Pressures at delivery of each main pump

Flow switch at inlet cooling water line/ lubricating water line

Differential pressure switch across the pressure filters at the discharge of lubricating water pumps

Portable vibration meter

Portable sound level meter

Portable speed meter

1.4.10 Valves and Piping at Pump Stations

Each pump shall be equipped with a main butterfly shut-off valve and a maintenance butterfly discharge valve.
The main butterfly valves are designed for shutting off the discharge pipe before starting the main pumps and also
after stopping of the main pumps to prevent backflow.

Each pump shall be provided with hydraulically operated discharge valve - oil pressure operated butterfly valve,
and electrically-operated bypass valve with guard valve for equalizing the pressure on the valve door before
opening, and a maintenance valve. The maintenance valves will be closed to enable repair and maintenance
works on the main valves without interrupting the operation of other pumps by dewatering a complete main raiser
pipe.

The discharge control valve shall have maximum capacity to allow maximum flow of pump discharge. The valve
shall be designed to withstand the maximum transient pressure and shall be free from vibration and abnormality
under the whole operating range of pump including any transient conditions of operations. The inside diameter of
the valve shall be decided by the bidder considering the maximum permissible discharge of the pump and velocity
limits permissible. The valve shall be so designed as to be capable of closing from fully open position under the
condition of maximum flow at every head with minimum oil pressure supplied to servomotor. Alternatively the
bidder may choose closing by counter weight.

The opening and closing time of the valve shall be selected depending on the pump characteristics including the
operating time of bypass valve with normal operating pressure. All valve oil piping and valves complete with
flanges, bolting materials, gaskets, packing etc., required for inter-connections between the various equipment
shall be included in the offer. All piping shall be steel, suitable for maximum oil working pressure. All valves shall
be ductile iron or fabricated steel valves having flanged ends.

It shall be of cast ductile iron or fabricated welded steel construction accurately bored, reinforced with heavy ribs
and flanges on both ends with rubber seals for connection to the upstream make up piece and downstream
dismantling joint and hubs for trunnions. The body shall be provided with self-lubricating bearings without any
external greasing at both ends where the shaft is horizontally in contact. The bearings shall be provided with
necessary packing cup seals inside to prevent inflow of sand or other foreign matter contained in the water and
also at the outside end to prevent water leaking. The trunnion bearings shall be designed to take full load exerted
because of maximum hydraulic pressure including the full weight of the valve disc and trunnion and smooth
opening/closing operations. The bearings shall be self-lubricated without external greasing.

The body shall be provided with weld deposited or separately fixed and accurately bored/ machined stainless
steel seating/contacting ring while the disc shall be fitted with rubber ring to have drop tight sealing under all
working conditions.

The valve body shall incorporate the bracket feet supports suitable for anchoring against maximum servomotor
and hydraulic forces. All necessary foundation plates and anchor bolts shall be provided.

Lattice/Bi-plane/flow through type, cast ductile iron or fabricated steel construction with integral trunnions
designed with sufficient strength not causing any distortion/deformation or any abnormal vibration when the disc is
in open position or during operation shall be provided. The valve disc shall be in one piece with integral high
strength spindles and streamlined/shaped to minimise flow disturbance and head loss. A peripheral rubber seal
shall be provided on the disc to seal the leakages, seating against stainless steel seal ring welded on the inner

33
surface of the valve body. The rubber seal ring shall be firmly fixed in position to the disc by removable rust
resistant steel rings fixed by stainless steel screws and stainless steel nuts.

The sealing shall be of reinforced rubber to metal in one length to be joined at site and shall definitely not involve
inflation or other similar forms of relative movement of elements in the seals or seats. It shall be possible to adjust
the sealing contact without dismantling the valve.

One bypass valve of suitable diameter shall be provided directly on the upstream pipe along with a guard valve.
The bypass valve which is required for balancing the pressure across the BF valve shall be designed for vibration
and noise free operations and shall have stainless steel or bronze parts (those coming in contact with water), thus
preventing corrosion.

Metal sealing shall be provided to have leak proof seal when the valve is closed. The bypass valve shall be
electrically operated with the provision of manual operation. All wearing parts of the bypass valve shall be
renewable and of bronze or stainless steel.

