.00 cumt. 300.00 Dismantling or removing 33.60 Rmt Rmt. existing pipeline incl. Removal of specials, valves, Jointing material, incl. Carting, loading, unloading And stacking of removal Material from site of work To the departmental store Or another site as directed Excl.excavation and
13,65,000.00
P.No.B-1 S.No.4
4.
10,080.00
P.No.B-6 S.No.71
115
Refilling incl. Gas cutting 500 mm dia. 5. 300.00 --dofor 300 mm dia. 22.40 Rmt. Rmt. 300.00 --dofor 200 mm dia. 15.70 Rmt. Rmt. 6,720.00 -doS.No.67 4,710.00 -doS.No.65
6.
7.
845.00 Providing sand or murrum 10.00 m3 Cumt. bedding incl. Ramming, watering, consolidating etc. complete from selected excavated earth 1 x 8000 x 1.60 x 0.20 = 2560.00 cumt. Now 33% of total cumt. = 844.80 cumt. Say 845.00 cumt. 1689.60--do-55.00 m3 cumt. Murram brought from outside lead beyond 2 Km. 1 x 8000 x 1.60 x 0.20 = 2560.00 cumt. Therefore, 66% of total Cumt. = 1689.60 cumt.
8450.00 M.R. .
8.
92,928.00
PWD S.No.692
9.
8000.00Manufacture, supply, 6235.00 Rmt. 4,98,80,000.00 Rmt. delivery, lowering and Laying in position to Correct line and level Of 700 mm I.D. and 6 mm thick, Fe-410 M S pipe with inside cement mortar lining of 10 mm thick in C.M. 1:1 as per AWWA-C-602-89 and outside gunniting with wiremesh of 3.1 MM dia and 100 x 100 MM C/C/ in C.M. 1:3, with 25 mm thick coating as per IS:1916-1989 or its latest revision and detailed specification with necessary materials, labour, equipments etc. Pipe having beveled ends confirming to IS-3589-1991 or its latest revision / amendment for thickness, including all taxes,
M.R. (Unit rate)
116
insurance, transportation, freight charges, octroi, inspection charges, loading, unloading, conveyance to site, with stacking etc. Laying on pedestal or chair upon prepared formation or prepared bedding in trenches the rates incl. Hoisting, marginal cutting wherever required, assembling and welding with hydraulic testing etc.comp. 10. 3.00 Nos. Providing, supplying, lowering, laying and Jointing in position C.I., D/F Butterfly valve PN-1 500 mm dia incl. all taxes insurance, transportation freight charges octroi inspection charges, loading, unloading, stacking etc. with cost of all labour, jointing material, nuts, bolts and giving satisfactory hydraulic testing etc.comp. --do200 mm dia. PN-1 sluice valve. 145000.00 No. 4,35,000.00 M.R.
11.
3.00 Nos.
14848.00
44,544.00
P.No.A-8 S.No.115 + P.No.B-3 S.No.41 M.R. (Unit rate)
12.
20.00 Nos.
100 mm dia. Double action kinetic type air valve with Isolation valve to be erected on 100 mm dia MS pipe with maxi.height 2.1 mt. above G.L. and 100 mm thick RCC coating around pipes, erection etc.comp.
12,000.00 Nos.
2,40,000.00
13.
3.00 Nos.
Construction of valve 2200.006,600.00 chambers of 0.90 mt. x No. 0.90 mt. x 1.00 mt. in brick masonary locally available, C.M. 1:6, foundation concrete 150 mm thick in C.C. 1:4:8 of trap metal. 25 mm to 40 mm inside cement plasters C.M.1:3,
M.R.
117
with precast RCC cover 150 mm thick in two parts. Key hole in two parts, each with handles or M S bars etc. comp. with all civil work excl. cost of excavation and refilling.
14.
3.00 Nos.
--dofor size of 0.60 x 0.60 x 1.00 mt.
1500.004500.00 M.R. Nos.
15.
17920.00 cumt.
Refilling the pipeline trenches incl.ramming watering, consolidating disposal of surplus stuff as directed within a radius of 3.00 km. 1 x 8000 x 1.60 x 2.0 = 25,600.00 cumt. Therefore 70% of Total cumt.=17,920.00 cumt.
5.00 cumt.
89,600.00
M.R.
16.
100.00 Providing C.C. M-100 1800.001,80,000.00 cumt for encasing pipe using cumt. trap metal size 12 mm to 50 mm including form work, curing, consolidateston etc.complete. 3.00 Nos.
M.R.
17.
Making job connection 858.00 2574.00 for old pipes in connec- Each job. ting the pipeline with existing main and inserted of special incl. cost of excavation, cutting of pipes, dewatering, testing, refitting etc.comp.incl. all jointing materials (excluding cost of specials, pipes) for 600 mm dia to 750 mm dia. Pipe.
P.No.B-8 S.No.108
18.
1200.00M S Specials 45.00 Kg. Kg. Plain end or socket ends.
54,000.00
P.No.B-19 S.No.301
19.
800.00 --dofor flanged ends. 50.00 Kg. Kg.
40,000.00
P.No.B-19 S.No.302
118
20.
150.00 Providing and laying C.C. 2422.003,63,300.00 cumt. 1:2:4 for RCC column or cumt. pillers with 12 to 20 mm size black stone crushed metal including centering, curing, finishing etc.comp. without reinforcement.
PWD S.No.292
21.
50.00 Kg.
Supplying, bending, Binding in position,steel Bars for reinforcement Incl.cutting, typing, Hooking and cost of Binders and binding Wire etc.comp. Piller 50.00 50 Kg.
33.00 Kg.
1650.00PWD S.No.1302
22.
200.00 Finishing to RCC sq.mt. member with C.M. 1:2 incl. chiseling and leveling the surface with niru or cement finishing etc.comp.
42.00 sq.mt.
8,400.00
PWD S.No.146
Total Say
----------------------5,45,10,376-00 5,45,10,500-00
119
Rajkot Municipal Corporation Abstract Form Nyarii--I Nyar I Name off work ::-- Repaiiriing work off exiisttiing vallve ttower and briidge.. Name o work Repa r ng work o ex s ng va ve ower and br dge Sr. No. Qnty. Description Rate Total amount S.O.R.No. (04-05 PWD SOR)
1.
12.20 cumt.
Providing and laying 2222.0027,108.40 C.C. 1:2:4 for RCC flat cumt slab with 12 to 20 mm size, black stone crushed metal incl. centering, curing, finishing, etc.comp. without reinforcement.
S.No.291
2.
700.00 Kg
Supplying, bending, binding in position steel bars for reinforcement incl. cutting, tying, hooking and cost of binders and binding wire etc.comp.
33.00 Kg
23,100.00 S.No.302
3.
16.20 cumt.
Providing burnt brick masonry with bricks of cumt. approved quality for S.S. incl. scaffolding racking out joints, watering as directed for 2nd class masonry In C.M. 1:6.
1074.0017,398.80 S.No.113
4.
100.00 20 mm thick sand face 57.00 5700.00 S.mt. cement plaster on wall Sq.Mt. Consisting of 12 mm thick Beacking coat of C.M. 1:3 And 8 mm thick finishing Coat of C.M. 1:1 etc.comp. Total Say
S.No.150
--------------73,307-20 75,000-00
120
Rajkot Municipal Corporation Abstract Form Nyarii--I Nyar I Name off work ::-- Otther miisc..iittems lliike jjob connecttiion ,, road crossiing ettc.. Name o work O her m sc ems ke ob connec on road cross ng e c Sr. No. 1. Qnty. L.S. Description Demolition, road crossing and misc.works. Rate L.S. Total amount 3,00,000.00 S.O.R.No. --
-------------3,00,000.00
9.5.2. Water Supply scheme based on Bhadar Reservoir