A bypass steel pipe of suitable diameter and length joining upstream to downstream of valve with necessary
flanges, fasteners and packings shall be provided.

The delivery pipe shall be of suitable diameter (nominal inside diameter) considering the permissible velocity limits
and shall conform to IS-3589 and of mild steel fabricated construction using required thickness plates (IS 2062).
The pipeline shall be complete with required specials (Viz. manholes, bends, connections etc., as per
requirement) fabricated and erected by the contractor. Sufficient No. of manholes and air valves shall be provided
by the bidder along the raising main at locations to be decided after award of contract.

Pipes shall be provided with stiffener rings at regular intervals of every 3 meters to retain the shape of pipes after
fabrication. Pipes shall also be provided with anchor rods, thermal expansion joints, etc., by the bidder as per the
requirement.

Low hydrogen electrodes conforming to AWS-E7018 class only shall be used during fabrication/erection.

Hydraulic testing shall be conducted.

During erection, line and level shall be ensured by the contractor. The bidder shall indicate the location of
supports anchor blocks, thrust block required to hold the pipes in position and accordingly include the supply and
erection of clamps and anchoring bolts, nuts in the scope.

The operating mechanism to open and close the valve and the bypass valve shall be capable of being controlled
from the control panel of the Pump house and also from the valve chamber. The operating mechanism shall be
such that the speed retards as the valve approaches the end of each operation. Necessary dampers shall be
provided to regulate the speed of operation and to arrest the travel of the valve exactly at the fully closed or open
positions controlled by the necessary pilot valve operated distributing valve as well as diaphragm so as to allow
for an easy adjustment of the closing time compatible with the upstream allowable pressure rise.

The valve shall be operated by means of oil operated servomotor attached to the door of the valve through a
lever. The oil to the servomotor shall be supplied under pressure by means of an oil pump. After balancing the
pressure on the upstream and downstream sides of valve by means of bypass, the oil pump shall be put into
operation. By means of the distributing valve, oil under pressure shall be supplied to the lower side of the piston
of the servomotor to bring about the opening stroke. At the end of opening stroke, an electric contact shall cut off
the supply to the oil pump-motor. In case the piston of the servomotor descends due to any leakage, an electric
contact shall automatically start the oil pump motor after a movement of 5% (approx.) of valve door in the closing
direction. It shall also be possible to open the Valve by manually operated pump in case of failure of electric
supply to the oil pump motor.

The closing shall be affected as under:

Normal closing

Emergency closing

34
 For normal closing, the oil pressure shall be admitted by means of a distributing valve to the upper side of
the piston of the servomotor to bring about the closing stroke. At the end of closing stroke an electric
contact shall cut off supply to the oil pump motor.

For emergency closing, the oil pressure in the cylinder shall be released through a solenoid operated
valve and due to the action of hydraulic torque and torque acting due to the counter weight, the valve disc
shall close. The movement of the disc shall be retarded by the servomotor which functions as dash pot
thus giving total security to the installation. The valve shall be designed to close against the maximum
velocity attained by pump .The operation of the valve may be carried out using the pressure oil system
contemplated for opening and closing of guide vanes. However, preferably the bidder should provide a
separate hydraulic power pack for operation of the valves.

The hydraulic power pack system shall consist of 1 main and 1 standby electrically driven high pressure oil pump
of vane type. The pump shall have sufficient capacity to supply the entire pressure oil requirement of the BF Valve
servomotor etc. The pump shall be of continuous duty, self-primed under the maximum oil pressure. Necessary
sump tank, control valves, non-return valves, pressure switches etc., shall be supplied. The sump tank shall be
welded steel construction, and of sufficient capacity to hold all the oil in valve servomotor system. The interior of
the sump tank shall be sand blasted and painted with two coats of suitable best quality oil resistant paint. The
sump tank shall be totally enclosed complete with inspection lid and provided with duplex strainers, which could
be cleaned with ease when the valve is in service. It shall also be provided with oil level gauge, breather and
suitable tapping required for connecting the filter set for circulation of oil. A hand operated stand-by pump of
adequate capacity for manual operation of the valve shall be provided. Oil pipes shall be of seamless, heavy
gauge and of suitable wall thickness. The electric motors shall be of continuous duty directly coupled to the pump
and it shall be TEFC with Clas n suitable for operation on 415 10% volts, 3 phases, and 50 +3% /-5%
Hz AC supply. The motors shall be provided with starters with protection equipment. The starting equipment shall
incorporate a device so as to start the motor and permit it to reach full speed before the pump is connected to the
pressure system and to unload the pump before the motor is disconnected from the power supply.