Sr 1 2 3 4 5 6 7 Item Replacement of raw water pumping machinery at Bhadar Replacement of raw water pumping machinery at Gondal Carrying out inside cement mortar lining in M S pipeline of 42 km Replacement of prestressed concrete pipe into metallic pipe 900 mm dia M S 16 km Construction of 6.6 million liter capacity pure water GSR at Ribda Shifting of existing 850 mm dia M S pipe near railway crossing Work of railway crossing by push through method Total Add 5% physical contingency Total Say Amount (In lacs) 225.00 200.00 225.00 1600.00 74.00 11.71 17.20 2352.91 117.64 2470.55 2470.00
In view of necessity, Rajkot Municipal Corporation has started the implementation of the project. As on date, 3 sets of vertical turbine pump at Bhadar valve tower has already been replaced. The additional storage of 6.6 ml capacity has been completed and commissioned. The works are being taken up in a phase manner based on the availability of funds. Sub Estimate No.1 Detailed estimate for replacement of pumping machinery at Bhadar and Gondal 1 Providing, erecting, testing and commissioning V.T. pumps having capacity 147 lps against head of 96 mt at valve tower along with all mechanical electrical works. Total 6 sets. Total installed K.W. 1200 at the rate of Rs.18750. Therefore 1200 x 18750 = Providing, erecting, testing and commissioning of C.F. pump having capacity 147 lps against head of 85 mt at Gondal pumping station including all electrical, mechanical works etc complete. Total nos. of sets 6. Total installed K.W. 1200 at the rate of Rs.16665/KW. 1200 x 16665 = 199.98 lacs Say 200 lacs.
225.00 lacs
121
Total Sub Estimate No.2 Detailed cost estimate for insitu C.M. lining for existing 850 mm dia M S pipeline Size of pipe 850 mm dia Length 42000 mt Area per R.M. 3.14 x 0.85 = 2.669 m2 Provide insitu 10 mm thick C.M. lining in C.M. 1:1 as per AWWA 603-C Standard Total area to be lined 2.669 x 42000 = 112098 m2 Present prevailing market rate for insitu lining by projection method is Rs.170/m2 Therefore, total cost works out to Rs.170 x 112098 = 190.56 lacs Extra for inside surface cleaning by wire brush, descalling, cutting, welding, excavation, refilling etc. comp. L.S. Total
200.00 lacs 425.00 lacs
9.44 lacs 200.00 lacs
Sub Estimate No.3 Cost estimate for replacement of existing 900mm dia PSC pipeline. Total length 16 Km.
Rate Qnty Unit Item 16000 Mt Providing, lowering, laying and jointing of 900 mm dia M S pipeline having plate thickness 7 mm including excavation, refilling, bedding, concreting, thrust block, valves with valve chambers, insitu cement motor lining of 10 mm thick in C.M. 1:1 and outside guniting in C.M. 1:3, 25 mm thick, testing commissioning etc complete.
Per Amount
10,000/- Mt
1600,00,000/Rs.1600.00 Lacs
122
Sub Estimate No.4 Cost estimate for the work of RCC GSR at Ribda
Item Rate Construction of RCC GSR in M-250, along with inlet outlet washout over flow arrangement, excavation in all strata, refilling, providing and fixing valves etc complete GSR capacity 6.6 M.L.
Per
Amount
Rs.1.12 Liter 74,00,000/Total 74,00,000/-
Sub Estimate No.5
Rajkot Municipal Corporation Abstract Form Name of work :- Shifting 864 mm dia M S pipeline near Gomta for permanent water supply scheme based on Bhadar dam. Sr. No. 1. Qnty. Description Rate Total amount S.O.R.No.
850.00 Excavation for pipeline 29.00 m3 24,650.00 cu.mt. trenches including all safety provisions using site rails and stacking excavationed stuff upto a lead of 90 Mt. cleaning the site etc.comp. upto 1.50 mt. depth soil soft murrum and hard murrum boulders including macadam road etc.(average rate). 1 x 1125.00 x 1.50 x 0.50 = 843.75.00 cu.mt. Say: 850.00 Cmt.
P.No.67 S.No.14.1 a+b/2 average.
2.
2850.00-do- In all sorts of soil and 22.00 Cmt. Soft murrum (for removing old pipe)
62,700.00 Cmt.
P.No.67 S.No.14.1a
1 x 1900.00 x 1.50 x 1.00 = 2850.00 Cmt.
123
Sr. No. 3.
Qnty.
Description
Rate
Total amount 2,02,800.00
S.O.R.No.
1690.00--do-120.00 m3 cumt. In hard rock with blasting or by chiseling only 1x1125.00 x 1.50 x 1.00 = 1687.50 Say 1690.00 Cmt.
P.No.67 S.No.14.1d
4.
850.00 cumt.
--do-125.00 m3 For upto depth of 1.50 to 3.00 mt. in hard rock with blasting or by chiseling only. 1 x 1125.00 x 1.50 x 0.50 = 843.75 SAY 850.00 Cmt.
1,06,250.00
P.No.67 S.No.14.2d
5.
1900.00Removing of 150.00 Rmt Rmt. existing pipeline incl. Removal of specials, valves, Jointing material, incl. Carting, loading, unloading and stacking of removed material from site of work, to the departmental store or another site as directed excl.excavation and refilling incl. Gas cutting 864 mm dia. M S Pipes 112.00 Providing sand or murrum 10.00 m3 Cumt. bedding incl. Ramming, watering, consolidating etc. complete from selected excavated earth 1 x 1125.00 x 1.50 x 0.20 = 337.50 cumt. Now 33% of total cumt. = 111.37 cumt. Say 112.00 cumt.