The Contractor shall supply all the control equipment such as solenoid operated distributing valve, control and
check valves (arranged for local and remote operation) and they shall be suitably mounted. The electrical control
panel shall consist of contactors, operating switches, indicating lamps etc. The panel proposed for this and to be
mounted for remote operation in the control room of the Pump house shall match in colour and size with the other
control panels in the control room. Sufficient number of limit and auxiliary switches shall be provided on the valve
operating mechanism in order to energise the following signalling alarm and trip circuits. (i) Indication of Valve

The indication of bypass valve

and the valve disc moves by

more than 5 deg. from the open position in the closing direction.

alve.

Any abnormal condition.

The limit switches shall be hermetically sealed and shall be of reputed make.

All indications and alarm shall be provided on the control cubicles to be installed near the valve and at control
room. The control devices, indicating and alarm devices, starters for motors etc. shall be mounted on the control
cubicles.

The water passage shall be shot or sand blasted and painted with two coats of zinc rich epoxy primer and three
coats of epoxy paints before dispatch. Each coat of primer shall be of thickness not less than 40 microns and that
of epoxy not less than 100 microns. The outside shall be provided with suitable paints.

1.4.11 Pump Motors

Motors shall be capable of giving rated output without reduction in the expected life span when operated
continuously under the following supply conditions:

35
 Quality Assurance : Quality Assurance Plan shall be got approved from the employer before
production start.

1.4.13.6 Sluice Valves

The sluice valves shall confirm to IS: 14846. Double flanged short body, Gland less (stem sealing rings)type
Sluice valves with appropriate pressure rating.

The material to be supplied under this sub-section shall include, but not be limited to, the following: All necessary
fittings including bolts, nuts, gaskets, backing rings, counter flanges, jointing material, strainers etc. shall be
supplied as required. The entire Gland less (stem sealing rings) sluice valve shall be provided with ball thrust
bearing and spur gear arrangement.

The Gland less (stem sealing rings) sluice valves shall be with non rising stem type. The valves will be used for
water supply on line installations in upright positions, with double flange, and cap or hand wheel for manual
operation. The valves shall be suitable for continuous use at their PN rating within the temperature range of -
10degrees C to 65degrees C.

The working pressure on the valves shall be appropriate to the working conditions and approved by the Employer.
The flanges and their dimensions of drilling shall be in accordance with IS: 1538 (part-I to XXII).

The makes given are acceptable makes however the material for different component parts of sluice valve shall
conform to the requirements given below:

Component Material Ref. to IS Grade / Designation

Body, bonnet, dome, stool S. G. Iron 1865 Gr.400/ 12
cover, wedge, stuffing box,
gland, thrust plate, hand wheel
and cap.
Stem Stainless steel 6603 12Cr 13 04Cr 18Ni 10 04Cr
17Ni 12 MO 2
Wedge, nut, shoe Leaded tin bronze 318 LTB-2
Body seat ring, wedge facing Leaded tin bronze 318 LTB 2
ring and bushes
Bolt Carbon steel 1363 (Part 1) Class 4.6
Nut Carbon steel 1363 (Part 3) Class 4
Gasket EPDM Rubber 11855 -
Gland packing Stem Sealing Ring 5414 Nil
Gear Spheroidal graphite 1865 Gr 500 / 7
iron
Gear housing S.G. iron 1865 Gr.400/12
Pinion and pinion shaft Wrought carbon 1570 (Part 3) C55Mn75
steel

The standard marking and packing of the valves shall be done as per Clause 11 and 13of IS: 14846. The
direction of rotation for OPEN, CLOSE position shall be marked on the hand wheel and on the bonnet of the
valve.

Hydraulic testing of each sluice valve shall be done for close end test in accordance with IS: 14846 Annex B, to
the test pressure and test duration as specified in table 5 and 6 of the IS.