2,85,000.00
P.No.7275 S.No.36 (XVII)B
6.
1120.00 P.No.68 S.No.18a
7.
223.00 --do-30.00 m3 cumt. Murrum brought from outside lead beyond 2 Km. 1 x 1125.00 x 1.50 x 0.20 = 337.50 cumt.
6690.00 P.No.68 S.No.18c
124
Sr. No.
Qnty.
Description Therefore, 66% of total Cumt. = 222.75 cumt. Say 223.00 Cmt.
Rate
Total amount
S.O.R.No.
8.
1125.00Lowering and laying 319.00 Rmt. 3,58,875.00 Rmt. in position to correct line and level of 864 mm O.D. M S pipe with outer coating and inside lining / epoxy painting, on pedestal or Chairs upon prepared formation or prepared bedding in trenches, the rates incl. conveyance from store to site of works, loading, unloading, hoisting, marginal cutting wherever required, assembling and jointing by welding with Hydraulic testing etc. comp. 2.00 Nos. Lowering, laying and 3500.007000.00 jointing in position C.I. Nos. D/F Reflux valves, Butterfly valves Sluice valves and air Valves of 900 mm dia with cost of all labour, jointing material, nuts, bolts and giving satisfactory hydraulic testing etc.comp. (Rate of all class of valves) --do100 mm dia. sluice valve.
P.No.59 S.No.3.a (XVII)
9.
P.No.65-66 S.No.13.a (XVIII)
10.
4.00 Nos.
220.00 880.00 P.No.65 S.No.13.a IV 340.00 340.00 P.No.65 S.No.13-a -VI.
11.
1.00 Nos.
-do- 150 mm valve
12.
4.00 Nos.
-dofor 100 mm dia. 250.00 1,000.00 Double flange air valve.
P.No.65-66 S.No.13.c (VI)
125
Sr. No. No. 13.
Qnty.
Description
Rate
Total amount
S.O.R.No.
4.00 Nos.
Construction of valve 3200.0012,800.00 chambers of 1.30 mt. x No. 1.30 mt. x 1.00 mt. in brick masonary or RR masonry in C.M. 1:6, foundation concrete 150 mm thick in C.C. 1:4:8 of trap metal. 25 mm to 40 mm inside cement plaster C.M.1:3, with precast RCC cover 150 mm thick in two parts. Key hole in two parts, each with handles or M S bars etc. comp. with all civil work excl. cost of excavation and refillings.
P.No.77 S.No.1a-1
14.
5213.00Refilling the pipeline 3.50 cumt. cumt. trenches incl.ramming watering, consolidating disposal of surplus stuff as directed within a radius of 3.00 km. (i) For new trench : 1 x 1125.00 x 1.50 x 2.0 = 3375.00 cumt. Therefore 70% of Total cumt.=2362.50 cumt. Say 2363.00 Cmt. (ii) For removing old pipe : 1 x 1900 x 1.50 x 1.00 = 2850.00 Therefore 2363.00 Cmt. + 2850.00 Cmt Total 5213.00 Cumt
18,245.50
P.No.69 S.No.20
15.
25.00 sqmt
Repairs of guniting in C.M. sqmt.1:3 with wiremesh etc. complete.
270.00 6,750.00
M.R.
126
Sr. No. 16.
Qnty. 2.00 Nos.
Description Making job connection for old pipes in connecting the pipeline with existing main and inserted of special incl. cost of excavation, cutting of pipes, dewatering, testing, refitting etc.comp.incl. all jointing materials (excluding cost of specials, pipes). M S Specials Plain end or socket ends.
Rate 348.50 Each job.
Total amount 697.00
S.O.R.No. M.R.
17.
200.00 Kg.
30.00 Kg.
6,000.00
P.No.47 S.No.32-a (I, II)
18.
100.00 Kg.
--dofor flanged ends. 32.00 Kg.
3,200.00
P.No.47 S.No.32-b (I, II) P.No.129 S.No.1-1.3
19.
20.00 cumt.
Providing and laying C.C. 1:2:4 for RCC column or pillers with 12 to 20 mm size black stone crushed metal including centering, curing, finishing etc.comp. without reinforcement.
2400.0048,000.00 cumt.
20.
10.00 Cumt.
Providing C.C.M-100 For encasing pipes, Using trap metal size 12 mm to 50 mm incl. Form work, curing, Consolidation etc.comp. Supplying, bending, Binding in position,steel Bars for reinforcement Incl.cutting, typing, Hooking and cost of Binders and binding Wire etc.comp. Piller 50.00 50 Kg.
1430.0014,300.00 Cumt.
P.No.109 S.No.18
21.
50.00 Kg.
19.50 Kg.
975.00
P.No.129 S.No.2-2.1 + 2.2
127
Sr. No. 22.
Qnty.
Description
Rate
Total amount
S.O.R.No.
100.00 sq.mt.
Finishing to RCC member with C.M. 1:2 incl. chiseling and leveling the surface with niru or cement finishing etc.comp. Total Say
29.60 sq.mt.
2,960.00.00
P.No.130 S.No.10
----------------------11,71,232-50 11,71,500-00
Sub Estimate No.6 Abstract Form Name of work :- Cross the railway line by boring and pushing method 1440 mm dia M S pipeline near Gomta Railway Station for permanent water supply scheme based on Bhadar dam. Sr. No. 1 Qnty. 25.00 Rmt. Description Crossing of railway track by push through Method in hard strata including cost of 1400 mm dia M S pipes with 20 mm plate thickness and jointing M S pipes with welding, all labour material etc. complete as per the requirement of Western Railway. Rate 68,800.00 Rmt. Total amount S.O.R.No. M.R.
17,20,000.00
Total
------------------17,20,000-00
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9.6 Augmentation of Sub head works