All the valves shall be inspected for flaw detection test in accordance with IS: 14846, clause 10.2.The design,
construction material, manufacture, inspection, performance and testing shall comply with all applicable Indian
Standards and Codes. Nothing in the specification will be construed to relieve the supplier of this responsibility.

The manufacturer shall provide a test certificate confirming that all the valves have been tested in accordance with
IS: 14846 and stating the pressures and medium used in the test.

97
The inspection and testing of the sample valves from a lot will be carried out by the employer and or inspecting
the tests as
required as per the IS: 14846 shall be carried out on samples from each lot (Number of samples from a lot shall
be as per the relevant IS for sampling and testing), in presence of the inspecting agency. The valves shall be
dispatched only after issue of the test certificate by the inspecting agency for satisfactory performance of the
tested valves. The inspection charges for such tests shall be paid by the contractor to the inspecting agency.

Acceptable makes for the sluice valves shall be either, VAG, IVC or Kirloskar or other reputed make as may be
approved by Chief engineer.

The installation of the sluice valves shall be done at the locations shown on L-sections of the pumping main as
washout valves and isolating valves for air valves. The job covers supply of the valves at work site with cost of all
the required material and all types of taxes and duties, cost of packing, loading, transportation, unloading,
stacking and installation at the specified location with cost of all jointing materials such as nuts and bolts,
EPDM rubber gaskets etc. The job also covers field hydraulic testing of the valves after installation for the
specified test pressure for the respective pipeline section.

1.4.13.7 Butterfly Valves

The Butterfly valves shall confirm to IS: 13095. Double flanged short body butterfly valves of required nominal
diameter and pressure rating shall be supplied. The material to be supplied shall include, but not be limited to,
that as shown in the table given below. All necessary fittings including bolts, nuts, gaskets, jointing material etc.
shall be supplied as required.

The butterfly valves shall be with disc and shaft and shall be designed to withstand the maximum pressure
differential across the valve in either direction of flow. The valves shall have no visible leakage past the disc in
closed position under test conditions. The shaft may be of one piece design or in two pieces separately attached
to the disc. The valves will be used for water supply on line installations in upright positions with manual operation.
The valves shall be suitable for continuous use at their pressure rating within the temperature range of -100C to
650C.

The working pressure on the valves shall be appropriate to the working conditions and approved by the Employer.
The flanges and their dimensions of drilling shall be in accordance with IS: 1538 (part-I to XXII).

The makes given are acceptable makes however the material for different component parts of butterfly valves
shall conform to the requirements given below:

Component Material Ref. to IS Grade

Body Sphéroïdal graphite 1865 Gr. 400/12
Iron. / Ductile Iron.
Disc Sphéroïdal graphite 1865 Gr. 400/12
Iron. / Ductile Iron.
Shaft Stainless steel 6603 -

Seating ring / Seal Integral Nicol - -

retaining ring Crominium
Welding
Seat EPDM Rubber - -
Shaft bearing seals Bronze / brass - -
rings
Internal fastners Stainless steel Suitable for duty
standard
External bolting Carbon steel; tensile strength - -
390 Mpa

All valves shall be capable of being operated at a differential pressure across the disc as marked on the valves.
Leaver, worm gear / traveling nut type or any other suitable type of operator can be used.

98
Manually operated valves shall be closed by turning hand wheel or leaver in a clockwise direction when facing the
hand wheel or leaver. The design of leaver when fitted shall be such that the leaver may only be assembled to the
valve so that it is parallel to the direction of flow when the valve is open.

All travelling nut operators shall be provided with suitable stops to prevent movement of the shaft beyond the limit
corresponding to the fully closed position of the disc.

All gear / travelling nut operators shall be self-locking type. All leaver operated valves shall be capable of being
locked at at-
indicate the direction of closure. The operator shall be provided with arrangement to indicate disc position.

All valves shall be hydraulically tested by the manufacturer before dispatch. The pressure shall be applied without
any significant hydraulic shock. Testing shall be carried out before application of paint or other similar treatment.

The body ends shall be blanked. The valve disc shall be in slightly open position and the pressure equivalent to
1.5 times the maximum permissible working pressure shall be applied with water. The duration of test shall be 5
minutes for 1600 mm diameter valve.