9.6.1. Aji Head works 1 2 Providing RCC cladding inside the sump with RCC roof slab, beam, etc complete. Work of area development providing paved flooring, internal road, lighting gardening, compound wall etc at head work site. Total 148.00 lacs 20.00 lacs 168.00 lacs
9.6.2 Dudhsagar head works Sr No 1 2 3 Amount in Rs. Description of Item lacs. Providing, lowering, laying and jointing DI pipes 450 mm dia 110.00 2.7 km in length LS Construction of GSR having capacity 3.5 ML at the rate of 46.00 Rs.1.2/lt. Job connection in distribution pipeline LS 08.00 Total 164.00
9.6.3 Sojitra head works Sr No 1 2 Amount in Rs. Description of Item lacs. Construction of GSR having capacity 1.1 ML as accepted 14.70 contract value Job connection in distribution pipeline LS 2.30 16.00 Total
9.6.4 Bajrangwadi head works Sr No 1 2 3 Amount in Rs. Description of Item lacs. Construction of GSR having capacity 3.5 ML as accepted 42.00 contract value Replacement of existing pumping machinery by higher capacity 45.00 Job connection in distribution pipeline LS 03.00 Total 90.00
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10
10.1 General
Fiinanciiall Anallysiis F nanc a Ana ys s
This Detail Project Report envisages addition of new sub head works, sources augmentation, new treatment plant, modification in transmission line & distribution line, addition in transmission and distribution facilities to meet requirements of un developed area of the Rajkot city. This would involve substantial capital outlays and operation and maintenance costs. AS part of JnNURM it is assumed that RMC has to make provision of 30% of capital expenditure while, 50% contribution will be shared by Govt of India and remaining 20% by the Govt of Gujarat. The total Operation and maintenance cost will be borne by Rajkot Municipal Corporation. Due to the constraints within the Corporation and heavy demands on the available funds from a variety of development, it is necessary that water supply system becomes self sustainable in its operation. A suitable water tariff structure needs to be designed to meet the operation.
10.2 Present Tariff, Billing and Collection Service Connection

The present water charges depend on the actual metered consumption or the size of the connection when unmetered. Present water tariff for different sizes of connections and
category of consumers is given below: Monthly water charges

Sr.No. 1 2 3 Connection Size
3 1 3
Residential Purpose ( In Rs.) 32.00 40.00 96.00
Commercial Purpose ( in Rs.) 64.00 80.00 192.00
/8 " /2 " /4 "
METERED CONNECTIONS 4 5 6
3
/4 "
360.00 960.00 2400.00
2900.00 4800.00 28800.00
1" 2" Year Income from Water Charge Expenditure Income v/s Exp. Level of subsidy
Level of subsidies
2004-05 (Rs.in millions) 71.40 485.68 6.80% 93.20%
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Billing and Collection: The billing system is computerized and decentralized. The collection of water charges is at three different places viz., (i ) Main office building (ii) City Civic center, Amin Road (iii) City Civic Center Krishnagar Meter readings for the domestic / Non-domestic connection are taken once a year. Bills to all consumers are sent on yearly basis. The responsibility of repair and maintenance lies with the consumers, responsibility to certify the meters rests with Rajkot Municipal Corporation. When a meter is found to be non-functioning, the bill is prepared as per average consumption. As per BPMC Act, 1949, if the consumer does not pay the bill within 15 days of the date of issue, 18% interest is to be levied. A notice is to be issued for disconnection of water connection if the consumer does not pay after next 30 days of the date of issue of the bill.
The demand and collection figures for the past three years are given below:: Rs. In Lakhs Head 2002-03 Water charges % Recovery 1348 Demand 2002-03 1219 2004-05 1056 2002-03 509 37.75% Collection 2003-04 500 41.00% 2004-05 830 88.60
From the above table, it is inferred that the collection of current demand varies from 38 % to 89% and collection arrears is about 62 to 12 %. Operating Cost: The costs incurred for water supply system operation and maintenance, establishment, power, chemical, repairs & maintenance, office overheads and water cess head of last three years are given below : Head 2002-03 Establishment Power Chemical Repairs & Maintenance Overheads Water Cess / Govt. Water bill Total . . . 327.00 772.27 19.55 234.04 8.5 30.67 1392.39 Cost (Rs. in lakhs) 2003-04 342.57 999.74 34.73 308.14 8.9 200.15 1894.33 2004-05 361.35 1441.74 30.43 492.28 13.78 508.01 2847.59
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Rajkot Municipal Corporation provides high amount of subsidy for water supply, which can be seen by comparing water revenue income & against expenditure : Head 2002-03 Total expenditure O & M Total Revenue Deficit 1392.39 531.21 861.18 Cost (Rs. in lakhs) 2003-04 1894.33 1372.05 1372.05 2004-05 2847.59 851.65 1995.94
It can also be observed from following table the cost per KL water: Head 2002-03 Total expenditure O & M ( Rs. In Lakhs) Total Water Supply in ML Cost of Water (Rs./KL) Planning for Tariff Revision: Capital Investment on development of additional water sources, new sub head-works, augmentation of head works, transmission and distribution system together with associated increase in the operation and maintenance costs would result in increase cost of water in future. Proper projections of capital costs.O & M costs and revenue would provide a framework for recovery of costs through tariff revisions. The water supply Project & Project Funding: The details of the JnNURM water supply projects and their cost estimated have been presented in the chapter of Design of water supply projects. Year wise distribution of project cost is given in table The project is proposed to be funded through Government of India mega mission Jawaharlal Nehru National Urban Renewal Mission (JnNURM). As per the fund guidelines, Govt. of India will contribute 50% of project costs, while 20% of project cost will be contributed by Government of Gujarat. Thus total funding & yearwise allocation of fund will be as shown in following table : Total JnNURM GOI Fund (50%) GOG contribution (20%) RMC' (30%) Total 22135 3175 3660 3900 4650 2650 2300 1800 Share 6640.50 952.50 1098 1170 1395 795 690 540 11067.50 1587.50 4427 635 2005-06 200607 1830 732 200708 1950 780 200809 2325 930 200910 1325 530 201011 1150 460 201112 900 360 1392.39 531.21 3.05 Cost 2003-04 1894.33 522.28 3.93 2004-05 2847.59 851.65 5.73
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O & M Costs: 1. Establishment: Establishment and total operating costs for the last five years are as below. Establishment & total operating costs for the last five year are assumed to increase first three year by 10% and then 15% for remaining years. Project Establishment & total operating cost including
chemical, repairs & maintenance & other cost are as estimated below : Revenue Projection: The cost would be recovered from the consumers through charges for consumption & water tax. Immediate increase in water tariff has been proposed to reduce level of subsidy. It is assumed that the tariff would be increased every second year thereafter. At present there are about 1,88,000 unmetered connections. About 4000 additional connections per year are being released . It has been assumed that about 5000 new connections per year will be given upto year 2010-11. This would be equivalent to providing a connection for every 6 persons in 2011. The total project no. of water connection will be 2,40,000 Sustainable Tariff: Modified Internal Rate of Return (MIRR) criteria has been used to determine the tariff structure. From the year 2006-07, the charges for unmetered consumers are proposed to be increase by 25%. The present tariff to account for the past accumulated losses. The tariff for the metered consumes is proposed to be clubbed with the proposals the tariff structure for 2006-07 would be as follows: Type of Connection Unmetered Consumers 15 mm 20 mm Metered Consumer 20 mm 25 mm 30 mm 40 mm 50 mm 65 mm 80 mm 100 mm 150 mm 200 mm 300 mm 360 600 900 1500 2400 3600 6000 9000 13500 18000 24000 2900 4800 7200 12000 19200 28800 48000 72000 108000 144000 192000 50 120 100 240 Proposed (Rs. per month) Domestic Non-domestic
133
The traff is proposed to be revised every second year. The tariff is assumed to increased by 15% every year for the unmetered and metered domestic consumers and non-domestic consumers.
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11
11.1 General
Enviironmentall IImpact Assessment Env ronmenta mpact Assessment
As Indian cities rapidly urbanize, the need to improve and expand urban environmental infrastructure is great. In order to assure that infrastructure projects are planned, designed and implemented in an environmentally sustainable manner, it is important that comprehensive Environmental Impact Assessment (EIA) is undertaken during the project planning stage. EIA should address all relevant biological, physical and social issues associated with the planned project and make recommendations that avoid or minimize any adverse environmental impacts. Environmental Impact Assessment is a project development tool which, when properly applied, improves the long term sustainability of infrastructure activities. While EIA often is viewed narrowly as a regulatory hurdle that must be crossed before finalizing project design, it is actually a tool that should be part of the project planning and design process. Conducting comprehensive EIA is an opportunity to look systematically at the way a potential project will affect the surrounding natural and built environment, allowing consideration of alternatives to the proposed project and seeking out participation by affected communities in decision making. EIA practice in India is relatively well established, though its application is not universal. The central government in India has created a foundation for environmental protection over the past two decades, beginning in 1974 with the enactment of the Water Prevention and Control of Pollution Act. A similar act addressing air pollution, the Air Prevention and Control of Pollution Act was passed in 1977. These laws established baseline thresholds for water and air quality. In 1986, a more comprehensive Environmental Protection Act was promulgated which established a framework for environmental clearance, requiring that EIAs be conducted for development projects with a cost of Rs. 50 crore or more. To rectify ambiguity regarding exactly what type of projects were subject to the Act, specific project types were enumerated in a 1994 EIA Notification issued by the Ministry of Environment and Forests. The Notification identified 29 categories of projects for which proponents must conduct EIAs and receive a clearance from the central government. These include a range of manufacturing facilities, power plants, highways, ports, airports, dams and tourist development in coastal areas. The Notification does not require EIAs for urban environmental infrastructure projects (UEIP) because these are assumed to result in positive environmental impacts. However, this assumption neglects two important facts characteristic of large scale infrastructure development projects: (1) most create significant short term disruptions to the physical and social environment during and just after completion of construction activities; and (2) many create localized, long term environmental impacts. Proper EIA practice does not weigh project positive environmental impacts against negative
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environmental impacts; rather, any significant negative impacts should be clearly identified and mitigated to acceptable levels. In addition to central government requirements, some states, regional development authorities and municipal corporations have established their own EIA requirements for projects under their jurisdiction. These requirements vary widely from one jurisdiction to another. Environmental clearance generally falls under the jurisdiction of the State Pollution Control Boards in each state. Some states require EIAs for certain types of UEIPs, others do not. Those that do require environmental clearance for UEIPs, generally specify sewage treatment and solid waste disposal. The situation is similarly mixed at the regional and municipal levels. In Gujarat, UEIP is also not compulsory, however, as part of JNURM projects it is guided to prepare EIA for UEIP. Hence, here all water supply projects for year 2005-2012 and related activities have been exercised for Environment Impact Assessment
11.2 EIA Methodology

The term environmental impact assessment is used to describe a wide range of activities whose purpose is examination of the environmental consequences of proposed projects. While EIA techniques use everything from very simple checklists of common environmental parameters to highly specialized testing regimes to quantify air or water quality, a basic methodology generally is observed.
11.3 Impact Identification

Environmental impacts both direct and indirect on various environmental attributes due to proposed water supply projects viz., a. Construction of ESR / GSR b. Water supply main line works c. Water treatment plant work d. Water supply distribution line works e. Other works related to development of water supply lines In this environment Impact Assessment, it is attempted to evaluate direct & indirect impact in the surrounding environment during construction & operational phase.
11.4 Impact Identification during Construction phase