Seat test shall be carried in accordance with clause 17.3 of IS: 13095 for 3 minute duration.

The test shall be conducted with the body flanges in horizontal position. The test pressure shall be 1.5 times the
maximum permissible pressure. With disc in closed position, hydro test pressure shall be applied to the lower
face of the disc for duration as per table 3 of the IS: 13095. There shall be no damage to the valve disc or any
part of the valve, or disc shall not be permanently deformed.

The manufacture shall provide a test certificate confirming that all the valves have been tested in accordance with
IS: 13095. The manufacturer shall also provide documentary evidence of having manufactured and supplied BFV
of similar design and specifications, working satisfactorily for minimum 10 years in India, through Performance
Certificate.

The inspection and testing of the sample butterfly valves shall be carried out by the employer and or inspecting
any paint. All the tests as
required as per the IS: 13095 shall be conducted in presence of the inspecting agency on the sample valves from
the lot (Number of valves to be tested from a lot shall be as per the relevant IS for sampling and testing). The
valves shall be dispatched only after issue of the test certificate by the inspecting agency for satisfactory
performance of the tested valves. The inspection charges for such tests shall be paid by the contractor to the
inspecting agency.

Marking shall be cast integral on the body or on a plate securely attached to the body. Marking shall be as
specified under clause 21 of IS: 13095.

The design, construction material, manufacture, inspection, performance and testing shall comply with all
applicable Indian Standards and Codes. Nothing in the specification will be construed to relieve the supplier of this
responsibility.

Acceptable makes for the double flanged butterfly valves shall be either, Fouress, VAG or IVC or other reputed
make as may be approved by the Chief Engineer.

The installation of the butterfly valves shall be done at the locations shown on L-sections of the pumping main as
online valves. The job covers supply of the valves at work site including all type of taxes and duties, cost of
packing, loading, transportation, unloading, stacking and installation at the specified location with cost of all
jointing materials such as nuts and bolts, EPDM rubber gaskets etc. The job covers field hydraulic testing of the
valve after installation for the specified test pressure for the respective pipeline section.

1.4.13.8 Kinetic Air valves

Kinetic air valves are required with pressure rating appropriate for the working conditions and approved by the
Employer, confirming to IS: 14845.

99
The air valves shall be capable of exhausting air from pipeline automatically when being filled. Air shall be
released at sufficiently higher rate so that there shall be no restriction for the inflow rate. Similarly, the valves shall
be capable of ventilating pipeline automatically when being emptied. The air inflow rate should be sufficiently high
to avoid development of vacuum in the pipeline.

The design shall be such that, higher the rate of flow the greater the resultant down thrust, keeping the ball 'glued'
to its seat until the last drop of air is expelled from the pipe system.

Each air valve shall be provided with an isolating sluice valve with flanged end connection. The possible air
velocity (inflow and outflow) must be at least 10 m/s.

The flow of air should be as unobstructed as possible. The low pressure orifice shall be in the same axis as the
main discharge / incoming air flow and must have a diameter sufficiently large. The valve body shall be designed
in such a way that the turbulent air at the time of filling of pipeline shall not circulate and cause the ball to be
caught in the discharging air stream and blowing the valve shut permanently. The cone angle of the low pressure
(large orifice) chamber shall be such that even at a critical velocity of air escaping at 344 m / sec the total impact
force on the vulcanite covered ball is less than the suction force on the annular area between the ball and cone.
The annulus around the low pressure vulcanite covered ball is to be generously proportioned for discharge of air
under various differential pressures. Normal range of cone angle is 45 0 to 600.

The orifice shall be carefully profiled to allow the requisite flow of air under varying differential pressures. It shall
be in moulded synthetic rubber such that even after extended contact the, vulcanite covered ball does not stick to
it, when the line pressure becomes zero.

The high pressure chamber having small orifice shall be so designed that the orifice is effectively sealed in
working condition. The orifice shall be profiled in such a manner that the rubber covered ball is not damaged even
after extended contact. There should be machined guide in the chamber which ensures that the ball travels
vertically and makes contact with the nipple and seals off the orifice without fail. The orifice size shall

Not be less than 2.5 mm and tapering to 10 mm suitable to release accumulated air within the pipeline. High
pressure orifice may be fitted from bottom side of the cover.