The impacts due to the construction of different water supply projects commence from the exploration activities, construction of around storage reservoir, construction of water treatment plant, installation of mechanical equipments / pumps, laying of pipe lines etc., may continue up to distribution of water supply, with nature and extent of impacts varying through the stages of various water supply projects.
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Activities like site preparation, excavation, drilling, blasting, foundation, deployment of machinery, erection, transportation dumping are taken up during construction phase. The likely impacts on the environment due to these activities are listed below : Impact during Construction Phase Construction & Operation Phase A. Site Work / Other facilities Activity i. Cleaning and grading Potential Environmental Impact Negligible
ii. Temporary facilities such as Dust emission and change in sheds, approach roads, traffic intensity sanitary facilities. iii. Earthwork comprising of Soil erosion, runoff, increase in excavation and trenches traffic, dust emission iv. Foundation work Dust, Visual Pollution and Noise
v. Mechanical erection and Dust, Visual utility system Pollution B. Construction of ESR / GSR i. Excavation / Water treatment plant / Pump houses ii. Drilling & Blasting
and
Noise
Dust, Soil Erosion and noise Dust, noise, and health hazards
iii. Dumping iv. Transportation C. Laying of pipe lines* i. Excavation ii. Drilling & Blasting
Dust, noise & visual impact Dust, noise & visual impact Dust, Soil Erosion and noise Dust, noise, and health hazards
iii. Dumping iv. Welding v. Transportation D. Socio-economic Due to rehabilitation disturbances resettlement aspects E. Accidents In all construction activities
Dust, noise & visual impact Dust, noise & visual impact Dust, noise & visual impact & No R&R site activities proposed Major or minor health impact
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11.4.1 Construction of Elevated storage Reservoir and Ground Storage Reservoir & water treatment plant In the proposed water supply projects 6 nos ESR / GSR, 6 GSR and one water treatment plant will be constructed. Besides, main & distribution lines will be laid. This construction work can lead to following impacts: Lost of forest, trees & vegetation. Geological disturbance due to blasting, excavation Soil erosion as excavation, cutting operation for laying water lines the natural slopes Interruption of drainage pattern particularly near water treatment plant Disturbance of underground water resources with blasting and discriminate disposal of fuel and lubricants from construction machinery Change in ground profile due at certain places due to dumping of excavated debris material, stuff Effect on Flora & Fauna Air Pollution due to dust from debris, construction machinery, vibratory equipments etc. The movement of machinery will increase the temperature & lower atmospheric humidity locally Actual site surveys were carried out and all above impacts were debated with Rajkot Municipal Corporation officer's, local people and mitigate measures adopted as under: Sr 1 Environment Impact Loss of forest / trees Location / Activity Measures 1. There are not more than 20 It is suggested to plant about 200 trees in total of all construction trees in total after completion of site construction work
4 5
2. At site of laying main pipe line there are no vegetation / trees in the alignment Geological disturbance 1. At ESR / GSR site due to blasting 2. Water treatment plant 3. Pipe line site Soil Erosion 1. At ESR / GSR site 2. Water treatment plant 3. Pipe line site Interruption of drainage During laying of pipeline pattern Disturbance of 1. At ESR / GSR site Underground water 2. Water treatment plant sources Change in ground Excavated stuff from ESR / GSR profile at WTP & main lines
As far as possible blasting should be avoided Negligible effect
Ground should be leveled same as before laying of pipeline Blasting should be avoided
Effect on Flora & Fauna
No place identified
Excavated stuff should not be dumped at single place Two unused mine sites are identified where excavated can be dumped to reclaim the land Negligible Effect
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Air pollution due to dust Minor at all sites from debris
Movement of machinery
Minor at all sites
Negligible effect Rubber padding is recommended at footing of equipments Sprinkling of water is suggested
11.4.2 Environment Impact due to Labour population Total water supply projects are scheduled to complete in seven years. Average no.s of labour requirement during project implementation period is estimated as under : Year 1st 2nd 3rd 4th 5th 6th 7th No. of labour (Unskilled) 300 400 400 500 500 500 500 No. of skilled & Technical staff 50 100 100 100 100 100 100 Total 350 500 500 600 600 600 600
The peak human man power would be around 600. Thus, for worst scenario 600 sould shall be taken. The other assumptions made for assessing human load are as under : Family size has been assumed as 5 80% labourers and technical staff are married 50% of labourers both husband & wife will work 50% technical staff will come with their families and only husband will work 2% of total migrating population has been assumed as service provider 50% of service providers will have families 1. Unskilled labour Calculations Married families (80% of 500) Single (20% of 500) Husband & wife both working (80% of 400) No. of families where both husband & wife will work (320/2) Families where only husband is working (20% of 400) Total labour population (160 x 5 + 100 x 5 + 100) 2. Technical Staff Married families (50% of 100) Single Total technical staff population (50 x 5 + 50) 3. Service Population 2% of total population No. of service providers with families Total population (17 x 5 + 17) 400 100 320 160 100 1400
-A
50 50 300
-B
34 17 102
-C
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Total population
Say
= = = =
A 1400 1802 2000
+ +
B 300
+ +
C 102
Separate accommodation and related facilities for workers, service providers and technical staff are to be arranged. The volume of labour force is most likely will create problems of sewage disposal, solid waste management and requirement of fuel etc. The increase in the population is expected to be in the order of 2000. The domestic water requirement for the outside labour is in the order of 0.07 MLD @ 35 lpcd. Assuming that about 80% of the water supplied will be generated as waste/ sewage. The BOD load contributed by domestic sources will be about 20 kg/day. As such there will be no significant impact on disposal of untreated sewage. Even then it is proposed to treat the sewage from labour camps before disposal. It is proposed to construct adequate number of septic tanks for treatment of sewage.
11.5 Impact Identification during Operational Phase

Only a small number of maintenance and operation staff will be stationed in the area in a wellplanned colony with piped water supply and proper sewerage treatment plant. In the operation phase, around 30 families (total population of 150 souls) will be housed in the area. About 0.03 MLD of sewage will be generated. The total BOD will be to the order of 10 kg/day. It is proposed to provide adequate number of septic tanks and soak pits to properly manage sewage and portable sewerage treatment plants are to be provided wherever the concentration of the construction population is high. Adequate care will be taken to locate these structures so as there are no leaches from this activity in natural water bodies. The labour for various activities during the construction phase shall be engaged from the surrounding villages. Some essential services are required to be provided. This will have an impact on drinking water supply and sanitary facilities. Economy of the nearby area will be improved due to increased job opportunities with corresponding increase in income. Other associated business activities like transport, hotels, consumer goods etc., will also be benefited. The major environmental parameters likely to be effected during construction phase are noise, dust pollution and sanitation. Water spraying system during high dust will minimize the dust level to some extent. A proper temporary hosing with water supply and sanitation for workers shall be planned. The effect due to construction phase is however, of temporary in nature and has no permanent effect on environment.
11.6 Impact Identification during Post- Operational Phase

The post-operational phase consists of a major activity i.e. effective implementation of bringing the affected area to its original form as far as possible. In this process the activities involved are dumping the left over solid waste at suitable places and plantation of trees on the reclaimed area so as to
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attain its original form. The main activities that may cause environmental impact on the surrounding environment during project completion are: Transportation of excessive solid waste material Dumping of solid waste material. Removal of temporary facilities, cleaning etc. During the project completion the likely potential environmental impacts are due to dust and noise.
11.7 Prediction of Impacts

The impact of the proposed construction of various water supply Project activities on environment (air, water, noise, land and socio-economic) is predicted in this section. The proposed construction activity may cause some adverse impacts on the surrounding environment unless other wise proper environmental management plan is adopted. An attempt has been made to quantify the possible impacts on various environmental parameters. 11.7.1 Impact on Air Environment Considerable amount of air pollution will be generated during different stages on construction of Ground storage reservoirs, Water Treatment Plants, lying of pipe lines and other operations such as excavation, drilling, blasting, loading, and transportation of material. Suspended Particulate Matter (SPM) is the main pollutant during construction. Most of the dust arises from drilling, excavation, crushing and transportation operations. Large quantities of dust become wind borne and are carried away from overburden dumps. The fugitive dust released during the construction activities may cause immediate effect on the construction workers who are directly exposed to the fugitive dust. However, the dust does not travel to longer distance because the project site is located isolated and there is no significant human population in the affected area. The other likely source of air pollution is due to emission from various construction equipments. The various equipments require combustion of fuel, normally diesel oil. The major pollutants, which get emitted from diesel vehicles, are hydrocarbons and SO2. The short-term increase in SO2 even for worst scenario is quite low i.e. 1 g/m3. Hence no major impact is anticipated. 11.7.2 Fugitive Emission from Crushers The operation of concrete mixture, welding machine, excavation machines during construction phase is likely to generate fugitive emissions which can move even up to 250-300 m in predominant wind direction. Suspended particulate matter will be generated. SPM can be easily controlled by providing water sprinkle system and wetting of stones. There is no human settlement near to WTP and Main lines while ESR/ GSR sites are located near human settlement but they do not have much impact; hence no impact is visualized due to this activity.
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11.7.3 Impact on Noise Environment The noise will be generated at the time of construction of ESR/GSR, WTP and lying of mains, machine operations, pumps, drilling machines, blasting, dumpers etc. Continuous exposure of workers to high level of noise may result in annoyance, fatigue, and may cause temporary shift of threshold limit of hearing and even permanent loss of hearing. The noise levels at the project site will be monitored and the maximum & minimum levels, during daytime and night time should not be more that 50 dB and 35 dB respectively. 11.7.4 Impact on Water Environment During the construction of ESR/ GSR , WTP etc. sub surface may get polluted due to the generation of large quantities of suspended particulate matter at the time of transportation of SWM and wastewater (sewage) coming from temporary arrangements like offices, labour camp sheds, etc. as same will be of small amount , effect is predicated as negligible. 11.7.5 Water Logging and Salinity These aspects are not going to pose any problem as the nallah near pipe line alignment is passing through, by and large, a narrow gorge of compact mass etc. there is no storage involved and consequently no water logging. Salinity is not applicable in this case. 11.7.6 Impact on land Environment The components of the project are mostly on barren land or underground and no area of cultivable land is required for the project. The construction of the project facilities also does not involve deforestation. Thus the danger of erosion and disturbance to hill slopes is negligible. The intake site is close to developed area. Only short length of link road is to be constructed on the barren land. Therefore no major construction of road is required. The construction of roads and project components will not involve any deforestation or huge deposition of excavated material in the nallah to affect the environment adversely. Some area is also observed under scrubs and pastures and negligibly smaller proportion of the land comes under the barren category. 11.7.7 Impacts on Flora and Fauna The proposed projects envisage a compensatory afforestation programme. Since there is no dam like storage structure, no submergence is involved. No land will be submerged and no habitation will be affected. The forestland or cultivated land, shrubs need not be affected. There is no reserved forest in the alignment and there is no submergence any where. The number of trees likely to be cut for water mains is negligible. Every wild life species whether mammal, bird, reptile, aquatic or amphibian plays an important role in the maintenance of balance of nature and is useful to mankind in many ways. Every individual animal, bird or insect has been endowed with certain specific protective measures so that it can protect
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itself and reproduce, thus ensuring the existence of the species. The construction also does not involve deforestation. The danger of erosion & disturbance to hill slope is negligible. 11.7.8 Impact on Climate As the project is very small having no submergence and impoundment of water that could influence the microclimate of the region, there will be no effect of the project on climate. 11.7.9 Impact to Seismicity The project area lies in the Saurashtra & Kutchha Region & is susceptible to earthquakes. The area as per ISI classification falls in seismic zone IV. the Bhuj earthquake of 2001 is a testimony to what damage can an earthquake cause in the region. Proper seismic coefficient shall have to be derived for different structures. However there is no immediate threat perceived of any loss to human life due to occurrence of earthquake specifically by project itself. All the project components are underground which are safe from earthquake consideration. Further there is no impounding or storage in form of dam & as such there will be no change or impact on Seismicity. 11.7.10 Impact on Socio-economic Environment A project of this magnitude is likely to entail both positive as well as negative impacts on the socio-cultural fabric of area. 11.7.10.1 Positive Impacts on Socio-Economic Environment During the project construction and operation phases: 1. Expatriate constructors who would probably come from other parts of the country would undertake construction activities. 2. A number of marginal activities and jobs would be available to the locals in the project improves the job opportunities during construction phase. 3. Education will receive a shot in the arm. The advantage of education to secure jobs will quickly percolate through all sections of the population and will induce people to get their children educated. 4. The availability of water to under develop area will reduce to under ground water and thus positive environment effect on sub surface water will be seen 5. With increased availability of water people will encourage to develop small gardens and to plan tree 11.7.10.2 Negative Impacts on Socio-Economic Environment Although, there are a number of positive impacts of the proposed project, one major negative impact is identified i.e. there will be negligible loss of land due to the proposed project. As per the TP scheme award two sites are identified for minor encroachment removal.
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11.8 Evaluation of Impacts