The makes given are acceptable makes however the material for different components parts of the air valve shall
conform to the requirements given below:

Component Material Reference to IS No. Grade of designation

Body,cover, valve disc, stuffing S. G. iron / Ductile 1865 Gr.400/ 12
box, valve guide, cowl, gland, iron
cap, joint support ring
Low Pressure seat ring and face Natural rubber 11855
ring
High pressure orifice Leaded tin bronze 318 LTB-2
Bolts Carbon steel 1363 Class 4, 6
Nuts Carbon steel 1363 Class 4
Gasket Rubber 638 Type B
Float Stainless steel - -
Float guide Leaded tin bronze 318 LTB-2

Minimum float diameters for kinetic air valves shall be as indicated in Table 3 of IS 14845. The inner core of the
floats shall be made from stainless steel having sufficient bearing strength and equivalent specific gravity.

Testing of all the air valves shall be carried out in the suppliers work shop as per IS:14845.

Following tests shall be carried for each valve.

Function and performance test as per clause 12.4.1

High pressure orifice test as per clause 12.4.2

100
 Low pressure orifice test as per clause 12.4.3

Body test as per clause 12.4.4

The performance of the valve for the above mentioned tests shall be as specified under Clause 12.1, 12.2 and
12.3 of IS 14845.

The manufacturer shall provide a test certificate confirming that all the air valves have been tested in accordance
with the relevant standards and performance of the test results observed.

The inspection and testing of the sample air valves shall be carried out by the employer and or inspecting agency

required as per IS 14845 shall be conducted in presence of the inspecting agency on the sample valves from the
lot (Number of valves to be tested from a lot shall be as per the relevant IS for sampling and testing). The valves
shall be dispatched only after issue of the test certificate by the inspecting agency for satisfactory performance of
the tested valves. The inspection charges for such tests shall be paid by the contractor to the inspecting agency.

Each valve shall be permanently marked with a plate securely fixed to the body with the information as specified
under clause 15.1 of IS 14845.

The design, construction material, manufacture, inspection, performance and testing shall comply with all
applicable Indian Standards and Codes. Nothing in the specification will be construed to relieve the supplier of this
responsibility.

Acceptable makes for the kinetic double orifice air valves shall be either, VAG, IVC or Kirloskar or other reputed
make as may be approved by the chief engineer.

The installation of the air valves shall be done with isolating sluice valve. The job covers supply of the valves at
the work site including all taxes and duties, cost of packing, loading, transportation, unloading, stacking and
installation at the specified location with cost of all jointing materials such as nuts and bolts, EPDM rubber gaskets
etc. The job covers field hydraulic testing of the valves after installation for the specified test pressure for the
respective pipeline section

1.4.13.9 Non-return Valves

Non-return valves generally conforming to IS 5312 Part I & II (Single or Multi Door Type) shall be provided on
delivery side of a l l pumps. The valves shall be suitable for continuous use at their pressure rating within the
temperature up to 60degrees C and shall be conforming to following specifications and requirements.

The non-return valve shall be swing check reflux valve type with S i n g l e o r multiple doors.

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 inbuilt high speed closing and non-slam characteristics achieved by suitable disposition of
weight on door and the hydraulic passage.

Valves of multi-door type shall be additionally provided with a supporting foot.

All faces and seat rings shall be riveted to the machined surface in the Casting. The door shall be integral with the
hinge and shall have a flat seating face. Minimum two (2) nos. suspension lugs shall be cast integrally on the
diaphragm plate and shall be of adequate strength.

Bypass of appropriate diameter with sluice valve of appropriate size and pressure class as per relevant applicable
code shall be provided.

No spring loaded/ spring return action or external dampening arrangement will be acceptable. All the Non-return
valves shall be from the same manufacturer.

101
The material for different component parts of Multi-door non-return valves shall conform to the requirements given
below:

Component Material of construction

Body / Door Ductile Iron GGG 40 / IS 1865 Gr. 500/7 to IS 1865 OR
(and Diaphragm) Caststeel gradeBconformingtoIS1030
Stub pin SS AISI 410
Seat and Face rings Soft seated up to 300 mm.
350 mm and above: Gun metal : IS 318 Gr. LTB 2
Rivets Soft annealed brass
Fasteners Carbon steel
Painting Liquid epoxy coating of DFT 300 microns with proper Blast
cleaning to near white - SA 2 ½ Grade and 2 coats of epoxy
based primer coating, prior to final coating.
Flange Drilling IS 1538 Table 4 & 6/ BS En 1092 2

The working pressure on the valves shall be appropriate to the working conditions and approved by the Employer.

All valves shall be marked to show the following information permanently.

name or trademark.

PN rating

Valve size

Direction of flow

generally as per IS 5312 Part 2.

Body of each valve shall be hydrostatically pressure tested at 1.5 times its rated working pressure. The test fluid
shall be water. Duration of test shall be 2 minutes. There shall be no leakage or permanent distortion of any
component under the test.

Each valve shall be tested for seat test by applying hydrostatic test pressure equal to its rated working pressure,
on outlet side. Duration of test shall be 2 minutes. During the test, there shall be no leakage of water through the
seats.

The manufacture shall provide a test certificate confirming that all the valves have been tested in accordance with
above specifications and relevant IS 5312 Part II. The manufacturer shall also provide documentary evidence of
having manufactured and supplied non-return valve of similar size and design, working satisfactorily for minimum
10 years in India, through Performance Certificate.

Acceptable makes for the double flanged butterfly valves shall be either, Kirloskar, VAG or IVC or other reputed
make as may be approved by the chief engineer.

The job covers supply of the Non-return valves at the work site including all taxes and duties, cost of packing,
loading, transportation, unloading, stacking and installation at the specified location with cost of all jointing
materials such as nuts and bolts, EPDM rubber gaskets etc. The job covers field hydraulic testing of the valves
after installation for the specified test pressure for the respective pipeline section.

1.4.13.10 Anti-vacuum Valves

The Anti vacuum valve will be installed to prevent the formation of vacuum in large diameter (having Ø of 1000
mm. and above) water mains to prevent line collapse under such conditions of flow as may result, for example,
from too rapid a closure of an upstream head gate or shut down valve, a downstream burst or ordinary emptying
or recharging of a pipeline.

102
Design of the anti vacuum valve shall automatically allow induction of large volumes of air to prevent vacuum
formation; and also provide an automatic means of ventilating a line when it is being emptied of water, and of
exhausting air when it is being recharged.

It should be suitable to react automatically, sensitively, and positively even after long periods of inactivity, to
changes of pressure within a pipe, and whenever necessary, permit air to flow in at a sufficiently high velocity, and
at low enough induction pressure, to safeguard the line against collapse.

Cowled Inlet Type of the anti - vacuum valve should have an annular cowl shrouding the orifice, providing
protection to the orifice and the seating. It should be suitable for air to flow through the ports provided around the
periphery of the body assembly. Such application is confined to situations where no damage is likely to occur
surrounding structures from sudden intakes of air.

About Operation, the valve element should be in the form of the disk which is sensitively balanced by a
counterpoising mechanism. The disk guide pin should be attached to a crosshead, to which is fitted at either end
a cranked lever that should rock about an intermediate pivot pin and should be applicable to carry an adjustable
counterweight on its outer arm. The parts should so arranged that by adjusting the position of the counterweights,
the valve must be balanced at any desired points on its working travel.

Thus, when swinging freely the valve may be balanced at a partially opened position in which case, if it is closed
by hand, it self-opens to the pre determined point of equilibrium, and vice- versa. Also attached to the crosshead
should be an oil dashpot which should give free opening, in a downward direction, but offer resistance to closing,
in an upward direction, and avoid all possibility of oscillation of the suspended.

In action, therefore, the valve should not remain at either extremity of its travel unless it is acted upon by some
external force. During normal operation, the disk should be held shut by the water pressure in the pipe. If the
pressure on the underside of the disk falls below that of the atmosphere, the valve should immediately open to
admit air and break vacuum. With very small vacuum, say 1 inch of mercury or about ½ psi below atmosphere,
should open fully and offer a wide passage for free flow of air. On the cessation of air inflow, the valve must return
to a position of slightly open, which is sufficient for the escape of air during refilling of the line. When the rising
water makes contact with the underside of the disk, closure is completed: only a very small water pressure should
be required to close the valve, consequently, the quantity of water over- flowing through the orifice during final
closure will be negligible.