The environmental impact of a project depends both on the project activities and on the background environmental setting. The environmental impact assessment process involves four basic steps: 1. Identification 2. Evaluation 3. Interpretation 4. Communication In the present case the impact of each project activity on each of the environmental attributes, evaluation and interpretation of impacts is mostly subjective and convey a holistic view of the environmental impact of the project. Evaluation for Alternative Scenarios 11.8.1 EIA without EMP This scenario was based upon the assumption that the proposed development would go ahead without any environmental management options being implemented. The total project impact for the scenario is on the appreciably adverse side. This shows that if the project goes ahead without Environment Management Plan (EMP) in form of mitigation measures, the adverse impact on the existing environment would be several times that of the impact without the project. Thus, the EMP described as mitigation measures will have to be implemented to minimize the potential negative impact due to the proposed activities. 11.8.2 EIA with EMP If the environmental impact mitigation measures discussed above is fully implemented, the adverse impact of the project would be reduced, and there will be an overall improvement in physical, chemical, biological and socioeconomic environment of the region. Therefore, the proposed activity will be beneficial for the environment of the area, provided the Environment Impact Mitigation in form of Environment Management Plan is in place. 11.8.3 Conclusions It is clear from the above, that the proposed Water Supply Projects would have negligible negative affect even without implementing certain environmental management strategies. If EMP, is adopted and implemented, the adverse impacts will be nullified and the overall environmental quality of the area would improve.
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12
12.1 Conclusion
Summiing up.... Summ ng up
The water supply services falls under essential service category and by Act, RMC has to maintain the city supply. As stated above, due to arid region, the water scarcity in this area is frequent. The every 3rd year is always lean year and water supply agencies in this region have to make special efforts to maintain adequate water supply to city or town.
Since the availability of water from all the sources is limited, so far RMC has adopted intermittent supply, for duration of 20 minutes daily. Since the present storage, filtration and pumping arrangement of Rajkot city, is inadequate and also the supply is limited, to maintain input and output in supply, the water is being supplied by zoning system. The water supply starts from early in the morning and ends at late night and people of Rajkot are getting their supply at odd hours.
However, on implementation of a drinking water supply project based on Sardar Sarovar Canal by Government of Gujarat, the water scenario in this region has been improved. In above project, the allocation of Rajkot is 160 MLD and as on date, Rajkot is getting about 75 MLD from Narmada pipeline project. Also within couple of years, the irrigation from Sardar Sarovar Canal will be started and because of which practically the lift irrigation in this region will be stopped, which will have a significant effect on underground water. Thus, now onwards, there will not be problem of availability of water for Rajkot and other towns of this region. Under the circumstances, RMC has now planned to start to augment its city supply and have decided to truncate the supply hours limited to 6 to 8 hours instead of 18 hours.
For reduction in the duration of the supply, it is necessary to have additional underground / above ground storage, filtration and adequate pumping arrangement so that for the period of 18 hours, water could be filtered and stored and within six hours the city supply could be completed. RMC has planned to have storage of around 72 hours i.e. up to 425 million liter. With this arrangement, there will be following advantages:
1.
People of Rajkot will get their requirement either in evening or in morning with adequate quantity and pressure.
2. 3. 4.
The line losses will also be reduced up to some extent. There will be saving in the power up to some extent. There will be saving in the man month for O&M.
145
12.2 Project Costing
At first instance, for the year 2005-06, RMC has prepared the detailed project report for below mentioned components costing Rs.22135 lacs. For remaining work, the detailed project report will be submitted in due course.
Sr No 1 2 3 4 5 6 7
Name of project
ESR & GSR at ward No.6 ESR & GSR at ward No.7 ESR & GSR at ward No.17 ESR & GSR in ward No.16 ESR & GSR in ward No.12 Total New head works at Raiya dhar Water supply scheme based on Nyari reservoir Water supply scheme based on Bhadar reservoir GSR at Sojitra ward -12 GSR & Pumping machinery GSR & Rising main at Dudhsagar Addition & Alternation to Aji head works Total
Estimated Present status cost ( Rs lacs ) 675 Work Under progress 431 Work Under progress 844 Work Under progress --3120 Tenders to be invited 740.85 Work Under progress
Remarks
Detail yet to be work out Detail yet to be work out
8 9 10 11 12
2470 Work Under progress 16 90 164 168 8718 Work Under progress Work Under progress Work Under progress Work Under progress
In view of above, it is requested to kindly approve our above projects and include the same under JNNRUM.
146

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DPR No.

: RMC/JnNURM/WS01-10/0507 Detail Project Report (DPR) for

Estimated Cost Rs.10573 lakhs Date of Preparation

Period 05-06 to 06-07 Date of Submission

DPR No.: RMC/JnNURM/WS01-10/0507

Rajkot Municipal Corporation

1.2 Need of the Project

Detail Project Report for Water Supply

Rajkot Municipal Corporation

1.4 Scope & Limitations of the study

Detail Project Report for Water Supply

Rajkot Municipal Corporation

Background of the study Background of the study

Detail Project Report for Water Supply

Rajkot Municipal Corporation

2.2 Linkage of the projects to the CDP

200 22135 100

Detail Project Report for Water Supply

Rajkot Municipal Corporation

Characteriistiic of the study area Character st c of the study area

3.1 Project Area

Detail Project Report for Water Supply

Rajkot Municipal Corporation

3.3 Climate & Rainfall

3.6 Environmental Setting

Detail Project Report for Water Supply

Rajkot Municipal Corporation

Exiistiing System Overviiew Ex st ng System Overv ew

supply to fulfill required additional water. demand of

This is the first

Detail Project Report for Water Supply

Rajkot Municipal Corporation

4.2 Transmission & Distribution

Detail Project Report for Water Supply

Rajkot Municipal Corporation

A total storage capacity of

4.3 Treatment Facility

4.4 Distribution Net work

Detail Project Report for Water Supply

Rajkot Municipal Corporation

Detail Project Report for Water Supply

Rajkot Municipal Corporation

Popullatiion & Water Demand Popu at on & Water Demand

subsequently railway track was removed.

5.2 Settlement Pattern

5.3 Land Use

Detail Project Report for Water Supply

Rajkot Municipal Corporation

especially in and around

Detail Project Report for Water Supply

Rajkot Municipal Corporation

5.4 Population Growth Rate

5.5 Population Projection

Independence i.e. after 1951, the rate of

Detail Project Report for Water Supply

Rajkot Municipal Corporation

5.6 Demand of Water

Detail Project Report for Water Supply

Rajkot Municipal Corporation

Detail Project Report for Water Supply

Rajkot Municipal Corporation

Detail Project Report for Water Supply