The manufacturer shall provide a test certificate confirming that all the Anti vacuum valves have been tested in
accordance with the relevant standards and performance of the test results observed.

The inspection and testing of the sample Anti vacuum valves shall be carried out by the employer and or

valves shall be dispatched only after issue of the test certificate by the inspecting agency for satisfactory
performance of the tested valves. The inspection charges for such tests shall be paid by the contractor to the
inspecting agency.

Each valve shall be permanently marked with a plate securely fixed to the body with the information as specified
under relevant standards.

The design, construction material, manufacture, inspection, performance and testing shall comply with all
applicable Indian Standards and Codes. Nothing in the specification will be construed to relieve the supplier of this
responsibility.

Acceptable makes for the Anti vacuum valves shall be either, Fouress, VAG or IVC or other reputed make as
may be approved by the chief engineer.

The job covers supply of the Anti vacuum valves at the work site including all taxes and duties, cost of packing,
loading, transportation, unloading, stacking and installation at the specified location with cost of all jointing
materials such as nuts and bolts, EPDM rubber gaskets etc. The job covers field hydraulic testing of the valves
after installation for the specified test pressure for the respective pipeline section.

103
1.4.13.11 Painting Specification for Valves

Final coating on internal and external surface of the Valve shall be carried out after satisfactory testing, prior to
dispatch.

Before inspection: Each valve shall be cleaned and surface shall be prepared by Sand blasting to SA 2½ Grade
Near white blast cleaning, and suitably protected by applying one coat of two component high build polyamide
cured re-coatable zinc phosphate epoxy primer.

After inspection: One coat of two component high build polyamide crude re-coatable epoxy coating shall be
applied to achieve DFT 150 micron, followed by one coat of two component aliphatic polyurethane finish to
achieve DFT 80 micron.

1.4.13.12 MS Expansion Joints and Cover Box

Expansion joints are necessary on the MS pipeline laid above ground to accommodate expansion and contraction
of the MS line due to temperature variations, so that the expansion or contraction is not cumulative over several
lengths. These joints permit linear movement of the pipe relative to the packing provided in the joint. Fabricated
steel Bellow-type expansion joints, as per the EJMA standards, shall be provided and installed at the locations
shown on longitudinal section of the pipeline.

Normally, on plain ground, the centre to centre distance of the expansion joints shall not be more than 300m.
When the length of above ground pipeline is less than 300 m but more than 100 m, one expansion joint at the
centre shall be provided. The pipe line shall be anchored firmly with concrete anchor blocks between two
expansion joints, so that the expansion or contraction between two anchor blocks is accommodated by the
expansion joint provided between the blocks. Supports / saddles shall be placed on each side of the expansion
joint at about one meter distance from the centre of the joint to avoid unequal deflection of the pipe on either side
of the joint.

The item covers providing and packing, transportation to work site and fixing wherever required on the pipeline
with hydraulic testing along with the pipeline section.

Acceptable makes for the Bellow-type expansion joints shall be of firm of repute make as may be approved by
the chief engineer.

BELLOWS MATERIAL SA 240 GR. 304

CENTRE SPOOL / WELD ENDS IS 2062 GR. B
INTERNAL SLEEVE SA 240 GR. 304

LIMIT RODS / NUTS & CHECK NUTS IS 1367

FLANGES IS 2062 ( AS PER IS 1538/ IS 6392)

Circular MS covers as shown on drawing shall be fabricated and fixed on the expansion joint for protecting the
joint from possible damages. The item covers the cost of plates and material required, nut bolts, all taxes and
duties, providing and applying two coats of epoxy paint in addition to one primer coat, transportation and fixing
charges etc complete

Bellow type Dismantling joint shall be provided for each online sluice valves, butterfly valve and washout valve to
facilitate removal of the valve for repairs whenever required.

The joints shall be fabricated as per EJMA standard. The item covers cost of Bellow type Dismantling joint,
including all taxes and duties and cost of coating, packing, transportation, cost of jointing including required
material such as nut bolts, rubber packing, labour cost, etc. complete with hydraulic testing to required pressure.

Alloy material SA 240 GR. 304

104